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This application claims the benefit of U.S. Provisional Application No. 60/161,090, filed Oct. 22, 1999.
FIELD OF THE INVENTION
The present invention relates to knitting aids, and in particular to knitting aids for use by persons having full use of only one hand.
BACKGROUND TO THE INVENTION
Recreation therapists have been searching for a tool to enable persons with only one functional hand and arm to knit. Most people with two functioning hands are capable of holding a knitting needle in each hand in order to guide the needle tips around each other in the correct motion, while simultaneously holding tension on the yarn and guiding it around the needles in order to make each stitch. However, a person who has lost the use of one hand and arm is able to hold and control only one needle, which under ordinary circumstances makes the knitting process impossible. For example, persons who have suffered a stroke, brain injury, or a shoulder, arm, or hand injury, may be disabled on one side of the body, or may be weak in or unable to use one hand. To do intricate work normally requiring the use of both hands, such persons require a means of gripping a tool or workpiece which substitutes for the hand they are unable to use effectively.
There are a number of knitting aids available for the disabled which are intended to hold the knitting needle from which stitches are being cast off, in a position from which it is easy to work, and from which the needle can be removed without too much difficulty when all the stitches have been cast off. However, in practice none of these known knitting aids effectively meets these two criteria.
One such known knitting aid comprises a block secured to a belt which can be fastened around the user's waist. The block has a hole in it for each size of needle, and in use the needle from which stitches are being cast off is pushed into its respective hole in the block and secured. However, being fastened on the belt around the user's waist, the needle is usually found to be far too close to the body to make knitting comfortable.
Another known knitting aid comprises a clamp which can be tightened onto the needle from which stitches are being cast off. The clamp is provided with means for securing it to the arm of a chair in which the knitter is sitting, and in this position it is usually possible to knit comfortably. The problem with this particular knitting aid is that the clamp must be loosened in order to release the needle each time all the stitches have been cast off, and then the clamp must be tightened onto the needle to which all the stitches have been transferred. It has to be appreciated that where the user is disabled in one hand, repeatedly tightening and loosening the clamp may become very tiring and may distress the user. The user may then require supervision and assistance, which takes away a lot of the enjoyment from the knitter and is undesirable from a therapeutic point of view.
Clamping a needle solidly in place does allow the individual to knit, provided the proper angle can be obtained. Each person requires the needle to be set at an angle specific to the individual needs of the person, which most clamping devices are unable to accommodate. Clamping does not allow for ease of changing from one needle to the other at the end of each knitted row. As well, clamping will not allow the stitches to be held in place without hindering the knitting process, and clamping reduces the number of stitches that can be placed on a knitting needle, because a portion of the knitting needle is taken up by the clamp.
Another known knitting aid comprises one or two resiliently biased stops, positioned between two opposing jaws so as to retain the needle in a channel formed by the two jaws. The resiliently biased stops permit the knitting needle to be moved without the necessity of loosening a clamp, but they do not act to tension the loops of yam on the needle, and this knitting aid does not permit the needle to be oriented at the user's optimum knitting position.
Therefore, there is a need in the art for a knitting aid which firmly secures a knitting needle while it is being worked from, and from which the needle can be easily removed when all the stitches have been cast off.
SUMMARY OF THE INVENTION
The present invention seeks to achieve these objectives by the provision of a knitting aid for use by individuals who have only the use of one functional hand and arm, thus enabling them to participate in the process of knitting with a pair of conventional knitting needles. In general terms, the invention is a knitting aid which includes a knitting needle holder having a magnetic field, created electrically or from a permanent magnet, to hold a knitting needle, plus means for tensioning yarn being knitted. Holding the knitting needle in this way also acts to secure the stitches in place on the needle, which helps in maintaining desired tension on the stitches as they are cast off the needle during the knitting process. By using a magnetic field to hold the needle and the stitches in place until needed, the stitches can be easily repositioned when required, by merely lifting the needle away from the magnetic source.
The knitting needle holder may be mounted on a pivoting head attached to a C-clamp, thus making it portable and permitting the knitting needle holder to be oriented in the position necessary for the proper execution of the knitting procedure.
When a knitting needle is positioned in the needle holder of the invention, it will become magnetically attractive, such that the needle tips will be attracted to each other. This can be an advantage in the knitting process for users with weak or unsteady hands. Instead of the user having to hold the needle tips together, the needles are automatically in that position and only need to be pulled apart to allow the movement of yarn between them. As with magnet therapy, the magnets used may have a therapeutic aspect: a North pole magnet is said to relieve aggravation from arthritis.
The knitting needle holder can be made of wood, plastic or any other suitable material capable of adequately supporting the source of the magnetic field. The yarn tensioning device may be made from any suitable material. In one embodiment, the yarn tensioning device contains material capable of being attracted by a magnet, and the yarn tensioning device is held in position by the magnetic field.
The knitting needles contain a substance capable of being attracted by a magnet, such as steel.
Accordingly, in one aspect the present invention is a knitting aid comprising a knitting needle holder including a source of magnetic field, wherein the magnetic field may be used to hold a knitting needle for knitting, plus a yarn tensioning device adjustably connectable to the knitting needle holder. In the preferred embodiment, the source of magnetic field is contained within a magnet housing, and the magnet housing defines a channel proximate to the source of magnetic field, such that a knitting needle may be positioned in the channel and will be held therein by the magnetic field. The source of magnetic field may be a permanent magnet; alternatively, it may be an electrical current or an electrical device.
In the preferred embodiment, the yarn tensioning device includes a member attached substantially perpendicularly to a plurality of proximate members through which yarn can be woven. Yarn traversing the proximate members in succession thus travels along a tortuous path with resulting friction and tension, thereby tensioning the yarn. The yarn tensioning device is adjustably connectable to the knitting needle holder, and preferably is shaped so as to be easy to use by people who may not have complete use of one hand, and such that it facilitates convenient use with either English or European knitting methods. In one embodiment, the yarn tensioning device contains material capable of being attracted by a magnet. As well, the invention may include a yarn tensioning device guide, adjustably mountable to the knitting needle holder, to assist in positioning the yarn tensioning device in a desired position relative to the knitting needle holder.
Also in the preferred embodiment, the knitting aid also includes a mounting attached to the knitting needle holder for securing it in a suitable location. Preferably, the mounting is adjustable such that the knitting needle holder may be roatated and tilted. In one embodiment, the mounting is a C-clamp attached to a fixable rotatable swivel which includes a fixable rotatable ball joint.
The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated and described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of an embodiment of the knitting aid of the present invention, showing the magnetic knitting needle holder, mounting device, and yarn tensioning device.
FIG. 2 is a perspective view of the magnetic knitting needle holder.
FIG. 3 is an elevation view of the back of the magnetic knitting needle holder showing the yarn tensioning device.
FIG. 4 is a top view of the magnetic knitting needle holder showing the magnetic knitting needle holder and yarn tensioning device in use.
DETAILED DESCRIPTION OF THE INVENTION
In the embodiment illustrated in FIGS. 1 to 4 , the invention is a knitting aid ( 10 ) comprising a magnetic knitting needle holder ( 12 ) and a yarn tensioning device ( 16 ). In the preferred embodiment, the knitting aid ( 10 ) also comprises a mounting ( 14 ).
In one embodiment, the magnetic knitting needle holder ( 12 ) comprises a magnet housing ( 20 ) having a channel ( 22 ) sufficiently large so as to contain a knitting needle ( 24 ) with loops of yarn ( 26 ). The magnet housing ( 20 ) may be made of any suitable material such as wood or plastic. The knitting needle ( 24 ) contains material capable of being attracted by a magnet, such as steel. Magnets ( 18 ) are fixed to the magnet housing ( 20 ) sufficiently proximate to the channel ( 22 ) so as to hold the knitting needle ( 24 ) in the channel ( 22 ). The magnets ( 18 ) may be permanent magnets or an electrical device which generates a magnetic field by means of a circulating electrical current provided by means of an electrical wire ( 23 ) as shown in FIG. 4 . In one embodiment, shown in FIG. 2, the magnets ( 18 ) are embedded in the bottom of the channel ( 22 ).
The mounting ( 14 ) comprises a mounting device attached to a fixable rotatable swivel. The mounting device may be any suitable mounting device. In one embodiment, shown in FIG. 1, the mounting device is a C-clamp ( 28 ). In one embodiment, shown in FIG. 1, the fixable rotatable swivel comprises a ball joint ( 30 ) and a ball joint clamp ( 32 ). The ball joint ( 30 ) has a stem ( 34 ) which is connected to the knitting needle holder ( 12 ).
In one embodiment, the yarn tensioning device ( 16 ) is attached to the magnet housing ( 20 ). In a preferred embodiment, the yarn tensioning device ( 16 ) comprises a substantially rectangular plate having a plurality of notches ( 19 ) along one side, with a plurality of proximate members ( 16 a ) defined by the notches ( 19 ). The yarn tensioning device ( 16 ) is attached to the magnet housing ( 20 ) in such a way that the position of the yarn tensioning device ( 16 ) can be adjusted.
In one embodiment, shown in FIG. 3, the yarn tensioning device ( 16 ) contains material capable of being attracted by a magnet, and the invention also includes a yarn tensioning device guide ( 17 ). The yarn tensioning device ( 16 ) is positioned by the user between the yarn tensioning device guide ( 17 ) and the magnet housing ( 20 ). The magnetic force and the yarn tensioning device guide ( 17 ) act together to keep the yarn tensioning device ( 16 ) in the position selected by the user. The yarn tensioning device ( 16 ) can be positioned at either end of the magnet housing ( 20 ) depending on the needs of the user, including whether the user has use of the right or left hand.
As illustrated in FIG. 4, the knitting aid ( 10 ) is mounted in a suitable location with the C-clamp ( 28 ). Then a knitting needle ( 24 ) is placed in the channel ( 22 ) and the magnet housing ( 20 ) is rotated and tilted until a satisfactory knitting position is discovered. The magnet housing ( 20 ) is locked in position with the ball joint clamp ( 32 ). Yarn ( 26 ) is woven through the notches ( 19 ) (FIG. 4) until sufficient tension is achieved. Then the user may begin knitting.
Knitting involves repeatedly looping yarn ( 26 ) around knitting needles ( 24 ). At any time during the knitting process, one or both of the knitting needles ( 24 ) will have a plurality of loops of yarn ( 26 ) around it. For greater clarity, the knitting needle held in the channel ( 22 ) of the knitting needle holder ( 12 ) may be referred to as the stationary needle ( 24 a ). If the stationary needle ( 24 a ) is the knitting needle receiving loops of yarn ( 26 ) during the knitting process, then the stationary needle 24 a may be lifted from the channel ( 22 ) to slide the loops of yarn ( 26 ) onto the stationary needle 24 a . If the stationary needle ( 24 a ) is the knitting needle from which loops of yarn ( 26 ) are being removed during the knitting process, then the loops of yarn ( 26 ) may be slid from between the stationary needle ( 24 a ) and the magnet housing ( 20 ), and the attractive force between the magnets ( 18 ) and the stationary needle ( 24 a ) is sufficient to properly tension the loops of yarn ( 26 ) as they are drawn from the stationary needle ( 24 a ).
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
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A one-handed knitting aid to facilitate hand knitting by persons without the full use of one hand comprises a needle holder with a magnet housing containing a source of a magnetic field, a yarn tensioning device, and an adjustable mounting. The magnet housing has a channel in which a knitting needle may be held by the magnetic field. The mounting may be attached to a convenient object, and may be adjusted so as to tilt or rotate the needle holder.
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FIELD
The present invention relates to sawhorses that can be disassembled when not in use. More particularly, it relates to sawhorses that can be reassembled into a second configuration for convenient transportation or storage.
BACKGROUND
A sawhorse is a useful tool for framers, carpenters, and many other trades, as well as for hobbyists, homeowners and gardeners. The sawhorse provides a simple yet effective working surface in the field and is particularly useful in pairs, although larger numbers are sometimes required. Function and ergonomics suggest that a sawhorse be approximately 30 inches tall, 30 inches long and 15 inches wide at its base. These factors combine to make sawhorses fairly bulky tools to transport or store.
Three main strategies have arisen to compensate for this bulkiness. Some people construct simple, disposable sawhorses at the job-site and abandon them when the job is finished. Others prefer sawhorses that are stackable and therefore somewhat easier to store and transport. Finally, others choose sawhorses that can be quickly disassembled or "knocked down" into their flat component parts. It is this last solution to which the present invention is directed.
Knockdown sawhorses are known to the art. Usually made of plywood or other sheet stock, they rely on simple dado joints and notches to attach legs to a horizontal beam (or "saddle"). When disassembled, most of these sawhorses become three or four independent flat parts which take up less space for storage or transportation than the assembled whole. However, a problem exists in that nothing holds the component parts together. Parts may go missing, resulting in frustration and work stoppages. Furthermore, a user carrying the parts to a job-site will have his hands full of loose parts slipping and sliding.
Two patents partially address this problem by providing components that can be assembled in a first configuration to form a functioning sawhorse and in a second, configuration to form a more compact and easily transportable package.
U.S. Pat. No. 4,923,051 issued on May 8, 1990 to Gerald E. Newville for a, "Collapsible Sawhorse," describes a sawhorse made up of three plywood parts: a saddle and two legs. The saddle is shaped as an elongated T, the crossbar providing a work surface and defining two parallel inverted-U-shaped channels, one against either side of the T-stem. When disassembled and packed for storage, the saddle is inverted and each leg is placed against one side of the saddle T-stem and inserted into one of the channel, friction retaining it snugly within. A handle cut in the saddle T-stem provides a means for carrying the device.
The major problem with this device is that the leg-retaining channels are subject to loosening over time as the sawhorse becomes worn from use. It is not unusual for the saddle of a sawhorse to become quite deeply scored by cutting operations. These cuts will weaken the channels and, where the saddle is not constructed as one integral whole, may even separate the saddle parts. Similarly, the screws or nails used to hold a multi-part saddle together are liable to be struck by a tool such as a saw, thereby damaging both saddle and tool.
U.S. Pat. No. 5,257,829 issued on Nov. 2, 1993 to Fred Weeks for a, "Sawhorse," discloses an alternative solution. The Weeks device comprises a saddle and two A-frame leg assemblies. The saddle is vertically grooved on both sides at each end to receive the leg assemblies and each leg assembly is notched at its apex to receive the saddle. A nut and bolt on each leg assembly allows the notch to be tightened, thereby gripping the saddle. Cross-bracing extends from the centroid of each leg assembly to the middle of the saddle for further stability.
To pack the sawhorse for storage, the two leg assemblies are placed parallel to each other, broad surface to broad surface, and the saddle is sandwiched between them, parallel to one of the legs. The bolt used for tensioning the cross-bracing is then passed through the centroids of both leg assemblies and tightened, holding all parts tightly together by friction. A latch mechanism acts as a physical barrier to prevent the saddle from falling out.
The main problem with the Weeks sawhorse is that it has too many parts. Machined bolts and nuts plus various hinge and latch mechanisms would make this product expensive. Some small parts might become loose and get lost resulting in frustration and lost productivity. The device is also too complicated to be quickly assembled and disassembled.
SUMMARY
What is needed is a cheap and simple sawhorse that can be knock downed and reassembled into a compact, secure package for convenient transportation and storage. The present invention is directed to such a device.
The present invention teaches a collapsible sawhorse having an operating configuration and a storage configuration. The sawhorse includes an elongated saddle and two independent inverted-V-shaped leg members. In the operating configuration, the saddle is supported at either end by a leg member, each leg member engaging one end of the saddle. In the storage configuration, the leg members are free from the ends of the saddle, being instead inverted to point toward the ground as V-shaped members and oriented broad face to broad face on either side of the saddle, retained in place by gravity and friction within two V-shaped channels on either side of the saddle.
In a preferred embodiment, the sawhorse includes a horizontal beam (or "saddle") and two supporting A-frame leg members that have notched apexes for receiving and retaining the saddle in operating configuration so that the working surface of the saddle faces away from the ground and is available for work. The saddle supports four mounting assemblies, two such assemblies at each end, one on either side. Each assembly defines an inclined channel, the channels located at like ends of the saddle being parallel and inclining toward the working surface from their end of the saddle to the far end. These channels are sized to receive and retain the notched apexes of the leg members in the operating configuration. Each mounting assembly further defines an external bearing surface, the bearing surfaces on like sides of the saddle opposing each other and lying on intersecting planes that meet beyond the working surface of the saddle to form an angle equal to the apex angle of the leg members. In storage configuration, the working surface of the saddle is faced toward the ground so that the bearing surfaces form a truncated V-shaped pocket into which the inverted leg members may be inserted for storage.
Therefore, according to one aspect of the invention there is provided for use in combination with first and second convex leg members to make a sawhorse having an operating configuration and a storage configuration, an apparatus comprising: an elongated saddle member having a first end, a second end, a work surface and a first side surface, the first end of the saddle being adapted to releasably engage or be releasably engaged by the first leg member proximate to its apex so as to direct the work surface away from the first leg member when in the operating configuration; and the second end of the saddle being adapted to releasably engage or be releasably engaged by the second leg member proximate to its apex so as to direct the work surface away from the second leg member when in the operating configuration; a first bearing surface normal to and abutting the first side surface, the first bearing surface being proximate to the first end of the saddle and facing the second end of the saddle; and
a second bearing surface normal to and abutting the first side surface, the second bearing surface being proximate to the second end of the saddle and facing the first end of the saddle such that the planes on which the first and second bearing surfaces lie oppose each other and intersect to form an apex angle equal to the apex angle of the first leg member whereby in storage configuration the first leg member may be inserted apex first into the slot defined between the first and second bearing surfaces, to be retained therebetween broad side against the first side of the saddle.
Preferably, the intersecting planes intersect beyond the saddle and particularly beyond the work surface of the saddle. The first and second bearing surfaces might be at least partially recessed into the first side of the saddle or alternatively might at least partially extend beyond the first side of the saddle. In fact, the first and second bearing surfaces might be flanged.
It is desirable that the first leg member be inverted-V shaped, preferably A shaped. The apex of the first leg member can define a longitudinal notch adapted to receive and retain within the first end of the saddle. Similarly, the saddle might define a channel along its first side at its first end, the channel being inclined toward the saddle work surface toward its second end and being adapted to receive and retain within a portion of the notched apex of the first leg member. The channel might be at least partially recessed within the saddle or the channel might at least partially project from the saddle.
The saddle might further include a carrying surface opposite the work surface and a second side surface opposite the first side surface. It is desirable that a handle be affixed to the carrying surface are be formed as an integral portion of it.
Preferably, the saddle includes a third bearing surface normal to and abutting the second side surface, the third bearing surface being proximate to the first end of the saddle and facing the second end of the saddle; and a fourth bearing surface normal to and abutting the second side surface, the fourth bearing surface being proximate to the second end of the saddle and facing the first end of the saddle such that the planes on which the third and fourth bearing surfaces lie oppose each other and intersect to form an apex angle equal to the apex angle of the second leg member whereby in storage configuration the second leg member may be inserted apex first into the slot defined between the third and fourth bearing surfaces, to be retained therebetween broad side against the second side of the saddle.
The first and second leg members may be gussetted at their apex, and in such case, there might be included a first pair of complemental couplers, one so placed on each gusset that the first pair of complemental couplers engage each other when the first and second leg members are retained between the first and second bearing surfaces and the third and fourth bearing surfaces respectively.
There might further be included a second pair of complemental couplers, one so placed on each of the first side of the saddle and the broad side of the first leg member that the second pair of complemental couplers engage each other when the first leg member is retained between the first and second bearing surfaces.
There might be included a third pair of complemental couplers, one so placed on each cross-brace that the third pair of complemental couplers engage each other when the first and second leg members are retained between the first and second bearing surfaces and the third and fourth bearing surfaces respectively.
Preferably, the pairs of complemental couplers are formed from hook and loop material.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a side view of a sawhorse embodying one aspect of the present invention in operating configuration,
FIG. 2 is an end view of a leg from the sawhorse illustrated in FIG. 1;
FIG. 3 is a side view of the sawhorse illustrated in FIG. 1 in storage configuration;
FIG. 4 is an alternative embodiment of the sawhorse illustrated in FIG. 3.
DESCRIPTION
With reference now to FIG. 1, a sawhorse embodying one aspect of the invention is generally illustrated at 10. The sawhorse 10, which is here depicted in its operating configuration, is formed from an elongated saddle 12 supported by first and second leg members 14, 14' which engage the saddle via first and second mounting assemblies 16, 16'.
The saddle has first and second ends 18, 20, a working surface 22 that faces away from the ground in the operating configuration, a carrying surface 24 that faces toward the ground in the operating configuration, and first and second side surfaces (26, not shown). The saddle is approximately 30 inches long and may be made of standard 1"×5" lumber, oriented so that the thick five inch thickness spans between the working surface 22 and the carrying surface 24.
With reference now to FIG. 2, one leg member 14, 14' is illustrated in greater detail. Each leg member 14, 14' has an inverted-V shape with an apex 28, 28' that defines a notch 30, 30'. As illustrated, the leg members 14, 14' are formed from opposing risers 32, 32', 34,34' that are linked by a cross-brace 36, 36' and a gusset 38, 38'. Each leg member 14, 14' may be built of lumber: 1"×4"s for the risers 32,32' 34,34' and plywood for the cross-bracing 36, 36' and the gusset 38, 38'. The cross-bracing 36, 36' joins the risers 32, 32', 34, 34' approximately four inches from the ground and the gusset 38, 38' reinforces the risers 32, 32', 34, 34' about three inches from their top. The gusset 38, 38' also serves to provide vertical support to the saddle 12. It has been found that an apex 28, 28' angle of 30 degrees contributes to good sawhorse 10 stability.
It should be noted that this construction is illustrative but not critical to the invention and many sorts of saddle 12 and leg member 14, 14' would suffice. In particular, it is envisioned that each of these components 12, 14, 14', 36, 36', 38, 38' could be manufactured in one or more pieces from plastic.
With reference now to FIGS. 1 and 3 the mounting assemblies 16, 16' will be described in further detail. There are two key features embodied in the mounting assemblies 16, 16'. In the operating configuration (FIG. 1), the mounting assemblies 16, 16' retain the leg members 14, 14' at a suitable orientation to the saddle 10 to form a stable sawhorse 10. In the storage configuration (FIG. 3), they retain the inverted leg members 14, 14' broad side against the side 26 of the saddle 12. It will be seen that the leg members 14, 14' are retained within inclined channels 40, 40' in the operating configuration (FIG. 1) and retained within a truncated V-slot sandwiched between two bearing surfaces 42, 42' in the storage configuration. It should be understood that there are identical inclined channels and bearing surfaces (not shown) on the far side of the saddle 12 (not illustrated).
The channels 40, 40' at each end 18, 20 of the saddle 12 are inclined towards the working surface 22 toward the far end 20, 18 of the saddle 12. It has been found that a 75 degree angle formed between the channel 40, 40' and the ground provides a suitable oriented leg assembly 14, 14' and reasonable sawhorse 10 stability in the operating configuration.
Each mounting assembly 16, 16' may be formed from a pair of opposing fingers 44, 44', 46, 46' that are so arranged as to ensure the channel 40, 40' is appropriately oriented and sufficiently wide to accept and snugly retain the leg members 14, 14'. The fingers may be 1"×1" strips attached to the saddle 12 by means of glue, screws, nails, staples or other suitable fasteners. Two pairs are placed at each end of the saddle, on opposite sides. Each pair of strips defines a raised channel whose width is slightly greater than the thickness of the A-frame material.
On each side (26, not shown) of the saddle 12, the pair of mounting assemblies 16, 16' are arranged so that the bearing surfaces 42, 42' oppose each other and form between them a truncated inverted-V-shaped slot. The bearing surfaces 42, 42' lie on planes that intersect beyond the working surface 22 of the saddle 12 to define an angle equal to the apex angle 28, 28' of the leg members 14, 14'. In the storage configuration with the saddle 12 inverted so that the carrying surface 24 faces away from the ground, the bearing surfaces 42, 42' form between them a truncated V-shaped slot adapted to receive and retain the inverted leg members 14, 14' for storage. It should be noted that, as shown in FIG. 3, the bearing surfaces 42, 42' could be channelled or otherwise overhung 43, 43' to even better retain the leg members 14, 14'. FIG. 4 illustrates an alternative embodiment of the sawhorse wherein the bearing surfaces 42, 42' are not overhung.
Additional hardware may be added to make the sawhorse 10 easier to use in either configuration. A handle 46 on the carrying surface 24 of the saddle 12 doesn't interfere with the working surface 22 but helps transport the stowed sawhorse 10. Hook fasteners 48, 48' on the leg assemblies 14, 14' and cooperating eye fasteners 50, 50' on the carrying surface 24 of the saddle 12 help retain the sawhorse 10 in its working configuration (FIG. 1) while the eye fasteners 50, 50' can be used to secure the sawhorse 10 in storage configuration (FIG. 3), serving as a fastening point for pegboard fasteners, rope, and the like.
Cooperating fasteners such as hook and loop fasteners 52a, 52b, 52'b, 54a, 54b, 54'b, 56, 56', 58, 58', 60, 60' releasably secure the leg members 14, 14' to each other and to the saddle 12 in storage configuration. It will be noted that the plywood for the cross-brace 36, 36' and the gusset 38, 38' is approximately one half of the thickness of the saddle, about 5/16ths or 3/8ths of an inch. When the leg members 14, 14' are placed on either side of the saddle for storage, the cross-brace 36, 36' and the gusset 38, 38' of one leg member 14, 14' will just contact that of the other, and the cooperating fasteners placed on the cross-braces 36, 36' and the gussets 38, 38' will engage.
In operation the user carries the sawhorse 10 to the job-site in its storage configuration (FIG. 3) using the handle 46. He then disengages the cooperating fasteners 52a, 52b, 52'b, 54a, 54b, 54'b, 56, 56', 58, 58', 60, 60' that fasten the leg members 14, 14' to each other and to the saddle 12. To put the sawhorse 10 in its operating configuration (FIG. 1), he rotates the saddle 12 so that the working surface 22 faces away from the ground.
He then slides the ends 18, 20 of the saddle 12 into the apex notches 30, 30' of the leg members 14, 14' and the apex notches 30, 30' into the channels 40, 40' of the mounting assemblies 16, 16'. The leg assemblies 14, 14' are thereby snugly engaged to the saddle 12 and the sawhorse 10 is ready for use.
To stow the sawhorse 10, the leg members 14, 14' are disengaged from the saddle 12 and the mounting assemblies 16, 16'. The saddle 12 is then inverted so that the carrying surface 24 faces away from the ground and the bearing surfaces 42, 42' on each side of the saddle (26, not shown) form a truncated V-shaped slot for receiving and retaining the inverted leg members 14, 14'. The leg members 14, 14' are inverted and inserted into the truncated V-shaped slots in the saddle 12 and the complemental couplers 52a, 52b, 52'b, 54a, 54b, 54'b, 56, 56', 58, 58', 60, 60' are engaged.
Although a specific embodiment of the present invention has been described and illustrated, the present invention is not limited to the features of this embodiment, but includes all variations and modifications within the scope of the claims.
For example, it is envisioned that the bearing surfaces 42, 42' do not need to be an integral part of the channel 40, 40' defining mechanism 44, 44', 46, 46'.
It is also envisioned that the bearing surfaces 42, 42' might oriented such that the working surface 22 and the carrying surface 24 are identical.
It is still further envisioned that the leg members 14, 14' need not be v-shaped but may be any convex or planoconvex shape.
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A stowable knockdown sawhorse can be assembled in two configurations: an operating configuration and a storage configuration. The sawhorse includes a pair of inverted-V-shaped leg members and a saddle having four mounting assemblies--two at each end, one per side. Each leg member has a notched apex that envelops one end of the saddle and is in turn enveloped within an inclined channel formed within each mounting assembly, thereby forming the sawhorse into its operating configuration. Each mounting assembly further defines an exterior bearing surface, the bearing surfaces on like sides of the saddle facing and opposing each other and lying on planes that intersect beyond the saddle working surface to form an angle equal to the apex angle of the leg members. The bearing surfaces are thereby oriented to accept and retain therebetween the leg assemblies when disengaged from the ends of the saddle and inverted between the bearing surfaces to form the sawhorse into its storage configuration.
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This application is a continuation-in-part of application, Ser. No. 578,592, filed on May 19, 1975 in the names of Norman C. Sidebotham, Paul D. Shoemaker and Clarence W. Young, III, for "Fabric Dye Stripping, Separation and Recovery of Polyester", now U.S. Pat. No. 4,003,880.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for selectively recovering thermoplastic polymers, and particularly polyester polymers from collections of yarns, films, fibers or fabrics, including dyed polyester fibers, for use in production of new undyed thermoplastic products, particularly polyester fibers, films and the like. More specifically, the invention relates to a process for selectively recovering polyester polymer by means of stripping the dye from dyed polyester fibers, subsequently dissolving the polyester fibers, separating the solution from any insoluble materials, and thereafter recoverying the polymer, without precipitation thereof, by evaporation of the solvent from the molten polymer.
2. Prior Art
The consumption of thermoplastic polymers is greater than ten billion pounds per year. Some, such as polyethylene, polypropylene, polyvinylchloride, polystyrene, polyamides and polyester, surpass the billion pounds per year rate. The use of many of these relatively expensive thermoplastic polymers for synthetic fibers has, notwithstanding significant periods of decline, increased tremendously.
Concomitantly the world is facing a shortage of raw materials for thermoplastic polymers; and sophisticated and efficient methods of recycling are needed.
Various methods have been described in the prior art for separation and/or recovery of thermoplastic polymer, including polyester polymers, from scrap polymers; and these have included the dissolution of the polymer in various solvents; thereafter precipitating and recovering the polymer. The objects of such processes were to avoid polymer degradation and/or to separate from the usable polymer the degraded polymer and/or monomers as impurities. The processes were slow and expensive; suitable only for laboratory usage; and they neither addressed themselves to nor did they solve fiber separation and dye removal problems.
Our copending U.S. patent application Ser. No. 578,592 filed May 19, 1975, now U.S. Pat. No. 4,003,850, discloses a process for recoverying polyester from waste fabrics or fibers by dye stripping, selectively dissolving the polyester fibers, removing the undissolved fibers and any other undissolved impurities from the solution; and thereafter precipitating polyester out of, and separating the polyester from the solution.
Whether by prior art processes or by the copending process described, the precipitation of polyester out of solution inevitability brings forth with the precipitated polyester polymer substantial quantities of the solvent and dye which must be separated from the newly precipitated polymer by way of decantation and/or filtration (for gross separation) as well as evaporation or solvent leaching or washing (for trace removal). Since the precipitation step does not eliminate the necessity for evaporation or equivalent treatment, and complicates rather than simplifies dye removal, it will be seen that elimination of the precipitation step in an efficient method of separating the polyester polymer from the solvent would be a meritorious advance in the art, and constitutes a primary object of this invention.
It is another advantage of this invention that the same solvent or solvent system may be used for both dye-stripping and polymer recovery, as well as for fiber separation.
It is also an advantage of this invention that removal of solvent from recovered polyester is greatly simplified and that solvent removal may be conveniently combined with a polymerization step wherever needed to increase molecular weight.
SUMMARY OF THE INVENTION
In accordance with the present invention, a process is provided whereby dye-stripping, separation and polymer recovery are combined in such a manner that the dye-stripping phase actually constitutes the first step of the dissolution and separation phase in that after completion of the so-called "dye-stripping" phase the fibers remain saturated with a dye-stripping solvent which serves as part of the solvent used for dissolution of the polyester, so that only one solvent system may be employed.
Briefly, the inventive concept is a process for selectively recovering polyester polymer from collections of dyed fibers or fabrics including dyed polyester fibers, comprising:
(1) contacting collections of yarns, films, fibers, or fabrics, including dyed polyester fibers with a dye-stripping solvent for polyester polymer which is preferably not a solvent for the remaining constituents at a temperature below which the polyester fibers dissolve and above which the crystalline lattice of the polyester fibers swell to as to release the dye, thereby stripping the dye from the polyester fibers;
(2) removing the excess of the dye-containing dye-stripping solvent which is not absorbed by the fibers and fabrics;
(3) contacting the fibers (which may contain residual dye-stripping solvent) with sufficient addition of a primary dissolution solvent under selective dissolution conditions for polyester fibers;
(4) removing the undissolved fibers or other solid impurities from the solution; and
(5) separating the solvent or solvents from the polyester by evaporaing the solvent from dissolved and/or molten polyester without precipitating the polyester from solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of this description, solvents will be classified as "dye-stripping solvents" and "primary dissolution solvents". A "dye-stripping solvent", as used herein, is any solvent which swells the crystalline structure of the polyester fiber, at the same time dissolving and thereby removing conventional dyes and finishes. It is selective in nature in the sense that it will dissolve a minimum, if any, of polyester and preferably will neither dissolve nor swell other components in the starting collection of materials. A "primary dissolution solvent" is a solvent whose primary function in the course of this invention is to dissolve the polyester. It should have the characteristic of dissolving a significant amount of polyester, selectively with respect to other components in the starting material, at moderate temperatures, all the while permitting subsequent removal from the polyester by vaporization. All presently known "primary dissolution solvents" are also "dye-stripping" solvents (when employed at lower temperatures and/or lower concentrations), but the converse is not necessarily true. Of course it is preferred, according to this invention, that the dye-stripping solvent and the primary dissolution solvent be the same, and such identity is one aspect of this invention. If identical solvents are not used, it is desirable that they be compatible in the sense that they do not functionally interfere with one another and that they be readily separable or functionally interchangeable, as this will permit a much more simplified recovery system.
It is also preferred that solvents employed in this invention do not significantly degrade or depolymerize the polyester under conditions required for removal by evaporation. In addition, the solvents should have the characteristic of being essentially non-solvents for the other components in a collection of yarns, films, fibers, fabrics, etc., if such a collection is employed as the starting material. Of course, whenever solvents are used together they should be compatible in the sense that they do not explode or react violently.
Suitable dye-stripping and primary dissolution solvents include most of the so-called "polyester dye carriers" which can be easily removed from the fibers under vacuum at a temperature at which no degradation occurs. It is well known, for example, that most solutions of the following compounds will cause an increase in the diameter of the polyester fiber immersed therein: phenol, metacresol, tetrahydronaphthalene, ortho-phenylphenol, paraphenylphenol, and such compounds may be employed as either dye-stripping solvents or primary dissolution solvents or both. Other known solvents and solvent systems for polyester which may be employed for both dye removal and dissolution include para-chloroanisole, nitrobenzene, acetophenone, propylene carbonate, dimethyl sulfoxide, 2,6 xylenol, quinoline, trifluoroacetic acid, ortho-chlorophenol and trichlorophenol. Preferred are polyester solvents and solvent systems which include compounds having at least one or more and more commonly two or more aromatic rings in their structure such as diphenyl, diphenyl ether, naphthalene, methylnaphthalene, benzophenone, diphenylmethane, paradichlorobenzene, acenaphthene, phenanthrene and similar compounds. Naphthalene has been found especially suitable for the practice of this invention for dye-stripping and as a primary dissolution solvent because the solubility of polyester in naphthalene is a strong function of temperature, ranging from 0 solubility at 170° C. to about 55 percent polyester solubility at 218° C. (boiling point of naphthalene). Naphthalene is also highly selective in the sense that although minor amounts of nylon 66 (<0.1%) may dissolve, it will not, at up to 218° C., dissolve most other common fibers including acetate, cotton, rayon, wool, silk, flax, nylon-6, acrylic, glass and metallic fibers, nor will it dissolve paper, glass or metal scraps.
Polyester solvents and solvent systems other than naphthalene which are known to be and have been demonstrated as suitable for dye-stripping and selective dissolution of polyester, are listed in the following table showing acceptable dissolution conditions only.
TABLE I__________________________________________________________________________ Selective of polyester as Approx. Ratios against all common fibers* (where applicable) except__________________________________________________________________________ Meta-cresol (25° C.) 100 Acetate, nylon 6, nylon 66 Benzophenone (210° C.) 100 Acetate, polypropylene 1,1,1,3,3,3-Hexafluoro- Acetate, acrylic, nylon 6, isopropanol (25° C.) 100 nylon 66 Diphenylmethane (210° C.) 100 Acetate (<1/3%), acrylic (˜1/2%) [Note: polypropylene melts but floats in separate phase] Biphenyl (210° C.) 100 None [Note: polypropylene melts but floats in separate phase] Acenaphthene (210° C.) 100 None [Note: polypropylene melts but floats in separate phase] Phenanthrene (210° C.) 100 Polypropylene__________________________________________________________________________ "Common fibers" are: acetate, acrylic, cotton, wool, nylon 6, nylon 66, polypropylene, and rayon.
The preliminary dye removal may be accomplished by any method of immersing, or otherwise intimately contacting and agitating the fiber or fabric collection with the dye-stripping solvent, in any manner which removes all or most of the dye concentration in the fiber or fabric collection. Any one of the following methods may be used to accomplish the preliminary dye removal. Although the starting material is described as "fabric" or "fabric collection", it should be understood to include "fibers" as hereinafter defined.
1. Contacting a batch of fabric with a large amount of dye-stripping solvent, which quantity is large enough to dilute the dye concentration in the fabric to the desired level.
2. Contacting a batch of fabric with dye-stripping solvent which the dye-containing solvent is agitated if desired and continuously removed and replaced with fresh or relatively dye-free dye-stripping solvent, in sufficient quantity to reduce the fabric's dye concentration to the desired level.
3. Contacting a batch of fabric with fresh or relatively dye-free dye-stripping solvent, using agitation if desired, for a given batch contact time; thereafter removing substantially all of the dye-containing solvent and contacting the fabric with fresh or relatively dye-free dye-stripping solvent, with agitation if desired; for some period of contact time which may differ from the original or subsequent batch contact times; thereafter repeating as many times as desired such dye-stripping solvent addition, fabric contacting, and solvent removal, in order to obtain the desired degree of dye removal from the fabric. (This method is substantially equivalent to the laboratory Soxhlet extractor.)
4. Fabric or a fabric collection is continuously moved along a path or conduit in one direction while simultaneously being contacted with a dye-stripping solvent, which solvent is more or less continuously flowing in a direction opposite to the movement of the fabric. Fresh or relatively dye-free dye-stripping solvent is added in a manner which maintains a relatively continuous flow of the dye-stripping solvent, and the dye-containing dye-stripping solvent is more or less continuously removed at or near the place where the fabric or fabric collection is first contacted with the dye-stripping solvent.
5. Fabric or a fabric collection is successively contacted with dye-stripping solvent in a multiplicity of dye-stripping solvent contact stages, with said contact stages arranged in such a manner that each subsequent contact stage reduces the dye concentration in the fabric collection; especially a counter-current flow arrangement of contact stages, in which fresh or relatively dye-free dye-stripping solvent is added only to the final fabric contact stage, with a more or less equal amount of dye-containing dye-stripping solvent removed from the final stage and added to the dye-stripping solvent in the next-to-final contact stage, such counter-current flow replenishment continues for as many contact stages as are used, with the dye-laden dye-stripping solvent removed from the first fabric contact stage.
Of course, in these dye-stripping solvent contacting processes, the fabric or fabric collection may be added to the dye-stripping solvent, or the dye-stripping solvent may be added to the fabric or fabric collection. Similarly, of course, the fabric may be moved through dye-stripping solvent which is kept more or less in one place; or the fabric may be held more or less at one place while the dye-stripping solvent is moved into contact with and subsequently removed from the fabric or fabric collection; or, both the fabric and dye-stripping solvent may be moved simultaneously or alternately.
For efficient dye-stripping without polymer loss, the temperature of the dye-stripping solvent during the dye-stripping phase must be below the temperature at which there is significant dissolution of the polyester fibers. However, it is well known among textile dyeing and finishing experts that most efficient dye-stripping of polyester fibers will occur at the highest temperature practical because of swelling of the crystalline lattice of the polyester is greatest at the higher temperatures. A significantly lower temperature will decrease swelling of the fiber, and at just above the freezing or solidification point of the solvent, there will be little or no dye-stripping. Preferred, therefore, is the highest temperature below which there is significant dissolution of the polyester.
Apparatus or equipment which may be used for the preliminary dye removal operation include tanks or vats, which may be agitated or not agitated, whether open top or covered or sealed to hold pressure or vacuum; bowl-type washing machines; pressure dyeing apparatus; centrifugal filters, with or without provisions for solvent rinsing or continuous or intermittent removal of fabric; continuously or intermittently moving conveyor belts passing through solvent-contacting zones; screw conveyor devices; and solvent spraying devices.
When the preliminary dye-stripping step is completed, and the dye-containing dye-stripping solvent is removed, the remaining wet fabric or collection of fabrics containing residual dye and solvent is contacted with sufficient additional relatively dye-free primary solvent under dissolution conditions for the polyester fibers. Of course, the residual dye-containing solvent-laden fabric may be added to the primary solvent, or the primary solvent may be added to the fabric. As previously mentioned, the additional primary dissolution solvent may or may not be the same solvent or solvent system as employed for dye-stripping; but it is preferable to use the same solvent or solvent system for process efficiency, simplicity, and economy. A recycling system is much preferred over a non-recycling system; and it might well be essential to the commercial feasibility of the process. Incompatible solvents or solvent systems would add to the complexity and cost of any such recycling.
When the polyester fibers have dissolved, any undissolved fabrics are removed from solution for discard or for subsequent use. The removal may be accomplished by any known physical separation procedures such as screening, centrifuging, decanting, filtration or any combination of these procedures.
We have found that polyester can be then recovered from a molten polyester solution by heating the solution above the boiling point of the solvent (or solvents), removing solvent vapors (for subsequent condensation and reuse), possibly displacing the solvent vapors with another gas such as an inert gas sweep. The removal of solvent by atmospheric boiling is usually slow and may require temperatures so far above the melting point of the polyester that polymer degradation can occur. Atmospheric boiling may also result in a high level of residual solvent with the polymer. In a solution composed of 70% naphthalene and 30% polyester, for example, atmospheric boiling at 260° failed to remove at least about 12% of the naphthalene. It has been found that a much more efficient procedure in the recovery of polyester from most dissolution solvents (and most particularly from the preferred class of solvents having at least one and more commonly two or more of the aromatic rings in their structure) is to boil vigorously at atmospheric pressure for a short time using a heat transfer medium slightly above the melting point of the polyester, and then sustain this vigorous boiling by applying a vacuum to the molten solution.
Of course temperature and pressure interact during the vacuum solvent boil-off. If the vacuum is applied too rapidly, very rapid vaporization of solvent cools the molten polyester solution enough to actually freeze it. If the polyester solution freezes (even only partially), the vaporization process is slowed considerably, and the recovered polyester will contain much more residual solvent. The higher the temperature of the molten polyester solution, the faster the vacuum can be applied for rapid solvent removal without freezing. As mentioned before, however, the higher temperature can promote polyester degradation; and therefore a balance must be maintained between the solution temperature and the rate of vacuum application.
Polyesters and copolyesters known to be useful in the practice of this invention are those derived from aromatic dicarboxylic acids such as terephthalic acid and isophthalic acid and glycols such as ethylene and butylene glycol. Representative examples include poly(ethylene terephthalate), poly(trimethylene terephthalate), poly(tetramethylene terephthalate), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(tetramethylene isophthalate), poly(hexamethylene isophthalate), poly(1,4-cyclohexylene terephthalate), and poly(ethylene-co-tetramethylene terephthalate).
Unless otherwise indicated, the terms "collections of fibers" and "polyester fibers", as used herein to describe the starting material which is subjected to dye-stripping, separation and recovery in accordance with this invention, includes fibers, filaments, monofilaments, bands, ribbons, tubes, films and other constructions of linear polyester and includes yarns, threads, fabrics and other products into which these constructions may be incorporated, as well as common impurities associated with such products, new or old.
EXAMPLES
The feedstock was first prewashed in naphthalene at 165° C. (whenever dye was present in the starting material). Polyester feedstock was then dissolved in naphthalene at about 30% polyester and at a solutioning temperature of about 210° C. The solution was then filtered to remove insoluble contaminates such as nylon, acrylics, paper, cotton, wool, silk, rayon, acetate and metals. The polyester/naththalene solution was then boiled in an oil-heated 3-neck boiling flask, fitted with a thermometer, an inert gas purge nozzle, and a short air-cooled condenser connected to a 2-neck flask, which functions as a naphthalene collector. A small purge of inert gas was used to sweep naphthalene vapors into the condenser. Boiling was accomplished in an oil bath maintained at a temperature of 260° C.-270° C. When the rate of boiling declined, the vacuum was slowly applied to the apparatus through the second neck of the naphthalene collector. A vacuum regulator was used to control the vacuum pull-down rate on the boiling solution to minimize foaming, splashing, and possible freezing of the solution. When solvent removal was completed, the vacuum was replaced with dry nitrogen and the flask was removed from the hot oil. The inert blanket was maintained as the polyester cooled and froze. The flask was wrapped in cloth because expansion of the solidifying polyester breaks the flask. After cooling was complete, the polyester product was recovered from the broken flask for analysis and subsequent spinning to fiber.
Using a controlled polyester flake stock having an intrinsic viscosity of 0.6413, the following recovery processes were employed as above using the finishing vacuum as indicated.
TABLE II______________________________________ Finishing Residual Intrinsic Vacuum Naphthalene ViscosityExamples (mm Hg) (Wt. %) of Product______________________________________1 760 11.83 0.66312 500 8.88 0.59153 300 3.15 0.63984 150 1.00 0.66515 80 0.12 0.67266 42 Neg. 0.70047 42 0.06 0.66108 24 Neg. 0.99759 23 Neg. 0.7707______________________________________
As can be seen from Table II, there was no significant drop in the intrinsic viscosity of the product, and in some cases it appeared that the viscosity was increased. Any such increase is believed to have been caused by further polymerization occurring during the vacuum removal phase.
Mixed polyester waste fabric was subjected to the same procedure, with the result that although the initial intrinsic viscosity could not be ascertained, recovered polymer of comparable fiber viscosity was obtained which appeared to be reasonable pure based on color observation. These recovered polymer samples were of a quality which could be subjected to melt spinning into synthetic fibers. The spinning procedure was to place chunks of recovered polyester in a laboratory autoclave; pressurize several times with dry nitrogen; place a vacuum (20-40mm Hg) on the autoclave; heat the autoclave until the polyester melts; bleed off the vacuum with dry nitrogen; remove the agitator shaft and affix a spinneret pack; apply dry nitrogen pressure to form filaments from the spinneret; and take up bobbins of the fiber on a Leesona Type 955 winder. Spun bobbins were subsequently drawn over a hot pin at 105° C. at several known draw ratios and physical properties of the drawn fiber were measured. Only crude indications of spinnability and drawability were obtained due in large part to the lack of denier control. The intrinsic viscosity of the recovered prewashed polyester mixed rag feedstock was 0.6867. The spun yarn (10 filaments with conventional fiber finish) was successfully drawn over a hot pin at 105° C., with drawn fiber properties as indicated in Table III.
TABLE III______________________________________Draw Drawn Tenacity ElongationRatio Denier (g/d) (%)______________________________________4.78 85.5 3.88 15.375.00 83.0 4.33 10.625.50 77.5 3.43 7.23______________________________________
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Polyester polymer is recovered from mixed collections of fibers in the form of fibers, filaments, yarns, or fabrics (including dyed or undyed fibers other than polyester fibers as well as dyed polyester fibers) and used in the production of new undyed fibers, by solvent stripping the dye from the polyester fibers without dissolving the fibers, and with additional solvent, selectively dissolving the polyester fibers in successive but functionally integrated steps; separating the dissolved fibers from an undissolved impurities and thereafter separating the residual dye-stripping solvent and the additional solvent from the polyester component without precipitiating the polyester component from solution by evaporating the solvent, preferably by atmospheric boiling and vacuum finishing of the molten solution.
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BACKGROUND OF THE INVENTION
The invention concerns an automatic multispindle turning lathe in which at least one cross-carriage carrying a tool holder is associated with at least one of the working spindles supported in a horizontally supported switchable spindle drum, each cross-carriage being movably guided in a guide body of a cross-carriage assembly provided on the bearing housing of the spindle drum.
In a known practical version of an automatic multispindle turning lathe of the initially mentioned type, the guide bodies of the individual cross-carriage assemblies carrying the cross-carriages form consoles built onto the bearing housing of the spindle drum. The cross-carriage assemblies are arranged symmetrically to the vertical, those for the lower working spindle pair being located in the horizontal plane and those for the center and upper working spindle pair being provided on each side in planes which are parallel to each other and in oblique position, the carriage assemblies being movable.
This type of carriage arrangement results in the cross-carriages being mounted partly on the underside of the bearing consoles of the cross-carriage assemblies, so that their turning tool holders must be suspended on the underside of these cross-carriages. This results in different working directions of the tools, which in turn requires different mounting positions of the latter on the turning tool holders, which is of particular disadvantage for a preadjustment of the turning tools (see the book "Automatic Turning Lathes" by Dr. H. Jager, p. 250).
In another machine design which is part of the state of the art, attempts have now been made to remedy the disadvantage resulting from the preadjustment of the turning tools by their different mounting positions by having all cross-carriage assemblies arranged at identical angular distances and in such a way that the path of tool displacement is located in planes passing through the respective spindle center and spindle drum center and the cross-carriages of the individual cross-carriage assemblies in the circumferential direction are each located on the same side of these planes. Although this measure allows the location of all turning tools in the tool holders at the same level, the cross-carriages in this design must also be provided below the consoles bearing them or in such planes that access to the tools of the rear lower as well as the front upper cross-carriage, for example, is difficult or unfavorable. Furthermore, this design makes it necessary to provide a cross-carriage in a zone of the machine working space where the chips drop down, with an unfavorable effect on chip removal.
The same disadvantages also exist with a cross-carriage arrangement according to German Utility Model Pat. No. 7,408,962, for it also requires a partly suspended arrangement of turning tools which not only requires different mounting positions but also results in difficult access to the tools and which requires the installation of a lower cross-carriage assembly in such a zone that the chips produced are hindered from removal from the working area.
SUMMARY OF THE INVENTION
This invention has as one object, to provide a construction and arrangement of cross-carriage assemblies which allows a constant mounting position of the turning tools for all cross-carriages on an automatic multi-spindle turning lathe and allows a rapid and simple change of the tools as well as unhindered chip removal.
According to the invention, this objective is realized by the fact that the tool holders of the cross-carriages of the cross-carriage assemblies are located on their front ends turned toward their respective working spindles and that the direction of displacement of the cross-carriages together with tools essentially is oriented toward the spindle center of the respective working spindle.
The special arrangement of tool holders on the cross-carriages as well as their selected direction of displacement provide the prerequisites that the same conditions for turning tool arrangement and their favorable handling are provided for all cross-carriages on one hand, and that a compact construction of the cross-carriage assemblies is possible, on the other hand, which no longer results in a cross-carriage arrangement with an unfavorable influence on chip removal.
The above-described known cross-carriage arrangements have an additional important disadvantage in the fact that the tool holder must be arranged so as to be movable and fixable in guide grooves of the cross-carriages parallel to the axis of the working spindle, so that the tool holders can be positioned at any desired point over the entire area to be subjected to transverse machining. Accordingly, consoles and cross-carriages of the cross-carriage assemblies must have a sufficient width in order to provide the necessary adjustment range of the turning tool holder with adequate stability. The necessary overall width of the cross-carriage at the same time is a considerable obstacle to chip removal and represents a further obstruction to access to the working space and tool holders.
These disadvantages and difficulties can be avoided by the design of the invention by the fact that the guide body of the cross-carriage assemblies in the bearing housing is displaceable and fixable in axially-parallel direction to the working spindles, for which purpose it will be of advantage to use a conventional drive system provided in the bearing housing of the spindle drum.
As a result, the width of the cross-carriages and guide bodies or the cross-carriage assemblies as a whole can be kept very small or narrow, so that their width dimensions are essentially limited to the machining site. Consequently, the room needed otherwise for the usual adjustment range of the tool holder on the cross-carriage has been made available for chip removal. The displaceability of the cross-carriage assemblies as a whole offers a further advantage that the respective displacement equipment can now also be used for longitudinal turning, so that longitudinal turning work can be performed with the cross-carriage assemblies, which was not possible in the prior art. Auxiliary drives which otherwise would have to be passed through the working space can be omitted.
In a preferred practical version, the cross-carriages are guided within the guide bodies designed as guide housings and their tool holder is exchangeably located in the front end of the cross-carriages. This design allows a particularly compact construction of cross-carriage assemblies. It results in a favorable design when the cross-carriages are formed by the piston rod, which is guided in the guide housing, of a hydraulically driven piston guided in a barrel of the guide housing, so that the drive shafts to drive the cross-carriages can be omitted. To the extent to which the invention is applied to automatic multispindle turning lathes in which the upper and lower working spindle pair are located in a horizontal plane after each switching of the spindle drum, a favorable cross-carriage arrangement results if at least the cross-carriages of the cross-carriage assemblies assigned to the two working spindles which are at the top after each switching of the spindle drum are displaceably arranged side-by-side and parallel to each other. To the extent to which one cross-carriage assembly is assigned to all working spindles, the parallel arrangement of the cross-carriages assigned to the upper two working spindles results in a relatively large distance to the neighboring cross-carriage assemblies, so that the working space of the turning machine becomes very simple and accessible. Furthermore, this parallel arrangement of cross-carriage assemblies allows the assignment of further cross-carriage assemblies to the other spindles, so that working piece machining can be divided into several passes at the individual stations. In this case, for example, longitudinal and flat-face operations can be performed, where otherwise only one plunge-cutting operation is possible. Furthermore, the possibility of dividing machining into several working passes results in simpler shapes of the turning tools which are also better suited for preadjustment. The cross-carriage arrangement of the invention furthermore allows the installation of automatic workpiece handling equipment and still permits a larger number of cross-carriage assemblies. For example, if two cross-carriage assemblies are to be assigned to several working spindles, these will be arranged at an acute angle, where it is of advantage for every conceivable arrangement of cross-carriage assemblies if their cross-carriages have the same angular ddistance of, preferably, 30° with respect to the planes passing through the axes of diametrically opposite working spindles. In this connection it is also of advantage if one of the two cross-carriages assigned to the working spindles at an acute angle is arranged to be displaceable parallel to one cross-carriage of two cross-carriage assemblies assigned to a neighboring working spindle.
Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic front elevational view of a six-spindle drum of an automatic multispindle turning lathe, with one cross-carriage assembly being assigned to each working spindle;
FIG. 2 is a fragmentary side elevational view of the carriage arrangement according to FIG. 1 seen in the direction of arrow A of FIG. 1; and
FIGS. 3 and 4 are schematic front elevational views of other possible variants of cross-carriage arrangements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
In FIG. 1, No. 10 designates a bearing housing of a horizontally supported spindle drum 12 of an automatic multispindle turning lathe 13 in which, for example, six working spindles 14 are supported at equal angular distances so that they can be driven by conventional means (not shown) for turning about the drum axes to hold the drum in a fixed, preselected position. A cross-carriage assembly 16 is assigned to or is operatively associated with each working spindle. These are hydraulically driven, i.e. the acutal cross-carriage 18 comprises a piston rod of a piston 20 which is displaceably guided in a barrel 22 of a guide housing 24 forming the guide body of the cross-carriage 18. Two cylinder chambers of barrel 22 provided on opposite ends of piston 20 can be alternately connected with a hydraulic oil source (not shown) so that the cross-carriage 18 can be appropriately driven in either of the two axial directions. As is clearly shown in FIG. 1, a receiving cone is provided at the front-end of the cross-carriage 18, i.e. at the face-end of the piston rod projecting from the guide housing 24, an exchangeable tool holder 26 being provided in said cone. The cross-carriage assemblies 16 are assigned to the individual working spindles 14 in such a way that the direction of motion of each cross-carriage 18 together with the turning tool 28 inserted in the tool holder 26 is essentially oriented toward the respective spindle center of the corresponding working spindle 14. The arrangement of the tool holder 26 at the front end of each cross-carriage 18 as well as the described arrangement of the cross-carriage 18 and cross-carriage assembly 16 relative to the associated working spindle 14 allows free access to all tools of the individual cross-carriage assemblies 16 and furthermore maintains a free lower zone a in the working space, so that the chips produced can drop down essentially without hindrance. The arrangement of the cross-carriage assemblies 16 is preferably made so that they have an angular dimension a of about 30° relative to planes b passing through the axes of diametrically opposite working spindles 14 as shown in FIG. 1.
As indicated by FIGS. 1, 3 and 4, the spindle arrangements shown for an automatic multispindle turning lathe 13, represent those in which the respective upper and lower working spindle pair will be in a horizontal plane after each switching of the spindle drum 12. The arrangement of cross-carriage assemblies 16 shown in FIG. 1 consequently allows a relatively large angular distance between the individual assemblies, so that the two cross-carriage assemblies 16 associated with the upper two working spindles 14 are placed side-by-side in such a way that their cross-carriages 18 move parallel to each other. Consequently, a relatively large angular distance is realized between the other cross-carriage assemblies 16, so that all turning tools 28 of the individual cross-carriages 18 are readily accessible within the working space, and their arrangement at the front-end of the cross-carriages no longer requires overhead mounting and the same mounting position can be selected for all cross-carriages 18. Thus the same conditions are created for preadjusting the turning tools 28 of all cross-carriages 18.
The guide housing 24 of the individual cross-carriages 18 can be mounted directly to the face of the bearing housing 10, so that its cross-carriage 18 can move only radially relative to the axis of the assigned working spindle 14. In the present practical example, the cross-carriage assemblies 16, however, are adjustable in the bearing housing 10 for axial movement in a direction parallel to the working spindles 14 and can be fixed, for which purpose they are located at the front-end of a bearing member 30 provided in horizontally displaceable manner in the bearing housing. This bearing member 30 is preferably adjustable axially in both directions at an adjustable speed for the performance of a feed advance for longitudinal turning with the use of a drive system which is not shown in detail. The cross-carriage assemblies 16 thus also form longitudinal turning devices which preferably are provided on the bearing housing 10 so that they can also be pivoted and fixed.
In the schematic illustrations of the invention the specific details of construction for the feed movement of the carriage assemblies 16 parallel to the working spindles 14 and the pivotal movement of the carriage assemblies 16 have been omitted, because such details of construction are well known in the art, as is shown for example in the assignee's prior U.S. Pat. No. 3,604,293, patented Sept. 14, 1971, in the names of Gerhard Foll et al.
In the example of FIG. 3, cross-carriage assemblies 16 are assigned in pairs at an acute angle B to a part of the workin spindle 14 located in the spindle drum 12. In this practical version, paired cross-carriage assemblies 16 are assigned, for example, to the two upper and the two middle working spindles, while only one cross-carriage assembly is provided for each of the lower two working spindles. It can be seen that one of the two cross-carriage assemblies assigned to the working spindles at an acute angle is positioned relative to one of the cross-carriage assemblies of a neighboring working spindle in such a way that their cross-carriages 18 can be displaced parallel to each other.
In the practical example of FIG. 4, two cross-carriage assemblies 16 are assigned to each of the two upper and--as viewed from the front or operating side--the rear center working spindles 14 of spindle drum 12, while only one cross-carriage assembly is assigned to each of the lower two working spindles, and these latter two assemblies have an angular distance or preferably about 120°. Consequently, the middle working spindle present on the operating side remains free to feed a workpiece from that side.
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Apparatus is disclosed relating to improvements in the construction and arrangement of cross-carriage assemblies carrying tool holders for use in conjunction with associated spindles carried on a rotary multispindle drum of the lathe. A plurality of arrangements are disclosed, all of which provide improved chip removal and greater access to the work space and tool holders.
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CROSS REFERENCE TO RELATED APPLICATIONS
This patent is a divisional of U.S. patent application Ser. No. 11/903,208 filed Sep. 19, 2007, which is a continuation-in-part patent application that claims priority and incorporates herein by reference U.S. patent application Ser. No. 11/056,848, now issued as U.S. Pat. No. 7,229,330; U.S. patent application Ser. No. 11/811,616, filed Jun. 11, 2007, now issued as U.S. Pat. No. 7,494,393; U.S. patent application Ser. No. 11/811,605 filed Jun. 11, 2007, now issued as U.S. Pat. No. 7,491,104; U.S. patent application Ser. No. 11/811,606, filed Jun. 11, 2007, now issued as U.S. Pat. No. 7,485,021; U.S. patent application Ser. No. 11/811,604, filed Jun. 11, 2007, now issued as U.S. Pat. No. 7,465,203; and U.S. patent application Ser. No. 11/811,617, filed Jun. 11, 2007, now issued as U.S. Pat. No. 7,494,394.
FIELD OF THE INVENTION
The present invention pertains to the field of water sports and boating and more specifically to electronic devices for use in water sports.
BACKGROUND OF THE INVENTION
Competitors in trick, jump, and slalom ski and wakeboard events require tow boats capable of consistent and accurate speed control. Successful completion of slalom and jump runs require passes through a competition water course at a precise specific speed. Competition rules usually require that said speed requirements be confirmed by use of a speed measurement system. For example, American Water Ski Association Three-Event Slalom and Jump competitions specify a required time window for completion of all segments of the course to confirm that speed was maintained adequately throughout the pass. These times have historically been measured either using manual stopwatch measurements or, more recently, using magnetic sensors which are triggered by the presence of magnets attached to buoys in the water in close proximity to the path of the tow boat at the required timing measurement points in the course. Course times have to be reported and logged for every individual pass in competition. Reliability of triggering the magnetic sensor, as well as maintenance of the magnets attached to the buoys has consistently caused major difficulties in running competitive 3-event competitions.
SUMMARY OF THE INVENTION
The present invention provides a consistent, maintenance free and accurate method of measuring time of passage of a tow boat and skier through courses such as those used for slalom and jump competitions without the need for magnets or other physical attachments to the course infrastructure. Global Positioning System (GPS) satellite technology is used to map and memorize the location of courses in a permanent memory within a computer system. The system is then able to recognize every time the tow boat passes through the course using continuously updated GPS position estimates. By interpolating between periodic position updates, the system can accurately estimate time of closest approach to the entry gate to the course, and subsequently track time to all points of interest down the course using either the same GPS position measurement technique, or by tracking displacement of the tow boat down the line of the course using other techniques such as integration of velocity to derive position displacement.
An automatic timing measurement system that provides a measure of time of passage of a watercraft through a prescribed course. Algorithms based on inertial or other estimates augmented by GPS speed/position measurements are used to track position of a watercraft. Said position estimates are used to allow the locations of prescribed courses to be mapped and memorized. Algorithms are then used to allow the apparatus to automatically detect passage of a watercraft through mapped courses for the purpose of measuring and reporting time of passage of said watercraft past key points in said course, and for modifying the behavior of the speed control portion of the apparatus if necessary at certain points in the mapped course. A measure of accuracy of driver steering can be provided along with the ability to automatically steer the watercraft through the course if “steer-by-wire” mechanism is available. GPS speed control is augmented with a secondary velocity measurement device that measures speed over water resulting in an optional user selectable real-time compensation for water current. Furthermore, GPS is used as the key input to produce boat speed-based pull-up profiles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of external housing of the device of the instant invention.
FIG. 2 is a block diagram of the electronics contained within the housing of FIG. 1 .
FIG. 3 is a feedback control loop diagram demonstrating the operation of an observer in accordance with a preferred embodiment of the present invention.
FIG. 4 is a diagram of an example water body including three ski courses.
FIG. 5 is a flow diagram disclosing a method that an observer in accordance with a preferred embodiment of the present invention may use to determine observed velocity and observed position.
FIG. 6 is a flow diagram disclosing a method for automatically detecting a previously-mapped course.
FIG. 7 is a flow diagram disclosing a method of detecting and reporting the time at which a plurality of events is detected.
FIG. 8 is a flow diagram disclosing a method by which a user interactively “maps” a desired water course, and by which the present invention stores the mapped water course into non-volatile memory.
FIG. 9 is an example of a competitive slalom ski course.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates generally to electronic event detectors and more specifically to electronic event detectors for use with power boats.
As show in FIG. 1 , the event detector 100 of the present invention includes a housing 102 for housing the electronics of the invent detector an accelerometer 106 and a GPS 104 . GPS 104 is preferably a unit separate from housing 102 , e.g. a GARMIN® GPS 18-5 Hz.
Electronic housing 102 includes a display 108 and interface buttons 110 . As will be appreciated by one skilled in the art the display 108 is preferably made out of moldable materials such as plastic, aluminum, glass, and the like, with a clear glass or plastic cover. Importantly, the housing is adapted to be waterproof to prevent damage to the electronics when in use. The display 108 may be a commercially available LCD display that is capable of displaying numbers or letters and information related to the event. User interface buttons 110 are actuators attached to the electronics covered in a rubberized membrane that allows buttons to remain waterproof during their actuation. The LCD display interface buttons 110 and glass cover are attached to an insulated housing 102 via e.g., screws, friction fit, adhesive, or the like inside the housing 102 are electronics, to be described below, that perform the functions of the device.
The electronics will now be described with reference to FIG. 2 . In general, the electronics of the event locator device 100 includes microprocessor 200 , non-volatile storage 202 , GPS interface 204 , Clock 206 , speaker 208 , power device 210 , user input interface 214 , accelerometer 216 , and analog-to-digital converter 218 .
Microprocessor 200 is the “brains” of the invention and performs location calculations and timing data for output to a user. Preferably microprocessor 200 is capable of being externally programmed. Volatile storage 202 is connected to microprocessor 200 and stores event data such as map information, location information, and timing information for the microprocessor's calculations. Clock device 206 provides time data to the microprocessor 200 which can be displayed to a user. GPS interface 204 interfaces with the GPS system which provides location data to the microprocessor 200 . Accelerometer 216 generates an acceleration signal and provides the same to the microprocessor 2000 . AC/DC converter converts the signal from the accelerometer to a digital signal for input into the microcontroller 200 . User input interface 214 is connected to the microprocessor and allows the user to program certain device settings into the non-volatile storage 202 such as map information, desired speed, and the like. Display 212 interacts with microprocessor to display event data speed, location and time information. Power supply 210 provides power to microcontroller and all of the associated electronics.
The general operation of microprocessor 200 will now be described in more detail with reference to FIG. 3 . Note FIG. 3 contemplates a scenario where course mapping information is already saved in memory and accessible by the microprocessor. As is shown, the accelerometer receives a signal from the boat indicative of the boat's acceleration and inputs this signal to a microprocessor. The microprocessor converts the acceleration value into a velocity value in step 15 and in step 16 receives both the velocity information from the accelerometer and the velocity data from the GPS. As one skilled in the art will appreciate the velocity from a GPS is not updated continuously, and the velocity information from the accelerometer is used to provide resolution to the velocity information from the GPS system in step 17 . An observed velocity is output at step 17 , and in step 70 the velocity information and direction information obtained from the GPS system is used to calculate a latitude and longitude value for the accelerometer. In step 80 , latitude and longitude information from the GPS system is compared to latitude and longitude information from the accelerometer. Much like step 17 , the latitude and longitude information from the accelerometer is then used to attenuate the GPS signal. The microprocessor then outputs a latitude and longitude observed signal, which is used in reference to map data input by the user at the start of the process. When a preselected event occurs, as calculated by the comparison observed latitude/longitude signals the microprocessor outputs a sound signal to speaker 208 and a display signal to user display 108 .
Collectively, the accelerometer 216 , analog-to-digital converter 218 , computing device 200 , GPS unit 204 , memory 221 and clock 206 comprise the elements of an observer 222 . The observer 222 is adapted to act both as a velocity observer (in which it outputs an observed velocity) and as a position observer (in which it outputs an observed position). In the preferred embodiment of the present invention, an accelerometer acts as the primary source of data for computing displacements over time, with periodic updates from the GPS provided to account for drift in the accelerometer. But it will be appreciated by those skilled in the art that there are many other methods available for performing this task. For example, over-water velocity may be measured directly by means of a transducer such as a paddle wheel or a pitot tube, and those measurements may or may not be corrected with GPS inputs. In the case of direct velocity measurement, only a single integration with respect to time is needed to compute a new position. And, as GPS technology becomes more accurate and as new data are available at a higher frequency, it is conceivable that a GPS unit will provide the sole velocity and position inputs. Other configurations for measuring velocity and position will be apparent to those of ordinary skill in the art, and it is intended for this patent to encompass such additional configurations.
The specific software flow of the microprocessor programming will be described with reference to FIGS. 5 through 8 .
FIG. 5 discloses the functioning of a preferred embodiment of an observer 222 . In step 501 , a GPS signal is received from the GPS device 204 . GPS device 204 provides a GPS position 513 , a GPS velocity 512 , and a GPS direction 511 . Step 501 uses the GPS position as its initial starting position. In Step 502 , there is a check to see if a new GPS position has been received. If a new GPS position has been received, in Step 503 it is checked to see if the GPS position is a valid GPS position. Step 503 compensates for the potential of invalid GPS signals such as occasionally occur in GPS devices known in the art. If the new GPS signal is a valid signal, then the observed position 509 is set to a value of the accelerometer corrected by the difference between the last observed position and the GPS position 513 . A constant 515 is provided such as is calculated to provide the appropriate weight to the GPS measurement. For example, if constant 515 is set to one, then the GPS position is afforded its full weight. If constant 515 is set to a value less than one, the GPS is provided less weight, and it if it set to a value greater than one, the GPS is provided more weight. This constant is selected in accordance with the relative accuracies of the GPS and accelerometer such that for a more accurate GPS device, greater weight can be given to the GPS value and for a less accurate GPS device, less weight can be given to the GPS value. The result of this calculation is an observed position 509 .
It is necessary to compensate for the 5 Hz resolution of the GPS device. This resolution is insufficient for the preferred embodiment of the present invention. So there is provided an alternative device, starting at step 505 , which includes an accelerometer 316 . The accelerometer provides a measured acceleration which is converted to a binary value in analog-to-digital converter 218 . It is then useful for being compared to digital values provided by the GPS device 204 . In step 506 , an observed velocity is computed. The velocity is computed by first taking the last observed velocity 510 and the velocity provided by the GPS 512 . This difference is adjusted by a velocity constant 517 . As with position constant 515 , velocity constant 517 is selected to compensate for the relative accuracy of the GPS device. The weighted difference is then added to the velocity computed by taking the first integral of the acceleration with respect to time, thereby providing a correction factor. In step 507 , an accelerometer-computed position 514 is calculated. This position is computed by taking the integral of the velocity vector with respect to time. The displacement calculated thereby is adjusted to the direction signal provided by the GPS. This GPS correction step is used in the preferred embodiment because, in the interest of simplicity, the three-accelerometer is used only to compute acceleration along the single axis of the length of the boat. The result is accelerometer-computed position 514 . The usefulness of accelerometer-computed position 514 is that it can be calculated at a frequency of approximately 1,000 hertz. So returning to step 502 , if no new GPS signal has been provided, then the observed position is provided by the change in position as calculated by the accelerometer with no further input from the GPS device. Thus, there is provided from the observer an observed position 509 as well as an observed velocity 510 .
FIG. 8 discloses a method of using a watercraft equipped with a position and velocity observer, such as is described in FIG. 5 , to map a competitive water course. In step 801 , there is initial determination of the position and velocity of the watercraft as provided by the observed velocity 510 and the observed position 509 . In step 802 , there is a check to see whether there has been a user input from a map button 214 . If no user input is provided, then the position observer continuously updates the position and velocity of the watercraft. Once there has been a user input at step 803 , the current observed position 509 and the current heading are stored in non-volatile storage 202 . In step 805 , there is provided a step of checking to see if it is desired to map another point. If another point is to be mapped, then there is a return to step 801 and the method is repeated until, at step 805 , there is no further point to mapped. When there is no further point to be mapped, at step 806 , the device may calculate a number of predetermined intermediate points in between the points mapped and stored in step 803 . These intermediate points are also stored in non-volatile storage 202 .
In FIG. 6 , there is disclosed a method of automatically detecting a course that has been mapped in accordance with the method of FIG. 8 . At step 601 , there is initial determination of position and velocity provided by observed position 509 and observed velocity 510 . In step 602 , compare the observed position 509 to a predetermined position as mapped in accordance with the method of FIG. 8 . This mapped position is provided from non-volatile storage 202 . In 603 there is a determination of which of a plurality of mapped courses as mapped in accordance with the method of FIG. 8 is the closest to the present observed position 509 . Once a closest course has been locked in, then, in step 604 , there is a check to see whether the watercraft is inside the lockout region of the closest water course. If the craft is within the lockout region, then there is also a check to see whether the craft is approaching from outside the course and is proceeding in the right direction along the center line of the course. If these criteria are not met, then continue looking for entrance into a course. If the criteria are met, then, in step 606 , check to see whether the craft has crossed the plane of the entry gate of the course. If it has not, then return to step 602 , continuing looking for entry to a course. If the criteria are met, then the craft has entered a mapped course and the course timing algorithm will automatically begin in step 607 . This provides an observed position at the entry point 608 .
In FIG. 7 there is disclosed a method for computing total time and intermediate times through a competitive water course. There is provided an observed position at the entry point 608 and there is also provided a clock signal 206 . In step 701 , the time at the entry point is recorded in temporary memory 221 . In step 702 , an observed position 509 is provided and this provides the present position of the watercraft. A plurality of points of interest are stored in non-volatile storage 202 . In step 703 , a point of interest is provided and there is a check to see if the current observed position 509 exceeds the position of the point of interest. If the present position 509 does not exceed the position of the point of interest, then the loop is continued until the present observed position exceeds the position of the point of interest. At this point, in step 704 , the present observed time 709 is recorded into temporary memory 221 and, in step 705 , the current observed time 709 is displayed on user display 212 . In step 706 , there is provided an ideal time 710 . An error time 711 is computed as the difference between the ideal time 710 and the observed time 709 . The error time 711 is also stored in temporary storage 221 and displayed on user display 212 .
In a parallel process to step 704 , when a point of interest is reached, there is also provided an audible signal through a speaker 208 to provide an audible indication to the user that this point has been passed. After steps 704 , 705 , 706 and 708 are completed, then in step 707 there is a check to see if this is the last point of interest. If it is not, then there is a return to step 702 . If this is the last point of interest, the process ends.
The use of the device will now be described with respect to FIGS. 3 , 4 and 9 .
As diagrammed in FIG. 3 showing feedback system 310 , the inertia measurement device (accelerometer) 216 measures the actual acceleration a a of a watercraft 50 and the GPS device 204 measures the actual velocity v a and position of the same watercraft 50 . The output from the accelerometer a Acc is input into a first step 15 that coverts a Acc to velocity V Acc . The output from first step 15 v Acc and the GPS output v GPS are input to a second step 17 . The output from a second step 17 v OBS and the output (Dir GPS ) indicating course or direction of travel from the GPS device 204 are input into a third step 70 to derive inertial-based estimates of the latitude (Lat Acc ) and longitude (Long Acc of the watercraft 50 . Direct GPS measurements of latitude (Lat GPS ) and longitude (Long GPS ) and the outputs from the third step 70 are input in a fourth step 80 to correct inertial-based estimates of the latitude (Lat Acc ) and longitude (Long Acc ) of the watercraft 50 to account for any inaccuracies due to drift or acceleration sensor inaccuracies. Lat OBS and Long OBS can then be used to allow the boat driver to record via a user interface the absolute latitude and longitude position coordinates of a course to be saved into a permanent non-volatile memory. Coordinates can be recorded either by direct numerical entry of measured coordinates, or by snapshotting course coordinates as the boat is maneuvering through the course to be mapped. The driver can identify course reference points via a user interface (not shown) or button press as the boat passes the point to be mapped. Since all courses of interest are laid out in straight lines, mapping of two known points in a course is sufficient to fully define the locations of all points of interest in a course and it's direction relative to earth latitude and longitude coordinates. All future passages of the towboat within a specified distance of selected course coordinates as measured by Lat OBS and Long OBS can then be detected and used to initiate timing measurements of the towboat through the mapped course.
FIG. 9 discloses a competitive slalom ski course. This is the type of course on which an embodiment of the present invention may be used. There is shown an entry gate 901 , which can be characterized by a precise global coordinate specified in latitude and longitude. The opposite end point of the course is exit gate 905 , which may also be characterized as a latitude and longitude. Because the course lies along a substantially straight line, the locations of all points of interest along the course can be found given the positions of the two end points. A course centerline 906 lies along a substantially straight line and is slightly larger than the width of a water craft. The centerline is defined by boat buoys 904 , which the water craft must stay in between. There are also provided ski buoys 902 , which the skier must ski around during the passage of the course, in an alternating pattern as shown by the ski path 903 . The skier must pass between the buoys defining first break point 907 before proceeding along ski path 903 . At the end of the course is a second break point 908 . The skier must ski between the two buoys defining second break point 908 after passing around the last buoy 902 . In between these points are six intermediate points 904 , each defined by a pair of buoys, which are positioned to be substantially collinear with the ski buoys 902 .
The entry gate 901 , exit gate 905 , break points 907 and 908 and intermediate buoys 904 are all points of interest whose passage may need to be detected. The time at which the boat 50 passes these points may be used to determine whether a run is valid, according to whether the time is within an allowable margin of error. Because these points are defined according to precisely-surveyed distances, their locations can be detected by a substantially accurate observer (such as is provided by the preferred embodiment of the present invention) given only the location of the two end points. So the mapping course-mapping method described in FIG. 8 provides the observer with sufficient information to determine when a point of interest has been passed in accordance with the method of FIG. 7 .
Once a course has been mapped, the location of the course can be stored in a permanent storage medium 202 such as a disk drive or flash memory. Further qualification of valid entry to a course can then be carried out based on GPS direction measurements so that timing measurements are only made when the towboat enters a mapped course while traveling along the known direction of the course centerline. Further, any deviations of the tow boat from the center line of the course can be detected and factored geometrically into the measurement of displacement down the centerline of the course so that errors in timing measurement due to driver steering error can be compensated for.
FIG. 4 discloses a water course with a plurality of competitive ski courses. There is disclosed a first slalom course 401 , a second slalom course 402 and a jump course 403 . First slalom course 401 has entry and exit thresholds 405 . Second slalom course 402 has entry and exit thresholds 406 . The slalom courses may be traversed in either direction through entry and exit thresholds 405 and 406 . A jump course 403 may be entered only through entry threshold 411 because ski jump 409 is unidirectional.
According to a preferred embodiment of the present invention, a user may approach a course, for example first slalom course 401 . Upon entering the entry threshold 405 in the direction of the course centerline 408 , the user will press a button whereby the computing device is alerted of the location of the entry/exit threshold. The user then proceeds along course centerline 408 and presses a button again at the opposite entry/exit threshold 405 .
The computing device also interfaces with a permanent storage medium. This storage medium contains the desired locations of intermediate buoys 407 , which are located at pre-determined distances from the entry/exit buoys. “This process” allows the computing device to learn the exact location of first slalom course 401 . “The process” can then be repeated to allow the computing device to learn the locations of second slalom course 402 and jump course 409 .
Once the computing device has learned the locations of courses 401 , 402 and 403 , it is desirable for the device to automatically detect which course it is at without further user intervention. So there are shown mapped lockout regions 404 around each of the entry/exit thresholds 405 , 406 and 411 . According to the method disclosed in FIG. 6 , the device will detect which of the mapped courses is closest to its present position. The device may also selectively detect only courses of a specific type (jump or slalom) depending on its current mode of operation. If the device then determines it is within a lockout regions 404 , it will check to see if the boat is approaching from outside the entry/exit threshold and in the correct direction along the course centerline. If these criteria are met, then the device will calculate the time of the closest approach to the plane of the entry gate. At that time it will begin timing the path without any intervention from the user.
Because the locations of intermediate buoys 407 are pre-programmed, the device may provide an audible or visual indication of the passing of each intermediate buoy 407 . It may also provide intermediate times at the passing of each intermediate buoy 407 . Finally, it will calculate the time at which boat 50 passes through the opposite entry/exit threshold 405 .
In this manner the device can automatically time a pass through a memorized course without any further intervention from the user.
A driver score can also be provided based on the degree of this error which can be used to rate driver performance and confirm accuracy of the boat path through the course, which is also a criterion used in judging whether a competitive pass is valid.
Any boat speed or engine torque modification requirements which may depend on position in the course can be triggered based on Lat OBS and Long OBS relative to the mapped course location.
As one skilled in the art will recognize, the device of the invention is one of the category of commonly understood instruments that measures an object's acceleration. The velocity of on object can be calculated by integrating the acceleration of an object over time. Further, the position of an object relative to a known starting point can be calculated by integrating the velocity of an object over time. A GPS device is one of the category of commonly understood instruments that use satellites to determine the substantially precise global position and velocity of an object. Such position and velocity measurements can be used in conjunction with timers to determine an object's instantaneous velocity and average velocity between two points, along with its absolute position at any point in time. A comparator is any analog or digital electrical, electronic, mechanical, hydraulic, or fluidic device capable of determining the sum of or difference between two input parameters, or the value of an input relative to a predetermined standard. An algorithm is any analog or digital electrical, electronic, mechanical, hydraulic, or fluidic device capable of performing a computational process. The algorithms disclosed herein can be performed on any number of computing devices commonly called microprocessors or microcontrollers, examples of which include the Motorola® MPC555 and the Texas Instruments® TMS320.
Use of observed velocity and position estimates based on inertial or other measurement sources allows for error correction of occasional glitches or interruptions in availability of accurate GPS velocity and position measurements. These can occur in the course of normal operations, either due to GPS antenna malfunction, or temporary loss of GPS satellite visibility due to overhead obstruction from bridges or overhanging vegetation and the like.
Other embodiments of the system could include automated steering of the boat down the centerline of the course making use of course location information stored as described in 0014 thru 0016 above. The present invention may be included as part of an electronic closed-loop feedback system that controls the actual angular velocity ωa of a boat propeller, and, indirectly, the actual over land velocity V a of the watercraft propelled by that propeller.
Another embodiment allows the apparatus to track the position of a skier behind the watercraft as he/she traverses the course. This can be achieved by mounting a GPS antenna somewhere on or near the body of the skier and capturing these data concurrently with data from a tow boat mounted antenna. Such GPS antennae can be either wired or wirelessly connected to the main apparatus.
It will be apparent to those with ordinary skill in the relevant art having the benefit of this disclosure that the present invention provides an apparatus for tracking the position and velocity of a watercraft through a prescribed course without the need for measurement aids such as magnets built into the course infrastructure. It is understood that the forms of the invention shown and described in the detailed description and the drawings are to be taken merely as presently preferred examples and that the invention is limited only by the language of the claims. The drawings and detailed description presented herein are not intended to limit the invention to the particular embodiments disclosed. While the present invention has been described in terms of one preferred embodiment and a few variations thereof, it will be apparent to those skilled in the art that form and detail modifications can be made to that embodiment without departing from the spirit or scope of the invention.
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An automatic timing measurement system provides a measure of time of passage of a watercraft through a prescribed course. Inertial or other estimates augmented by GPS speed/position measurements are used to track position of a watercraft, and those estimates are used to allow the locations of prescribed courses to be mapped and memorized. The apparatus may automatically detect passage of a watercraft through mapped courses for the purpose of measuring and reporting time of passage past key points in the course, and for modifying the behavior of the speed control of the apparatus if necessary at certain points in the mapped course. GPS speed control may be augmented with a secondary velocity measurement device that measures speed over water resulting in an optional user selectable real-time compensation for water current. Furthermore, GPS may be used as the key input to produce boat speed-based pull-up profiles.
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The invention described herein may be manufactured, used, and licensed by the U.S. Government for governmental purposes without the payment of any royalties thereon.
CROSS-REFERENCED APPLICATIONS
This application is related to U.S. Pat. No. 3,971,886 issued to the present inventor and to copending application Ser. No. 650,483, entitled "Automatic Low Frequency Gain Limiting by Addition Method in Video Processing System" by the present inventor and coinventor, Earl M. Thomas, now U.S. Pat. No. 4,038,688.
BACKGROUND OF THE INVENTION
This invention is in the field of AC coupled FLIR video processing systems. A problem existing in these video processing systems is that of insufficient dynamic range because of smoke, dust, fire or background signals that are saturated at the output of the preamplifier or within the post amplifiers.
Some means is needed to vary the height of the pedestal (or low frequency) signals such that the perceivable scene dynamic range is enlarged to preserve the details (high frequency) signal at the display when the preamplifier output signal is very large.
It is an object of the present invention to provide a common module FLIR system with a higher degree of hands-off operation by replacing the existing manual gain control with an automatic gain control (AGC) circuit.
It is a further object to provide an automatic low frequency gain limiting circuit that expands the perceivable scene dynamic range and resolve the image streaking problems for airborne applications.
The present invention solves the above problems.
SUMMARY
The present invention comprises an electronic means that is inserted in the video channels between an input video signal processing circuit and an output video signal display circuit, and specifically an automatic low frequency gain limiting and first post amplifier circuit that is inserted in each of a plurality of video channels between the preamplifier and a second post amplifier to provide automatic low frequency gain limiting of the low frequency components of the input video signal in each video channel to preserve sufficient dynamic range for enhancing detail signals. The electronic means is further comprised of an automatic gain control circuit that is connected between the outputs of a selected number of the second post amplifiers and their internal bias circuits for applying gain control signals back to the respective selected number of second post amplifiers. By the automatic low frequency gain limiting and first post amplifier circuit having the first post amplifier therein, both the package size and power dissipation will be reduced. The automatic low frequency gain limiting and first post amplifier circuit comprises a first post amplifier cascaded with a variable pedestal limiting amplifier and a feedback limiter circuit connected between the output of the variable pedestal limiting amplifier and the input to the first post amplifier such that the large amplitude low frequency output signal from the first post amplifier is limited to below the saturation level. The gain of the variable pedestal limiting amplifier may be set variable. Therefore, the output pedestal from this amplifier is also variable. A leakage current decoupling circuit is included in the feedback limiter circuit in order to limit the current fed back into the input of the first post amplifier.
Some of the features of the present invention are that the perceivable scene dynamic range is increased to 71 decibels, an observer is able to detect targets behind smoke, dust, or fire, high voltage biasing is not required, and there is a large degree of automatic operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in a partial block diagram a common module video channel with the present scene dynamic range expander;
FIG. 2 illustrates an electrical schematic of the common module video channel showing the present scene dynamic range expander;
FIGS. 3A and 3B respectively show a typical amplifier circuit having a feedback diode limiter and the resulting output limiting level of the diode forward threshold voltage;
FIGS. 4A and 4B respectively show a typical two amplifier cascade feed back limiter and the resulting lowered output limiting level of the forward threshold voltage divided by the gain of the second amplifier; and
FIG. 5 illustrates by electrical schematic the cascade feedback diode limiter of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Refer now to FIG. 1 for a brief discussion of how the scene dynamic range expander circuit 24 operates in the video channels of an AC coupled FLIR video processing system. Circuit 24 is comprised of an automatic low frequency gain limiting and first post amplifier circuit 26 and a second post amplifier 28 in each of the video channels, and a single unit AGC circuit 30 that controls the bias voltages to a select number of the second post amplifiers 28 for overall display control of an output signal therefrom to an output video signal display circuit 80. First, the input video signal that is applied to the input video signal processing circuit 90 comprises high frequency (HF) detail signals mixed with low frequency (LF) pedestal components. When the amplitude of the LF pedestal component exceeds a certain level, the fire and background signals become saturated somewhere within the video processor chain, indicating that the LF pedestal is outside its dynamic range. It was found that the fire and background signals have sometimes become saturated at the output of the second post amplifier 28. The LF pedestal is shown at the output of the preamplifier 22 as 400 millivolts only as an example, but may be as high as 1 volt peak-to-peak. In airborne operations, the AC coupled FLIR video processing system is also subject to streaking problems caused by signal suppression. The waveform W, shown at the output of the second post amplifier 28, is a reproduction of the large signal at the output of the preamplifier 22 that has been limited by the scene dynamic range expander 24 to the linear dynamic range between the white streaking level and the black streaking level. Conversely, should the system gain be below a certain level, an automatic gain control circuit 30 samples the amplitude of W at the output of a selected sequential number of the second post amplifiers 28 and is fed to circuit 30 by leads 30a whereupon circuit 30 automatically increases the post amplifier 28 gain to the maximum dynamic range of the display. It should be noted that waveform W represents only the largest amplitude signal with all other signals being equally amplified in circuit 30 but amplified from a smaller signal than W. The signal sampling for the circuit 30 may be performed only at a preselected number of video channels, say three video channels per sample, and then the sampled signal may be multiplexed out into every third one of the second post amplifiers by one of leads 30a to circuit 30 and one of leads 31a to 28. The gain control signal to the selected number of the post amplifiers 28 passes through leads 31a. Leads 30a and 31a are shown numbered 1 through 4 for convenience, but of course are not limited to that number since there may be 500 or more individual video channels. This type of automatic gain control of an amplifier is well known in the art.
The operation of the present circuit is as follows. The incoming signal is detected by a detector 18 that is placed in series with a bias resistor 20 between a ground terminal 100 and a detector bias voltage. Capacitor C1 couples the detected video signal V o directly to the input of preamplifier 22. A potentiometer 26 and capacitor C2 couples the amplified output signal from the preamplifier 22 into the present scene dynamic range expander 24. The above mentioned detecting of an input signal V o and coupling into and out of the preamplifier 22 into the input to the scene dynamic range expander 24 is conventional. Also, the output video signal display circuit 80, which may be comprised of light emitting diode (LED) driver 32, resistor 34, and an output display shown as one LED 36 of an LED array which processes signal W, is conventional.
The specific scene dynamic range expander 24 may be used with the AC coupled FLIR video process system between the input video signal processing circuit 90 and the output video signal display circuit 80 in smoke, dust, and fire type environments and yet maintain sight of say a tank or an army personnel carrier moving behind the smoke, dust, or fire. Refer to the electrical schematic of FIG. 1 for an explanation of the operation of circuit 24. Please note that two waveforms are presented, one immediately over the other, throughout circuit 24. The lower waveform represents a signal that exceeds the dynamic range of the video processing system. This is known as the limiting mode signal. The unlimiting mode signal is shown throughout as being directly above the limiting mode signal.
Previous, each video channel of an AC coupled FLIR video processing systems had two post amplifiers between the preamplifier and the display drives. In this invention, the first post amplifier is a part of circuit 26. Circuit 26 limits the LF component of a high frequency detail contained low amplitude pedestal signal at the output of circuit 26 to a level within the dynamic range of the AC coupled FLIR video processing system. Also, AGC circuit 30 samples a selected number of outputs from the second post amplifiers 28 and, if the largest sampled signals in one field is below a determined minimum level, circuit 30 increases the gain of that second post amplifier 28 until it reaches a level that is the maximum display dynamic range which is represented by waveform W. With the operation of the AGC circuit 30 and post amplifier 28 cooperating with the operation of circuit 26, the signal W that is applied to the output video signal display 80 is the largest sampled signal that is always within the dynamic range of the AC coupled video system and the high frequency detail signature of a scene under observation is observable at the display.
FIG. 3A shows a typical amplifier A 1 having a back-to-back diode feedback limiter comprised of the parallel network of diodes D1 and D2 and feedback resistor R F connected between the output and the negative input terminals of the amplifier. FIG. 3B illustrates the resulting output level voltage e out versus the input voltage e in of the amplifier circuit of FIG. 3A. The output level for e out is the diode forward threshold voltage V D . The voltage V D would be too high to operate in circuit 26. This problem may be partly alleviated by adding a second amplifier in cascade with the feedback limiter of FIG. 3A. The cascaded amplifiers limiter is shown in FIG. 4A.
Refer to FIG. 4A wherein the first amplifier A 2 has an input e in applied to a negative input terminal and an output e out that is applied through capacitor C6 and resistor 41 to a positive input terminal of a second amplifier A 3 . The output of amplifier A 3 is e a , the value of e a being limited to the forward threshold voltage ±V D of the diodes D3 and D4. The value of e out is e a divided by the gain G 2 of amplifier A 3 . The value of e out in the cascaded amplifiers of FIG. 4A is therefore much less than e out of the one amplifier A 1 alone. FIG. 4B depicts, but not to scale, the reduced value of e out from the cascade amplifiers A 2 and A 3 . If the gain G 2 of amplifier A 3 is set to be variable, the voltage e out limiting level will be variable also. The typical forward threshold voltage V D for a silicon diode, represented by diodes D3 and D4, is about 0.5 volts. If the gain G 2 of amplifier A 3 is set at 50, the e out limiting is ±0.5 volts divided by 50 or ±10 millivolts. This is generally within the dynamic range of the AC coupled video system. Capacitor C F and resistor R A are provided for system stability. Resistors R F1 and R F2 are feedback resistors respectively for amplifiers A 2 and A 3 .
FIG. 5 illustrates a typical cascade feedback diode limiter 70 of this invention and shown in the electrical schematic of FIG. 2. The circuit has a feedback limiter comprised of back-to-back diodes D7 and D8 and a leakage current decoupler 56 comprised of back-to-back diodes D5 and D6 and a drain resistor R D connected to ground terminal 100. Circuit 56 minimizes the diode leakage current feedback through circuit 58 and resistor 54 to the amplifier A 4 input by sinking the current to ground 100 through resistor R D . The voltage e out is picked off at an output voltage terminal between amplifiers A 4 and A 5 . Actually two terminals are involved and are shown in FIG. 2 as a first output composite voltage terminal 7 and a second output composite voltage terminal 8.
Look now at FIG. 2 wherein the electrical schematic is explained with reference to the limiting signal, representing saturation, and the unlimiting signal that is within the dynamic range of the system. The unlimiting signal is shown throughout the channels of the video processor as being immediately over the limiting signal. First, assume that the input signal e in is below the limiting level, i.e. the unlimiting signal. The input signal e in is applied to both a first high pass filter 62 and to the negative terminal of the first post amplifier A 4 of the cascade feedback diode limiter 70. Only the high frequency portion of e in is passed through filter 62 with leading and trailing edge spikes, and this signal is then amplified by amplifier 60 and applied to a first negative input terminal of second post amplifier 28. Meanwhile, input signal e in has been amplified by first post amplifier A 4 , which has the same gain, represented by G 1 , as amplifier 60. The output of A 4 is applied to a variable pedestal limiting amplifier A 5 that establishes the amplitude of the signal e out existing at terminals 7 and 8 between the cascaded amplifiers A 4 and A 5 . Thus the voltage e out contains the high frequency detail on the low frequency components when the signal e in was not saturated. Signal e out is applied to a second high pass filter 64, which is matched to the first high pass filter 62. The output from filter 64 is applied to a positive terminal of said second post amplifier 28, thus cancelling the signal from amplifier 60 applied to the first negative input terminal amplifier 28. Amplifier 28 also has a second negative input terminal into which e out is directly applied. The output of second post amplifier 28 is then an amplified e out signal. Polarity control and gain control are applied to amplifier 28 to control polarity and gain. The function of the AGC circuit 30 has been explained above.
When the input signal e in is in the limiting mode, the input signal goes through the same paths as the unlimiting signal but the operations performed are somewhat different. The input signal is band stopped in filter 62 leaving only the high frequency detail with spikes at the leading and trailing edges to be amplified in 60 and applied to the first negative input terminal of 28. The input signal e in is amplified in first post amplifier A 4 and is amplitude limited at terminals 7 and 8 between amplifiers A 4 and A 5 in the same manner as explained above. It must be noted, however, that the amplitude limited output signal e out does not contain any high frequency detail since the signal e in was saturated in amplifier A 4 and the high frequency detail was lost therein. The amplitude limited output signal e out is simultaneously fed through filter 64 to the positive input terminal of 28. Analyzing the three inputs to second post amplifier 28 shows that the signals on the first and second negative input terminals add to the high frequency detail superimposed on the limited output signal e out and that the signal from filter 64 applied to the positive input terminal is negligible. Therefore, the amplitude limited signal with the high frequency detail added thereon is amplified in the second post amplifier 28 and is presented to the LED driver 32 as an unsaturated signal. Looking at FIG. 1, the output signal W from amplifier 28 is shown with the high frequency detail, HF, amplified since the HF components are amplified even though the LF components are limited.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
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A means for expanding the dynamic range of a forward looking infrared (FL video processing system by inserting an automatic low frequency gain limiting and first post amplifier circuit means at the output of the preamplifiers in each video channel to provide variable pedestal limiting of the low frequency components of the video signal. The automatic low frequency gain limiting and first post amplifier circuit means compresses the pedestal of signals derived from smoke, dust, or fire to arbitrary small levels to preserve sufficient dynamic range for enhancing the high frequency detail signal riding on the pedestals at a display.
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CROSS REFERENCE TO RELATED APPLICATION
This application is the U.S. National Phase application of PCT International Application No. PCT/JP2010/068244, filed Oct. 18, 2010, and claims priority to Japanese Patent Application No. 2009-293899, filed Dec. 25, 2009, the disclosures of both applications are incorporated herein by reference in their entireties for all purposes.
FIELD OF THE INVENTION
The present invention relates to a water producing system utilizing composite water treatment technologies, and an operation method therefor, and to a water producing system in which fresh water is produced from plural kinds of raw water, and an operation method therefor. In more detail, the present invention relates to a fresh water producing system that can be applied to the field of water clarification treatment in waterworks, and the field of industrial-use water production such as industrial water, food and medical process water, agricultural water, and semiconductor-related component cleaning water.
BACKGROUND OF THE INVENTION
In recent years, technologies relating to a separation membrane are being developed, and with characteristics such as space-saving, energy-saving, and filtrate water quality improvement, the technologies are widely used for various purposes such as water treatment. For example, a microfiltration membrane (MF membrane) and an ultrafiltration membrane (UF membrane) are applied to a water cleaning process for producing industrial water or tap water from river water, groundwater, or treated sewage, and applied to pre-treatment and a membrane bioreactor in a seawater desalination reverse osmosis membrane treatment step. A nanofiltration membrane (NF membrane) and a reverse osmosis membrane (RO membrane) are applied to removal of ions, seawater desalination, and a wastewater reclamation process.
Currently, as a method for reclaiming sewage/drainage, for example, there is a method of performing treatment called a “membrane bioreactor (Membrane Bioreactor; MBR)” in which sewage or industrial drainage which has conventionally been treated by an activated sludge process is treated by the MF/UF membrane directly immersed in an activated sludge tank, and performing filtration with the NF/RO membrane installed at the later stage to obtain pure water as product water.
As a system for producing fresh water from seawater or brackish water, there is a technology in which pre-treatment by sand filtration which is a conventional water clarification technology is carried out, and thereafter filtration is carried out with the NF/RO membrane. In addition, there is a method in which seawater or brackish water is pre-treated using the MF/UF membrane as described above, and filtration is carried out with the NF/RO membrane. With this system, since seawater cannot be desalted by the pre-treatment, desalination entirely depends on the treatment with the NF/RO membrane at the later stage.
With the NF/RO membrane separation method, supply pressure being higher than osmotic pressure is desired. Thus, pressure must be applied when supplying raw water to the NF/RO membrane with a pump called a “booster pump”. That is, as a salt concentration of raw water supplied to the NF/RO membrane is higher, the osmotic pressure becomes higher. Thus, it becomes necessary to apply higher pressure with the booster pump, and more energy for allowing the booster pump to operate becomes necessary.
Therefore, in a water producing plant, only one of a sewage/wastewater reclamation process and a seawater desalination process is performed in general. However, in recent years, a membrane treatment system integrating a sewage high-level treatment process and the seawater desalination process has been developed (Patent Document 1, Non-Patent Document 1, Non-Patent Document 2). According to this technology, after sewage is treated by the MBR, fresh water is produced using an RO membrane, and concentrate produced as a by-product at the time of separation of the RO membrane is mixed with seawater. Thus, a salt concentration in the supplied seawater is lowered, and hence the specification of the booster pump in an operation of RO membrane separation used in seawater desalination can more be simplified than in the conventional manner. Therefore, the system becomes further energy-saving.
In such an integrated membrane treatment system using plural kinds of raw water, for example, sewage/drainage and seawater from different supply sources are used as raw water. Thus, feed water quantities thereof are sometimes largely changed from time to time. In particular, sewage/drainage is easily changed due to a human activity time, a plant operation time, or the like. When the respective feed water quantities of raw water are changed, a mixing ratio between the RO membrane concentrate produced as a by-product from a sewage treatment line and seawater is changed. Thus, the salt concentration (osmotic pressure) in seawater to be supplied to the RO membrane on the side of a seawater treatment line is changed.
In a case where although a necessary product water quantity is determined, a sewage/drainage quantity is largely changed, and the product water quantity is ensured by a seawater intake quantity, the salt concentration after mixing is sometimes largely changed. Thus, there is a need for installing a booster pump capable of responding to high pressure to low pressure on the side of the seawater treatment line. When a booster pump having large capacity is controlled and operated by an inverter or the like, efficiency is interior at the time of low pressure, so that an energy-saving effect is decreased. When the mixing ratio of seawater is too high, an effect of diluting the sewage RO membrane concentrate relative to seawater is decreased, and the salt concentration is not really lowered. Thus, there is a problem that an advantage of the integrated membrane treatment system is almost lost. Further, in a case of a fixed mixing ratio, when the feed water quantity of sewage/drainage is decreased, the sewage RO membrane concentrate is unavoidably reduced. Thus, mixing seawater is also reduced, and the feed water to the RO membrane on the side of the seawater treatment line is reduced. Therefore, there is also a problem that the necessary product water quantity cannot be obtained.
In each plant of a sewage plant and other plants, an inflow quantity of sewage and a discharge quantity of drainage are generally determined. In a case where such sewage and drainage are taken as raw water and a collection rate and a mixing ratio of an RO membrane process are uniformly determined, the product water quantity of the system is naturally decided, and the quantity does not always match with user needs. In a case where the sewage/drainage quantity is small but the necessary product water quantity is large, in the system of Patent Document 1, Non-Patent Document 1, Non-Patent Document 2, a concentrate quantity of the sewage/drainage RO membrane process is decreased, and when the seawater intake quantity is increased at a designing stage, there is a problem that an energy-saving effect is small in the system.
Meanwhile, as an example that the sewage high-level treatment and the seawater desalination are performed in one water producing plant, there is a known method of supplying sewage/drainage in a case where sewage/drainage having a lower salt concentration than seawater or brackish water exists as feed water, or supplying seawater or brackish water in a case where sewage/drainage cannot be supplied due to the dry season, stoppage of the plant, or the like (Patent Document 2 and Non-Patent Document 3). According to this technology, sewage/drainage is used as feed water. Thus, the technology is more energy-saving than the seawater desalination using only seawater or only brackish water, and a fixed flow rate of product water can be surely obtained.
In a system in which sewage/drainage is switched with raw water having a different salt concentration (osmotic pressure) such as sewage/drainage and seawater or brackish water to perform filtration with the same RO membrane as in Patent Document 2 and Non-Patent Document 3, the system is often chosen in accordance with the sewage/drainage quantity which is an already determined water quantity.
In recent years, seawater desalination with a reverse osmosis membrane is adopted in a drought-prone region such as the Middle East, and there are a number of large-sized reverse osmosis membrane plants whose water production quantity exceeds 100 thousand m3/d. It is predicted that a necessary water production quantity will be increased and large-sized reverse osmosis membrane plants will be increased in the future.
An enough sewage/drainage quantity can be ensured when a plant is constructed near a large-sized sewage plant and a large plant. However, it is difficult to ensure a large sewage/drainage quantity in a small sewage plant, diversified type sewage plants, and small and middle plants. Therefore, there is a problem that the system of Patent Document 2 and Non-Patent Document 3 cannot cope with a size increase of the system in a case where the necessary water production quantity is large or the sewage/drainage quantity is small.
Patent Documents
Patent Document 1: International Publication WO 2010-61879
Patent Document 2: Japanese Patent No. 3957081
Non-Patent Documents
Non-Patent Document 1: “Kobelco Eco-Solutions Co., Ltd. and Four Others Conduct Demonstration Experiment of Model Project Launched by Ministry of Economy, Trade and Industry in Shunan-shi”, [online], Mar. 5, 2009, Nihon Suido Shinbun, [searched for on Jul. 2, 2009], via the Internet <URL:
http://www.suido-gesuido.co.jp/blog/suido/2009/03/post — 2780.h tml> Non-Patent Document 2: “Adoption of “Discover Technology Seeds Aiming at Low-Carbon Society/Social System Verification Model Project””, [online], Mar. 2, 2009, press release from Toray Industries, Inc. [searched for on Jul. 2, 2009], via the Internet <http://www.toray.co.jp/news/water/nr090302.html> Non-Patent Document 3: IDA World Congress-Atlantis, The Palm-Dubai, UAE Nov. 7-12, 2009, PEF: IDAWC/DB09-033
SUMMARY OF THE INVENTION
The present invention provides a water producing system of utilizing composite water treatment technologies in which a plurality of membrane units using a semi-permeable membrane is arranged to produce fresh water from plural kinds of raw water, the water producing system being capable of ensuring a necessary water production quantity and coping with a size increase of the system while responding to change in a water intake quantity of raw water, and an operation method therefor.
The water producing system and the operation method therefor in the present invention have any of the following preferred configurations.
(1) A water producing system, at least including a semi-permeable membrane treatment process A, a semi-permeable membrane treatment process B, and a semi-permeable membrane treatment process C, wherein the semi-permeable membrane treatment process A includes a semi-permeable membrane treatment step A for subjecting treatment target water A to semi-permeable membrane treatment to produce membrane permeate A and concentrate A, and a treatment target water A delivery means for delivering the treatment target water A to the semi-permeable membrane treatment step A, the semi-permeable membrane treatment process B includes a treatment target water B branching means for branching treatment target water B 2 into two or more, a semi-permeable membrane treatment step B for subjecting the treatment target water B to the semi-permeable membrane treatment to produce membrane permeate B and concentrate B, and a first treatment target water B delivery means for delivering one of the treatment target water B branched by the treatment target water B branching means to the semi-permeable membrane treatment step B as treatment target water, and the semi-permeable membrane treatment process C includes a semi-permeable membrane treatment step C for subjecting treatment target water to the semi-permeable membrane treatment to produce membrane permeate C and concentrate C, a first water mixing means for mixing the other treatment target water B branched by the treatment target water B branching means with at least part of the concentrate A produced in the semi-permeable membrane treatment step A, a mixed water delivery means for delivering the mixed water by the first water mixing means to the semi-permeable membrane treatment step C as treatment target water, and a second treatment target water B delivery means for delivering the other treatment target water B branched by the treatment target water B branching means to the first water mixing means as treatment target water.
(2) The water producing system according to (1), wherein the semi-permeable membrane treatment step B and the semi-permeable membrane treatment step C are respectively provided with one or more semi-permeable membrane treatment device, at least one semi-permeable membrane treatment device selected from a group of the semi-permeable membrane treatment devices of the semi-permeable membrane treatment step B and the semi-permeable membrane treatment step C is a semi-permeable membrane treatment device X for subjecting both the treatment target water B and the mixed water to the semi-permeable membrane treatment, and the water producing system includes a treatment target water switching means for switching the treatment target water to be delivered to the semi-permeable membrane treatment device X in such a manner that both the treatment target water B and the mixed water are deliverable to the semi-permeable membrane treatment device X.
(3) The water producing system according to (2), wherein the semi-permeable membrane treatment device X subjects only one of the treatment target water B and the mixed water to the semi-permeable membrane treatment at one time.
(4) The water producing system according to (2) or (3), wherein the semi-permeable membrane treatment device X communicates with both the delivery means of the first treatment target water B delivery means and the mixed water delivery means.
(5) The water producing system according to any of (2) to (4), wherein at least one delivery means selected from a group consisting of the first treatment target water B delivery means and the mixed water delivery means is a delivery means Y capable of delivering both the treatment target water B and the mixed water.
(6) The water producing system according to (5), wherein the delivery means Y delivers one of the treatment target water B and the mixed water at one time.
(7) The water producing system according to any of (1) to (6), including a second water mixing means for mixing the treatment target water A with the concentrate A or the treatment target water B or the mixed water, and a treatment target water A bypass delivery means for delivering the treatment target water A to the second water mixing means.
(8) The water producing system according to (7), wherein the first water mixing means and the second water mixing means are the same water mixing means.
(9) The water producing system according to any of (1) to (8), including a biological treatment device for subjecting organic component contained water to biological treatment to obtain biological treatment water, and a membrane treatment device A for subjecting the biological treatment water to treatment with a microfiltration membrane or an ultrafiltration membrane to obtain membrane treatment water A, wherein the membrane treatment water A serves as the treatment target water A.
(10) The water producing system according to any of (1) to (9), including a water intake means for taking in salt contained water, and a membrane treatment device B for subjecting the salt contained water taken in by the water intake means to the treatment with the microfiltration membrane or the ultrafiltration membrane to obtain membrane treatment water B, wherein the membrane treatment water B serves as the treatment target water B.
(11) The water producing system according to (10), including a membrane treatment water B storage reservoir that stores the membrane treatment water B, a first membrane treatment water B delivery means for delivering the membrane treatment water B to the membrane treatment water B storage reservoir, a mixed water storage reservoir that stores the mixed water, a second membrane treatment water B delivery means for delivering the membrane treatment water B of the membrane treatment water B storage reservoir to the mixed water storage reservoir, and a concentrate A delivery means for delivering the concentrate A to the mixed water storage reservoir, wherein the first treatment target water B delivery means is a delivery means for delivering the membrane treatment water B stored in the membrane treatment water B storage reservoir to the semi-permeable membrane treatment step B, and the mixed water delivery means is a delivery means for delivering the mixed water stored in the mixed water storage reservoir to the semi-permeable membrane treatment step C.
(12) An operation method for a water producing system, wherein in the water producing system according to any of (2) to (11) including a first flow rate measuring means for measuring a flow rate of the treatment target water A or the concentrate A, the treatment target water of one or more semi-permeable membrane treatment device X is switched by the treatment target water switching means based on a measured value of the first flow rate measuring means.
(13) An operation method for a water producing system, wherein in the water producing system according to any of (2) to (11), based on a predetermined value of an accumulated membrane permeate quantity or a predetermined value of a treatment time of one or more semi-permeable membrane treatment device X, the treatment target water of the semi-permeable membrane treatment device X is switched.
(14) An operation method for a water producing system, wherein in the water producing system according to any of (7) to (11) including a second flow rate measuring means for measuring a flow rate of the treatment target water A delivered by the treatment target water A bypass delivery means, the treatment target water of one or more semi-permeable membrane treatment device X is switched by the treatment target water switching means based on a measured value of the second flow rate measuring means.
(15) A water producing system, including a semi-permeable membrane treatment device for subjecting a plurality of different kinds of treatment target water to semi-permeable membrane treatment, and a treatment target water switching means for delivering the treatment target water to the semi-permeable membrane treatment device, wherein the semi-permeable membrane treatment device is formed by a plurality of semi-permeable membrane treatment devices arranged side by side, and the water producing system includes a treatment target water switching means for switching the treatment target water to be delivered to a semi-permeable membrane treatment device X in such a manner that one or more semi-permeable membrane treatment device selected from the plurality of semi-permeable membrane treatment devices serves as the semi-permeable membrane treatment device X for subjecting two or more kinds of treatment target water selected from the plurality of different kinds of treatment target water to the semi-permeable membrane treatment.
(16) The water producing system according to (15), wherein the semi-permeable membrane treatment device X subjects only one kind of the treatment target water selected from the plurality of different kinds of treatment target water to the semi-permeable membrane treatment at one time.
(17) The water producing system according to (15) or (16), wherein the semi-permeable membrane treatment device X communicates with a plurality of treatment target water delivery means.
(18) The water producing system according to any of (15) to (17), wherein one or more treatment target water delivery means serves as a treatment target water delivery means for delivering plural kinds of treatment target water to the semi-permeable membrane treatment device X by switching the kind of the treatment target water to be delivered by the treatment target water switching means.
(19) An operation method for a water producing system, wherein in the water producing system according to any of (15) to (18) including a flow rate measuring means for measuring a flow rate of one kind of treatment target water selected from the plurality of different kinds of treatment target water, the kind of the treatment target water to be delivered to one or more system of the semi-permeable membrane treatment device X is switched based on a measured value of the flow rate measuring means.
(20) An operation method for a water producing system, wherein in the water producing system according to any of (15) to (19), based on a predetermined value of an accumulated membrane permeate quantity or a predetermined value of a treatment time of one or more system of the semi-permeable membrane treatment device X, the kind of the treatment target water to be delivered to the semi-permeable membrane treatment device X is switched by the treatment target water delivery means.
Effects obtained by the present invention may include as follows.
The invention preferably includes the semi-permeable membrane treatment process A for subjecting the treatment target water A to the semi-permeable membrane treatment, the semi-permeable membrane treatment process B for subjecting the treatment target water B to the semi-permeable membrane treatment, and the semi-permeable membrane treatment process C for subjecting the mixed water in which part of the concentrate A and part of the treatment target water B are mixed to the semi-permeable membrane treatment. Thus, for example, in a case where the treatment target water A is sewage/drainage and the treatment target water B is salt contained water such as brackish water and seawater, the semi-permeable membrane treatment step B for performing seawater desalination is designed to treat an insufficient amount of a necessary product water quantity for the entire system, the amount not covered by a total treatment water quantity produced from the semi-permeable membrane treatment step A and the semi-permeable membrane treatment step C, or an amount assumed to be insufficient. By increasing and decreasing a treatment water quantity of the semi-permeable membrane treatment step B in response to change in a sewage/drainage intake quantity, the necessary product water quantity can be ensured. At least, at the time of stopping supply of the treatment target water A and stopping the semi-permeable membrane treatment step A, a minimum quantity of product water can be obtained by the semi-permeable membrane treatment step B. In a case where the sewage/drainage intake quantity is small, the semi-permeable membrane treatment step B for performing the seawater desalination is designed to be large, so that the system becomes a large-sized water producing system.
Since sewage/drainage has lower osmotic pressure than seawater, a sewage/drainage semi-permeable membrane treatment process can be operated with lower energy than a seawater semi-permeable membrane treatment process. Therefore, the sewage/drainage semi-permeable membrane treatment process is desirably operated at as a high collection rate as possible. However, the higher the collection rate is, the less the generated concentrate is. In a conventional water producing system as in Patent Document 1, Non-Patent Document 1, Non-Patent Document 2, little concentrate is generated. In a case where the necessary product water quantity is large, a necessary quantity of mixed water is produced by mixing a lot of seawater with the concentrate, and the mixed water is subjected to semi-permeable membrane treatment, so that the product water quantity is obtained. Dirty components such as organic matters are condensed in concentrate derived from sewage/drainage. Thus, membrane clogging and biofouling are generated more often in the mixed water than seawater, so that there is a possibility that agent cleaning has to be frequently performed. In the water producing system, the concentrate and seawater are mixed within a range that an energy-saving effect due to a dilution effect is generated, the mixed water is subjected to the semi-permeable membrane treatment in the semi-permeable membrane treatment step C, and the remaining seawater is subjected to the semi-permeable membrane treatment in the semi-permeable membrane treatment step B. Thus, feed water containing the concentrate derived from sewage/drainage is reduced more than the conventional water producing system, and the number of performing the agent cleaning against the membrane clogging and the biofouling is reduced for an amount of seawater supplied to the semi-permeable membrane treatment step B. Further, in a case where the necessary product water quantity is decreased, by decreasing the treatment water quantity of the semi-permeable membrane treatment step B for performing the seawater desalination, the step requiring large power for a booster pump, the product water quantity can be adjusted.
The plural systems of semi-permeable membrane treatment devices arranged side by side are preferably provided, and the treatment target water B and the mixed water can be appropriately selected or mixed by the treatment target water switching means and subjected to the semi-permeable membrane treatment. Therefore, for example, in a case where the treatment target water A is sewage/drainage and the treatment target water B is salt contained water such as brackish water or seawater, and in a case where a water quantity of the treatment target water A is large and a water quantity of the concentrate A is large, the mixed water is increased. Thus, by the treatment target water switching means, a treatment water quantity in an energy-saving mixed water semi-permeable membrane treatment process is more increased, so that the seawater semi-permeable membrane treatment process requiring a lot of energy can be reduced. In a case where the water quantity of the treatment target water A is small, the mixed water is reduced. Thus, by increasing a water intake quantity of the treatment target water B, and increasing the treatment water quantity of the treatment target water B by the treatment target water switching means, that is, increasing the seawater semi-permeable membrane treatment process, the necessary product water quantity can be ensured. Even in a case where the necessary product water quantity is unchanged or the water quantity of the treatment target water A is hardly changed, by regularly switching a treatment ratio of the treatment target water B and the mixed water by the treatment target water switching means, a load applied to a semi-permeable membrane due to differences between the treatment target water B and the mixed water in terms of water qualities such as a salt concentration and a membrane contaminant concentration is uniformized, contributing to extension of the life of the membrane and simplification of maintenance such as membrane replacement and agent cleaning. Thus, treatment cost and treatment energy are reduced.
The treatment target water A bypass delivery means for mixing the treatment target water A with the concentrate A or the treatment target water B or the mixed water is preferably provided. Thus, for example, even in a case where a problem is generated in the semi-permeable membrane treatment device A and hence the semi-permeable membrane treatment cannot be performed, or in a case where a flow rate of the treatment target water A is increased, by mixing the treatment target water A with raw water of the semi-permeable membrane treatment step B or the semi-permeable membrane treatment step C to lower the salt concentration and supplying the treatment target water A, pressure of the booster pump is reduced, so that energy is saved.
In a case where the treatment target water A is water generated from organic component contained water, and when the treatment target water is subjected to treatment with a MF/UF membrane after the biological treatment, an influence of organic components over the semi-permeable membrane is preferably reduced, so that a stable operation can be performed.
In a case where the treatment target water B is water generated from salt contained water, and when the treatment target water is subjected to the treatment with the MF/UF membrane after water intake, suspended matters and organic components are preferably removed, so that a stable operation can be performed for a semi-permeable membrane at the later stage.
The membrane treatment water B storage reservoir and the mixed water storage reservoir are preferably provided. Thus, even when the membrane treatment water B cannot be obtained temporarily, for example, at the time of a cleaning step of the MF/UF membrane, the membrane treatment water B stored in the membrane treatment water B storage reservoir can always be delivered to the mixed water storage reservoir and the semi-permeable membrane treatment device B. Even in a case where steps on the upstream side of the mixed water storage reservoir such as the semi-permeable membrane treatment device A is stopped, or the like, and hence the concentrate A cannot be obtained temporarily, the mixed water can be supplied to the semi-permeable membrane treatment step C. A mixing ratio of the treatment target water B and the concentrate A can be precisely adjusted.
By measuring the flow rate of the treatment target water A or the concentrate A, or the accumulated membrane permeate quantity or the treatment time of the semi-permeable membrane treatment device X, and automatically switching the treatment target water to be delivered to the semi-permeable membrane treatment device X by the measured value, the life of the semi-permeable membrane treatment device can be reasonably extended, and operation management can be easily performed.
The plural systems of semi-permeable membrane treatment devices arranged side by side are preferably provided, and the treatment target water A and the treatment target water B can be appropriately selected or mixed by the treatment target water switching means and subjected to the semi-permeable membrane treatment. Since sewage/drainage has lower osmotic pressure than seawater, the sewage/drainage semi-permeable membrane treatment process can be operated with lower energy than the seawater semi-permeable membrane treatment process. Thus, for example, in a case where the treatment target water A is sewage/drainage and the treatment target water B is salt contained water such as brackish water or seawater, and in a case where the water quantity of the treatment target water A is large, the treatment water quantity in the energy-saving sewage/drainage semi-permeable membrane treatment process is more increased by the treatment target water switching means, so that the seawater semi-permeable membrane treatment process requiring a lot of energy can be reduced. In a case where the water quantity of the treatment target water A is small, by increasing the water intake quantity of the treatment target water B, and increasing the treatment water quantity of the treatment target water B by the treatment target water switching means, that is, increasing the seawater semi-permeable membrane treatment process, the necessary product water quantity can be ensured. Even in a case where the necessary product water quantity is unchanged or the water quantity of the treatment target water A is hardly changed, by regularly switching a treatment ratio of the treatment target water A and the treatment target water B by the treatment target water switching means, a load applied to the semi-permeable membrane due to differences between the treatment target water A and the treatment target water B in terms of water qualities such as a salt concentration and a membrane contaminant concentration is uniformized, contributing to extension of the life of the membrane and simplification of maintenance such as membrane replacement and agent cleaning. Thus, treatment cost and treatment energy are reduced.
The semi-permeable membrane treatment device X can optionally subject only one kind of treatment target water selected from the plurality of different kinds of treatment target water to the semi-permeable membrane treatment at one time. Thus, for example, in a case where one treatment target water is not supplied due to failure or maintenance of a pre-treatment device, exhaustion of a raw water source, or the like, by subjecting only other treatment target water to the semi-permeable membrane treatment, the necessary product water quantity can be surely obtained.
By providing communication between the semi-permeable membrane treatment device X and the plurality of treatment target water delivery means, without considering a switching route of the treatment target water, the treatment target water can be easily switched to the respective semi-permeable membrane treatment devices.
The treatment target water delivery means for supplying the treatment target water to the respective semi-permeable membrane or the semi-permeable membrane unit is preferably provided, and the kind of the treatment target water to be supplied to the treatment target water delivery means is switched by the treatment target water switching means. Since the treatment target water delivery means does not communicate with other semi-permeable membranes or semi-permeable membrane units, a flow rate, a collection rate, and pressure suitable for the respective semi-permeable membrane or the semi-permeable membrane unit can be easily controlled by the treatment target water delivery means. In a case where the system is stopped due to maintenance or the system is stopped at the abnormal time, the system can be easily stopped by stopping the treatment target water delivery means.
The flow rate of the treatment target water having low osmotic pressure from the plurality of different kinds of treatment target water is preferably measured, and in a case where the measured value of the flow rate becomes large, by increasing a delivery quantity of the treatment target water having low osmotic pressure to the semi-permeable membrane treatment device X by the treatment target water switching means, and reducing delivery of other treatment target water having high osmotic pressure, treatment energy is more reduced.
The kind of the treatment target water to be delivered to the semi-permeable membrane treatment device X is preferably switched by the treatment target water switching means based on the predetermined value of the accumulated membrane permeate quantity or the predetermined value of the treatment time of the semi-permeable membrane treatment device X, the treatment ratio of the treatment target water A and the treatment target water B is regularly switched. Thus, the load applied to the semi-permeable membrane due to differences between the treatment target water A and the treatment target water B in terms of water qualities such as a salt concentration and a membrane contaminant concentration is uniformized, contributing to extension of the life of the membrane and simplification of maintenance such as membrane replacement and agent cleaning. Therefore, treatment cost and treatment energy are reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of one embodiment of a water producing system of the present invention.
FIG. 2 is a flow diagram of another embodiment of the water producing system of the present invention.
FIG. 3 is a flow diagram of still another embodiment of the water producing system of the present invention.
FIG. 4 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 5 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 6 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 7 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 8 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 9 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 10 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 11 is a flow diagram of yet another embodiment of the water producing system of the present invention.
FIG. 12 is a flow diagram of yet another embodiment of the water producing system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following, with reference to the drawings, a description will be given of desirable embodiments of the present invention. It is to be noted that, the scope of the present invention is not limited thereto.
FIG. 1 is a flow diagram of one embodiment of a water producing system to which the present invention is applied. The water producing system is provided with a semi-permeable membrane treatment process A 100 for subjecting treatment target water A 1 to semi-permeable membrane treatment in a semi-permeable membrane treatment device A 101 , a semi-permeable membrane treatment process B 200 for subjecting treatment target water B 2 to the semi-permeable membrane treatment in a semi-permeable membrane treatment device B 201 , and a semi-permeable membrane treatment process C 300 for subjecting mixed water to the semi-permeable membrane treatment in a semi-permeable membrane treatment device C 301 .
The semi-permeable membrane treatment process A 100 includes a treatment target water A reservoir 21 accommodating the treatment target water A 1 , a treatment target water A delivery pipe 1 a for supplying the treatment target water A 1 to the semi-permeable membrane treatment device A 101 , a booster pump 11 installed in the treatment target water A delivery pipe 1 a , the booster pump for supplying the treatment target water A 1 from the treatment target water A reservoir 21 to the semi-permeable membrane treatment device A 101 , and the semi-permeable membrane treatment device A 101 for subjecting the treatment target water A 1 to the semi-permeable membrane treatment.
The semi-permeable membrane treatment process B 200 includes a treatment target water B reservoir 22 accommodating the treatment target water B 2 , a treatment target water B delivery pipe 2 a for supplying the treatment target water B 2 to the semi-permeable membrane treatment device B 201 , a booster pump 12 installed in the treatment target water B delivery pipe 2 a , the booster pump for supplying the treatment target water B 2 to the semi-permeable membrane treatment device B 201 , the semi-permeable membrane treatment device B 201 for subjecting the treatment target water B 2 to the semi-permeable membrane treatment, a treatment target water B delivery pipe 2 b for supplying the treatment target water B 2 from the treatment target water B reservoir 22 to a mixed water reservoir 23 , and a pump 15 installed in the treatment target water B delivery pipe 2 b , the pump being for supplying the treatment target water B 2 to the mixed water reservoir 23 .
The semi-permeable membrane treatment process C 300 includes a concentrate A delivery pipe 4 a communicating with the primary side (side of the treatment target water) of the semi-permeable membrane treatment device A 101 for supplying concentrate A of the semi-permeable membrane treatment device A 101 to the mixed water reservoir 23 , the mixed water reservoir 23 communicating with the treatment target water B delivery pipe 2 b and the concentrate A delivery pipe 4 a for making the mixed water in which the treatment target water B 2 and the concentrate A are mixed, a mixed water delivery pipe 9 for supplying the mixed water to the semi-permeable membrane treatment device C 301 , a booster pump 13 installed in the mixed water delivery pipe 9 , the booster pump being for supplying the mixed water to the semi-permeable membrane treatment device C 301 , and the semi-permeable membrane treatment device C 301 for subjecting the mixed water to the semi-permeable membrane treatment.
Obtained membrane permeate A 3 , membrane permeate B 5 , and membrane permeate C 7 can be accommodated in a membrane permeate reservoir, and then discharged out of the system or reclaimed for industrial water, landscaping water, agricultural water, or the like.
The treatment target water A 1 indicates feed water to be supplied to the semi-permeable membrane treatment device A 101 . Properties and components of the treatment target water A 1 are not particularly limited. For example, sewage, plant drainage, seawater, brackish water, lake water, river water, groundwater, and the like are used. Alternatively, the raw water described above may be subjected to biological and/or physical and/or chemical pre-treatment such as activated sludge treatment, prefiltering, microfiltration membrane treatment, ultrafiltration membrane treatment, activated carbon treatment, ozonation, and ultraviolet irradiation treatment, to serve as the treatment target water A 1 , so that fouling generated in the semi-permeable membrane treatment device A 101 is reduced.
The same is applied to properties and components of the treatment target water B 2 as the treatment target water A 1 . However, when the raw water is combined in such a manner that osmotic pressure of the concentrate A and osmotic pressure of the treatment target water B satisfy the following relationship “(osmotic pressure of concentrate A)<(osmotic pressure of treatment target water B)”, osmotic pressure of the mixed water serving as feed water to be supplied to the semi-permeable membrane treatment device C 301 is lowered more than the treatment target water B 2 in a semi-permeable membrane treatment step C, so that a booster level of the water to be supplied to the semi-permeable membrane treatment device C 301 can be suppressed more than the treatment target water B 2 . Thereby, in comparison to water production respectively with the treatment target water A 1 and the treatment target water B 2 , water production respectively with the treatment target water A 1 , the treatment target water B 2 , and the mixed water saves more energy and cost due to a decrease in a water production quantity with the treatment target water B 2 .
The osmotic pressure indicates pressure to be applied to the solution side to stop incoming of a solvent from the solvent side to the solution side when the solvent and a solution are brought into contact with each other with a semi-permeable membrane interposed therebetween. In an embodiment of the present invention, a difference between the osmotic pressure of the concentrate A and the osmotic pressure of the treatment target water B is important. Thus, by bringing the concentrate A and the treatment target water B into contact with each other with the semi-permeable membrane interposed therebetween, it can be determined that the osmotic pressure on the side where the pressure is applied to stop the incoming of the solvent is higher.
In order to obtain such a relationship of the osmotic pressure, raw water having lower osmotic pressure is used as the treatment target water A 1 , and raw water having higher osmotic pressure is used as the treatment target water B 2 . Preferably, water having a lower salt concentration is used as the raw water having lower osmotic pressure, and water having a higher salt concentration is used as the raw water having higher osmotic pressure. The water having a lower salt concentration generally includes sewage, industrial drainage, river water, or treatment water obtained by subjecting the water described above to the pre-treatment. The water having a higher salt concentration generally includes seawater, salt lake water, and brackish water. Specifically, an example includes a combination of secondary treatment water obtained by subjecting sewage/drainage to treatment with a membrane bioreactor as the treatment target water A 1 , and seawater as the treatment target water B.
In the middle of the various pipes described above, biological and/or physical and/or chemical treatment such as activated sludge treatment, prefiltering, microfiltration membrane treatment, ultrafiltration membrane treatment, activated carbon treatment, ozonation, ultraviolet irradiation treatment, and chemical liquid injection, an intermediate tank, or the like may be provided.
As long as the semi-permeable membrane treatment device A 101 , the semi-permeable membrane treatment device B 201 , and the semi-permeable membrane treatment device C 301 have a function of separating into permeate and concentrate by a semi-permeable membrane provided in the device, shapes and materials thereof are not particularly limited. In a case where the raw water is water containing a lot of fouling substances such as sewage and industrial drainage, a low-fouling semi-permeable membrane is preferably used.
The semi-permeable membrane is a semi-permeable membrane that does not allow part of components in the treatment target water to permeate through. For example, the semi-permeable membrane includes a semi-permeable membrane that allows the solvent to permeate through and that does not allow a solute to permeate through. One example of the semi-permeable membrane used in water treatment technologies includes an NF membrane and an RO membrane. The NF membrane or the RO membrane is desired to possess the performance of being capable of reducing the concentration of the solute contained in the treatment target water to the level at which the solute can be used as reclaimed water. Specifically, it is desired to possess the performance of blocking various ions such as salt, mineral components and the like, e.g., divalent ions such as calcium ions, magnesium ions, and sulfate ions, the monovalent ions such as sodium ions, potassium ions, and chlorine ions, and dissoluble organic substances such as humic acid (molecular weight Mw 100,000), fulvic acid (molecular weight Mw=100 to 1,000), alcohol, ether, and sugars. The NF membrane is defined as an RO membrane whose operation pressure is equal to or smaller than 1.5 MPa, and whose molecular weight cutoff ranges from 200 to 1,000, and sodium chloride blocking rate is equal to or smaller than 90%. A membrane whose molecular weight cutoff is smaller than that and which possesses high blocking performance is referred to as the RO membrane. Further, of the RO membranes, one close to the NF membrane is referred also to as the loose RO membrane.
The NF membrane and the RO membrane can take forms of a hollow fiber membrane and a flat sheet membrane, to both of which the present invention can be applied. Further, in order to achieve easier handling, a fluid separation device (element) can be used, in which the hollow fiber membrane or the flat sheet membrane is stored in a casing. Preferably, the fluid separation device has the following structure in a case where the flat sheet membrane is used as the NF membrane or the RO membrane: a membrane unit, including the permeate flow channel member made up of the NF membrane or the RO membrane and tricot and a feed water flow channel member such as a plastic net, is wrapped around a cylindrical center pipe to which a multitude of pores are bored, which is then entirely stored in a cylindrical casing. It is also preferable to connect a plurality of fluid separation devices in series or in parallel so as to form a separation membrane module. In this fluid separation device, the feed water is supplied from one end into the unit, and before the feed water reaches the other end, the permeate permeating through the NF membrane or the RO membrane flows into the center pipe, and taken out of the center pipe at the other end. On the other hand, the feed water that did not permeate through the NF membrane or the RO membrane is taken out as the concentrate at the other end.
As the membrane material for the NF membrane or the RO membrane, polymer materials such as cellulose acetate, cellulose-base polymer, polyamide, and vinyl polymer can be used. Representative NF/RO membranes may be a cellulose acetate-base or polyamide-base asymmetric membrane, and a composite membrane having a polyamide-base or polyurea-base active layer.
As long as the pipes of the treatment target water A delivery pipe 1 a , the treatment target water B delivery pipe 2 a , the treatment target water B delivery pipe 2 b , the concentrate A delivery pipe 4 a , and the mixed water delivery pipe 9 have a function of moving liquids, materials and shapes thereof are not particularly limited. However, the pipes preferably have resistance against properties of the liquids to be moved, properties of agents to be charged, and pressure to be applied.
The booster pump 11 , the booster pump 12 , and the booster pump 13 are pumps having a booster function for respectively applying the pressure to the treatment target water A 1 , the treatment target water B 2 , and the mixed water to respectively supply and separate the liquids to and in the semi-permeable membrane treatment device A 101 , the semi-permeable membrane treatment device B 201 , and the semi-permeable membrane treatment device C 301 . The booster pump 11 , the booster pump 12 , and the booster pump 13 respectively show one specific embodiment of a treatment target water A delivery means for delivering the treatment target water A 1 to a semi-permeable membrane treatment step A, a first treatment target water B delivery means for delivering the treatment target water B 2 to a semi-permeable membrane treatment step B, and a mixed water delivery means for delivering the mixed water to the semi-permeable membrane treatment step C. The means are not limited to the mode of the booster pump. Preferably, in a case where the osmotic pressure of the target water is low, a feed pump for applying the pressure by supplying the target water is installed, and in a case where the osmotic pressure of the target water is high, a pump for delivering the target water, and a booster pump for boosting the pressure of the target water and supplying the target water to the semi-permeable membrane treatment device to carry out membrane permeation are installed.
As long as a first water mixing means has a function of mixing the treatment target water B and the concentrate A, a method and a form thereof are not particularly limited. An example includes the method with the mixed water reservoir 23 described above, a method with a line mixer, and a method of utilizing a delivery pump. As long as the treatment target water A reservoir 21 , the treatment target water B reservoir 22 , and the mixed water reservoir 23 can store the mixed water and have resistance against deterioration due to a chemical liquid such as a disinfection agent and a neutralization agent, the reservoirs are not particularly limited and a concrete reservoir, a glass fiber reinforced plastic reservoir, a plastic reservoir, or the like is used. An agitator for agitation in the reservoir may be provided.
As long as a second treatment target water B delivery means for delivering the treatment target water B from the treatment target water B reservoir 22 to the mixed water reservoir 23 has a function of moving the treatment target water B from the treatment target water B reservoir 22 to the mixed water reservoir 23 , a method and a form thereof are not particularly limited. An example includes the method with the pump 15 described above, a method using a head difference, and a method utilizing overflow.
In a case where water containing a lot of impurities is used as the raw water, as shown in FIG. 2 , pre-treatment water obtained by removing the impurities in a pre-treatment plant is preferably used as the treatment target water A and the treatment target water B. In particular, as the pre-treatment plant, an activated sludge treatment plant, a two-step treatment plant of the activated sludge treatment and the microfiltration/ultrafiltration membrane (MF/UF membrane) or the sand filtration, a membrane bioreactor (MBR) plant, an MF/UF membrane filtration treatment plant, a sand filtration treatment plant, or the like can be used.
In FIG. 2 , as the pre-treatment plant, the semi-permeable membrane treatment process A 100 includes a biological treatment reservoir 102 for subjecting the treatment target water A 1 to biological treatment, a biological treatment water deliver pipe 1 b for supplying the biological treatment water subjected to the biological treatment in the biological treatment reservoir 102 to a separation membrane device 103 , the separation membrane device 103 communicating with the biological treatment water deliver pipe 1 b , a membrane treatment water A delivery pipe 1 c communicating with the secondary side (side of the membrane permeate) of the separation membrane device 103 , and a pump 16 installed in the membrane treatment water A delivery pipe 1 c , the pump being for supplying the biological treatment water to the separation membrane device 103 , and the semi-permeable membrane treatment process B 200 includes a pump 14 for supplying the treatment target water B 2 to a separation membrane device 202 , the separation membrane device 202 for subjecting the treatment target water B 2 to separation treatment, and a membrane treatment water B delivery pipe 2 c communicating with the secondary side (side of the membrane permeate) of the separation membrane device 202 . It should be noted that a reservoir for adjusting a flow rate may be provided at the former stage of the separation membrane device 103 and the separation membrane device 202 .
The treatment target water A 1 is a liquid containing substances serving as substrates of microorganisms in a liquid inside the biological treatment reservoir 102 . For example, the treatment target water A 1 includes organic drainage such as household drainage, urban sewage, and plant drainage. A means for supplying the treatment target water A 1 to the biological treatment reservoir 102 may be a suction means for supplying the treatment target water from a treatment target water reservoir, a lake, or the like by a suction pump, or a means for supplying the treatment target water by utilizing a head difference between the treatment target water A 1 and a liquid surface of the biological treatment reservoir. The separation membrane device 103 may be immersed in the liquid of the biological treatment reservoir 102 or installed out of the reservoir. A membrane separation method includes an immersed membrane method, an external membrane separation method, and a rotation flat sheet membrane method, and not particularly limited.
The treatment target water B 2 is water containing organic matters to an extent that the biological treatment is not required but containing substances causing fouling on the semi-permeable membrane such as suspended matters and impurities. For example, the treatment target water includes water such as seawater, brackish water, and plant drainage. The suspended matters and the like are separated by the separation membrane device 202 , so that fouling of the semi-permeable membrane treatment device 201 can be suppressed. Thus, the separation membrane device is preferably installed at the former stage of the semi-permeable membrane treatment device.
A membrane structure of the separation membrane device includes a porous membrane, and a composite membrane obtained by combining the porous membrane with a functional layer, but not particularly limited. A specific example of the membrane includes a porous membrane such as a polyacrylonitrile porous membrane, a polyimide porous membrane, a polyethersulfone porous membrane, a polyphenylene sulfide sulfone porous membrane, a polytetrafluoroethylene porous membrane, a polyvinylidene fluoride porous membrane, a polypropylene porous membrane, and a polyethylene porous membrane. However, the polyvinylidene fluoride porous membrane and the polytetrafluoroethylene porous membrane are particularly preferable due to high chemical resistance thereof. Further, the membrane structure includes a composite membrane obtained by combining the porous membrane described above with rubber copolymer such as cross-linked silicone, polybutadiene, polyacrylonitrile-butadiene, ethylene-propylene rubber, and neoprene rubber as the functional layer.
Membrane pore size of the separation membrane device is preferably pore size with which an activated sludge and suspended matter contained water can be separated into a solid component and a solution component. With large membrane pore size, although membrane permeability is improved, a possibility that the solid component is contained in the membrane treatment water tends to be high. Meanwhile, with small membrane pore size, although the possibility that the solid component is contained in the membrane treatment water is reduced, the membrane permeability tends to be lowered. Specifically, the pore size is preferably equal to or greater than 0.01 μm and equal to or smaller than 0.5 μm, and further preferably equal to or greater than 0.05 μm and equal to or smaller than 0.5 μm.
A mode of the separation membrane device includes a hollow fiber membrane, a tubular membrane, and a flat sheet membrane. However, any mode of membrane can be used in the present invention. The hollow fiber membrane is a circular tube separation membrane having an outer diameter which is less than 2 mm, and the tubular membrane is a circular tube separation membrane having an outer diameter which is equal to or greater than 2 mm. With respect to these separation membranes, in a case of the hollow fiber membrane, the hollow fiber membrane is bundled into a U shape or an I shape and accommodated in a case so as to be made into a hollow fiber membrane element. In a case of the tubular membrane, the membrane is made into a tubular element. In a case of the flat sheet membrane, the membrane is made into a spiral element or a plate-and-frame element. Preferably, the single element is used or the plurality of elements is combined and modularized.
In a case where a problem is generated in the semi-permeable membrane treatment device A 101 and hence the semi-permeable membrane treatment cannot be performed, the treatment target water A 1 is preferably mixed with the raw water of the semi-permeable membrane treatment process B 200 or the semi-permeable membrane treatment process C 300 to lower the salt concentration and supplied to the semi-permeable membrane treatment device B 201 or the semi-permeable membrane treatment device C 301 . A method and a form of a means for moving and mixing the treatment target water A 1 with the concentrate A or the treatment target water B 2 or the mixed water are not particularly limited. However, the treatment target water is only required to be mixed on the upstream of the semi-permeable membrane treatment device B 201 or the semi-permeable membrane treatment device C 301 . As in FIG. 3 , a treatment target water A bypass delivery pipe 30 is preferably provided so as to communicate with the treatment target water A reservoir 21 and the concentrate A delivery pipe, or to communicate with the treatment target water A reservoir 21 and the mixed water reservoir 23 , or to communicate with the treatment target water A reservoir 21 and the membrane treatment water B delivery pipe 2 c , or to communicate with the treatment target water A reservoir 21 and the treatment target water B reservoir 22 , or to communicate with the treatment target water A reservoir 21 and the treatment target water B delivery pipe 2 a , or to communicate with the treatment target water A reservoir 21 and the treatment target water B delivery pipe 2 b . Preferably, a valve is provided in the treatment target water A bypass delivery pipe 30 , and the valve is closed at the time of a normal operation and the valve is opened in a case where a problem is generated in the semi-permeable membrane treatment device A 101 . Preferably, automatic open/close control of the valve is control based on a concentrate A flow rate of the semi-permeable membrane treatment device A 101 or control based on a signal at the time of stopping the semi-permeable membrane treatment device A 101 . An example of a means for delivering the treatment target water A 1 from the treatment target water A reservoir 21 through the treatment target water A bypass delivery pipe 30 includes a method of installing an underwater pump in the treatment target water A reservoir 21 , a method using a head difference, and a method utilizing overflow.
Here, the first water mixing means and a second water mixing means are the same, that is, the treatment target water A bypass delivery pipe 30 is provided so as to communicate with the treatment target water A reservoir 21 and the mixed water reservoir 23 . This is preferable because the salt concentration supplied to the semi-permeable membrane treatment device B 201 is not largely changed, so that there is no need for providing an inverter for changing supply pressure of the booster pump 12 , and there is no confluence pressure loss in a pipe-joint part generated in a case of communicating with the pipe.
FIGS. 4 to 9 show examples of embodiments in which plural systems of semi-permeable membrane treatment devices arranged side by side are provided, and the treatment target water B and the mixed water can be appropriately selected or mixed by valves 40 and subjected to the semi-permeable membrane treatment.
In the embodiments shown in FIGS. 4 , 5 , a pipe 31 is provided so as to communicate with the treatment target water B delivery pipe 2 a and the mixed water delivery pipe 9 , and the valves 40 are provided in the pipe 31 . By opening/closing the valves 40 , semi-permeable membrane treatment devices X 401 communicate with the mixed water delivery pipe 9 or the treatment target water B delivery pipe 2 a or both the pipes of the mixed water delivery pipe 9 and the treatment target water B delivery pipe 2 a through the pipe 31 , so that the mixed water or the treatment target water B 2 can be selectively subjected to the semi-permeable membrane treatment.
In a case where a mixed water quantity is decreased by a decrease in the treatment target water A 1 , stoppage of the semi-permeable membrane treatment device A 101 , a decrease in the concentrate A due to agent cleaning, or the like, by reducing the number of the semi-permeable membrane treatment devices for subjecting the mixed water to the semi-permeable membrane treatment or the number of units and controlling the valves 40 in such a manner that the treatment target water B 2 is delivered to the above semi-permeable membrane treatment devices, a product water quantity can be ensured without decreasing to a large extent. Alternatively, by slightly or entirely opening the valves 40 serving as borders between the mixed water and the treatment target water B 2 , the treatment target water B 2 to which higher pressure is applied due to higher osmotic pressure flows into the mixed water. Then, the treatment target water B is supplied to the mixed water while adjusting pressure and a flow rate by a degree of opening/closing of the valves 40 , so that a necessary feed water quantity can be supplied to the semi-permeable membrane treatment devices communicating with the mixed water delivery pipe 9 .
In a case where the mixed water quantity becomes zero, by stopping the booster pump 13 and controlling the valves 40 in such a manner that the treatment target water B 2 is delivered to all the semi-permeable membrane treatment devices X 401 , the semi-permeable membrane treatment devices X 401 are operated as the semi-permeable membrane treatment devices B. Thus, the product water quantity can be ensured without decreasing to a large extent.
In a case where the mixed water quantity is increased, by stopping the booster pump 12 and controlling the valves 40 in such a manner that all the semi-permeable membrane treatment devices X 401 communicate with the mixed water delivery pipe 9 , or by adjusting the booster pump 12 and controlling the valves 40 in such a manner that the semi-permeable membrane treatment devices X 401 communicating with the mixed water delivery pipe 9 are increased, a treatment water quantity of the mixed water with which the semi-permeable membrane treatment can be performed at lower pressure than the treatment target water B 2 is increased. Thus, energy and cost are saved.
Here, the semi-permeable membrane treatment devices X 401 subject only one of the treatment target water B and the mixed water to the treatment at one time, that is, the valves 40 are controlled and operated in such a manner that the treatment target water B and the mixed water C are not mixed. This is preferable because liquid movement from the booster pump side where the supply pressure is higher to the side where the pressure is lower is reduced, so that an operation with stable osmotic pressure can be performed.
The pipe 31 is provided so as to provide communication between the treatment target water B delivery pipe 2 a and the mixed water delivery pipe 9 , and delivery pipes are installed so as to communicate with the respective semi-permeable membrane treatment devices from the pipe 31 . This is preferable because the number of pipes and valves can be reduced more than a case where delivery pipes are installed so as to communicate with the respective semi-permeable membrane treatment devices from the treatment target water B delivery pipe 2 a or the mixed water delivery pipe 9 .
As in embodiments shown in FIGS. 6 , 7 , the semi-permeable membrane treatment devices B and the semi-permeable membrane treatment devices C are installed so as to subject minimum water intake quantities of the treatment target water B and the mixed water to the semi-permeable membrane treatment. This is preferable because the number of valves is reduced.
In a case where there are a large number of semi-permeable membrane treatment devices in a large plant, as in embodiments shown in FIGS. 8 , 9 , the booster pump is installed for each of the semi-permeable membrane treatment device units or the semi-permeable membrane treatment devices. This is preferable because the pressure of each of the semi-permeable membrane treatment devices can be surely boosted, and the flow rate is easily adjusted.
The mixed water has a lower salt concentration than the treatment target water B. Thus, the delivery pipes of the mixed water and the treatment target water B are not the same as in FIG. 8 . This is preferable because there is no need for providing highly corrosion-resistant pipes and valves on the side of the mixed water delivery pipe.
As in FIG. 9 , the treatment target water is switched on the upstream side of the booster pumps, so that the number of pipes on the downstream side of the booster pumps is reduced. This is preferable because a region for high-pressure pipes on the downstream of the booster pumps can be reduced.
Types of the membranes of the semi-permeable membrane treatment devices X are the same. This is preferable because more flow rate changes can be responded, and alternatively, by switching the treatment target water, chemical fouling, biofouling, and the like due to differences of the salt concentration, pH, and the like can be suppressed.
FIG. 10 is a diagram showing a flow of yet another embodiment of the water producing system to which the present invention is applied. The water producing system includes the treatment target water A reservoir 21 accommodating the treatment target water A 1 , the treatment target water A delivery pipe 1 a for supplying the treatment target water A 1 to the semi-permeable membrane treatment devices, the booster pump 11 for supplying the treatment target water A 1 from the treatment target water A reservoir 21 to the semi-permeable membrane treatment devices, the treatment target water B reservoir 22 accommodating the treatment target water B 2 , the treatment target water B delivery pipe 2 a for supplying the treatment target water B 2 to the semi-permeable membrane treatment devices, the booster pump 12 for supplying the treatment target water B 2 from the treatment target water B reservoir 22 to the semi-permeable membrane treatment devices, the pipe 31 providing communication between the treatment target water A delivery pipe 1 a and the treatment target water B delivery pipe 2 a on the downstream side of the booster pump 11 and the booster pump 12 , the valves 40 provided in the pipe 31 for changing the kind and the mixing ratio of the feed water to be supplied to the semi-permeable membrane treatment devices, the semi-permeable membrane treatment devices A 101 for subjecting the treatment target water A 1 to the semi-permeable membrane treatment, the semi-permeable membrane treatment device B 201 for subjecting the treatment target water B 2 to the semi-permeable membrane treatment, and the semi-permeable membrane treatment devices X 401 for subjecting the treatment target water A 1 or the treatment target water B 2 or the mixed water of the treatment target water A 1 and the treatment target water B 2 to the semi-permeable membrane treatment.
By opening/closing the valves 40 , the semi-permeable membrane treatment devices X 401 communicate with the treatment target water A delivery pipe 1 a or the treatment target water B delivery pipe 2 a or both the pipes of the treatment target water A delivery pipe 1 a and the treatment target water B delivery pipe 2 a through the pipe 31 , so that the treatment target water A 1 or the treatment target water B 2 or the mixed water of the treatment target water A 1 and the treatment target water B 2 can be selectively subjected to the semi-permeable membrane treatment.
In a case where the treatment target water A 1 is decreased, by reducing the number of the semi-permeable membrane treatment devices for subjecting the treatment target water A 1 to the semi-permeable membrane treatment or the number of the units and controlling the valves 40 in such a manner that the treatment target water B 2 is delivered to the above semi-permeable membrane treatment devices, the product water quantity can be ensured without decreasing to a large extent. Alternatively, by slightly or entirely opening the valves 40 serving as borders between the treatment target water A 1 and the treatment target water B 2 , the treatment target water B 2 to which higher pressure is applied due to higher osmotic pressure flows into the treatment target water A 1 . Then, the treatment target water B 2 is supplied to the treatment target water A 1 while adjusting the pressure and the flow rate by the degree of opening/closing of the valves 40 , so that the necessary feed water quantity can be supplied to the semi-permeable membrane treatment devices communicating with the treatment target water A delivery pipe 1 a.
In a case where a treatment target water A 1 quantity becomes zero, by stopping the booster pump 11 and controlling the valves 40 in such a manner that the treatment target water B 2 is delivered to all the semi-permeable membrane treatment devices, all the semi-permeable membrane treatment devices are operated as the semi-permeable membrane treatment devices B. Thus, the product water quantity can be ensured without decreasing to a large extent.
In a case where the treatment target water A 1 is increased, by stopping the booster pump 12 and controlling the valves 40 in such a manner that all the semi-permeable membrane treatment devices communicate with the treatment target water A delivery pipe 1 a , or by adjusting the booster pump 12 and controlling the valves 40 in such a manner that the semi-permeable membrane treatment devices communicating with the treatment target water A delivery pipe 1 a are increased, the treatment water quantity of the treatment target water A 1 with which the semi-permeable membrane treatment can be performed at lower pressure than the treatment target water B 2 is increased. Thus, the energy and the cost are saved.
Here, the semi-permeable membrane treatment devices subject only one of the treatment target water A 1 and the treatment target water B 2 to the treatment at one time, that is, the valves 40 are controlled and operated in such a manner that the treatment target water A 1 and the treatment target water B 2 are not mixed. This is preferable because the liquid movement from the booster pump side where the supply pressure is higher to the side where the pressure is lower is reduced, so that the operation with stable osmotic pressure can be performed.
The pipe 31 is provided so as to communicate with the treatment target water A delivery pipe 1 a and the treatment target water B delivery pipe 2 a , and delivery pipes are installed so as to communicate with the respective semi-permeable membrane treatment devices from the pipe 31 . This is preferable because the number of pipes and valves can be reduced more than a case where delivery pipes are installed so as to communicate with the respective semi-permeable membrane treatment devices from the treatment target water A delivery pipe 1 a or the treatment target water B delivery pipe 2 a.
The semi-permeable membrane treatment devices A 101 and the semi-permeable membrane treatment device B 201 are installed so as to subject minimum water intake quantities of the treatment target water A 1 and the treatment target water B 2 to the semi-permeable membrane treatment. This is preferable because the number of valves is reduced.
In a case where there are a large number of semi-permeable membrane treatment devices in a large plant, as in embodiments shown in FIGS. 11 , 12 , the booster pump is installed for each of the semi-permeable membrane treatment device units or the semi-permeable membrane treatment devices. This is preferable because the pressure of each of the semi-permeable membrane treatment devices can be surely boosted, and the flow rate is easily adjusted.
The treatment target water A 1 has a lower salt concentration than the treatment target water B 2 . Thus, the delivery pipes of the treatment target water A 1 and the treatment target water B 2 are not the same as in FIG. 11 . This is preferable because there is no need for providing highly corrosion-resistant pipes and valves on the side of the treatment target water A delivery pipe.
As in FIG. 12 , the treatment target water is switched on the upstream side of the booster pumps, so that the number of pipes on the downstream side of the booster pumps is reduced. This is preferable because a region for high-pressure pipes on the downstream of the booster pumps can be reduced.
Types of the membranes of the semi-permeable membrane treatment devices X are the same. This is preferable because more flow rate changes can be responded, and alternatively, by switching the treatment target water, chemical fouling, biofouling, and the like due to differences of the salt concentration, pH, and the like can be suppressed.
The present invention includes the water producing system using composite water treatment technologies in which a plurality of membrane units using a semi-permeable membrane is arranged, and an operation method therefor. A plurality of treatment target water A, B having different osmotic pressure such as sewage and seawater serves as raw water. The present invention can be favorably applied to a case where freshwater is produced by fresh water conversion technologies. In more detail, the present invention can be applied as a water producing device in the field of water clarification treatment in waterworks, the field of industrial-use water production such as industrial water, food and medical process water, and semiconductor-related component cleaning water, and fresh water can be produced in an energy saving and efficient manner.
DESCRIPTION OF REFERENCE CHARACTERS
1 : treatment target water A
1 a : treatment target water A delivery pipe
1 b : biological treatment water deliver pipe
1 c : membrane treatment water A delivery pipe
2 : treatment target water B
2 a : treatment target water B delivery pipe
2 b : treatment target water B delivery pipe
2 c : membrane treatment water B delivery pipe
3 : membrane permeate A
4 : concentrate A
4 a : concentrate A delivery pipe
5 : membrane permeate B
6 : concentrate B
7 : membrane permeate C
8 : concentrate C
9 : mixed water delivery pipe
11 : booster pump
12 : booster pump
13 : booster pump
14 : pump
15 : pump
16 : pump
21 : treatment target water A reservoir
22 : treatment target water B reservoir
23 : mixed water reservoir
30 : treatment target water A bypass delivery pipe
31 : pipe
32 : pipe
33 : pipe
40 : valve
100 : semi-permeable membrane treatment process A
101 : semi-permeable membrane treatment device A
102 : biological treatment reservoir
103 : separation membrane device
200 : semi-permeable membrane treatment process B
201 : semi-permeable membrane treatment device B
202 : separation membrane device
300 : semi-permeable membrane treatment process C
301 : semi-permeable membrane treatment device C
401 : semi-permeable membrane treatment device X
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A water producing system which is provided with a semi-permeable membrane treatment process A 100 to produce membrane permeate A 3 and concentrate A, a semi-permeable membrane treatment processB 200 which is equipped with a treatment target water B branching means for branching treatment target water B 2 into two or more to produce a membrane B 5 and concentrate B 6 , and a semi-permeable membrane treatment process C 300 which is equipped with a first water mixing means for mixing one of the treatment target water B with at least part of the concentrate A, and subjects the mixed water to the semi-permeable membrane treatment to produce membrane permeate C 7 and concentrate C 8 , thereby producing fresh water from a plurality of kinds of raw water which differ in osmotic pressure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Exposed grid suspended ceiling constructions are extensively used in private and commercial building. Such constructions employ metal L-beam members, often called wall angles, fastened with nails or screws to the perimeter walls. Metal main T-beam members are then supported on wire hangers in predetermined fashion and transverse or cross T-beam members cooperatively interconnect in a determined manner to form a rigid grid system within the perimeter.
This metal grid network serves as a convenient support system for lay-in modules or panels, such as acoustical units, light fixtures and the like.
Maintenance on these exposed grid ceilings is accomplished by painting and/or replacing the lay-in acoustical panels. However, the exposed metal flanges accumulate a film of smoke, grease and dirt that results in poor paint adhesion unless expensive pre-treatment, such as washing or sanding is effected. Also, priming is necessary where rust occurs.
It is desirable therefore to have a decorative trim strip to mechanically resurface the exposed flanges of the dirty metal grid runners or beams.
Moreover, it is advantageous to have available an economical trim strip that may be installed with the panels and light fixtures in place and may be used on either L-beam members or T-beam members.
2. Description of the Prior Art
Grid ceiling covers have been disclosed in the prior art, and particularly in U.S. Pat. No's. 3,594,972 and 3,936,990. However, even though the structures disclosed in these patents have merit in the highly decorative and expensive new installation field, they do not lend themelves to the economical renovation of old ceilings, which is the primary object of this invention.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method of improving existing suspended ceiling constructions.
It is a further object of this invention to provide a decorative trim strip that may be used on either the structural L-beams or T-beams of an existing suspended ceiling construction.
It is yet another object of the invention to provide a decorative trim strip for use on existing suspended ceiling constructions wherein the trim strip can be easily positioned with the ceiling panels in place in the grid network.
Another object of the invention is to provide a decorative intersection cap for use with the decorative trim strip.
These and other objects of the invention attained by use of a longitudinally hollow "J" section having an opening running lengthwise of the hollow portion and communicating with the interior thereof, through which a single laterally extending flange portion of a structural grid beam can enter for subsequent positioning.
DESCRIPTION OF THE DRAWING
In the accompanying drawing,
FIG. 1 is an isometric view looking upwardly that shows a portion of a suspended ceiling construction employing structural T-beam members using the decorative trim strips and a decorative intersection cap according to the present invention;
FIG. 2 is an enlarged isometric view of a portion of the decorative trim strip according to the invention as depicted in FIG. 1;
FIG. 3 is an end elevation exemplifying an initial step in positioning the trim strip illustrated in FIGS. 1 and 2 on the flange of a typical structure T-beam member;
FIG. 4 is an end elevation illustrating the trim strip in supported and aligned position on the structural T-beam flange;
FIG. 5 is an enlarged isometric view of a portion of the trim strip illustrating the tear-away conversion of the trim strip for use on structural L-beam flanges;
FIG. 6 is an end elevation of a modified trim strip according to the principles of the invention, supported and positioned on the structural L-beam flange, as used about the perimeter of a suspended ceiling construction;
FIG. 7 is an enlarged isometric view of the decorative intersection cap unit as depicted in FIG. 1; and
FIG. 8 is an end elevation illustrating the trim strip in supported and aligned position on a structural T-beam member and the intersection cap in supported and aligned position on the decorative trim strip.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a suspended ceiling construction using trim strips and an intersection cap unit in accordance with the principles of this invention. The suspended ceiling construction includes a grid having rows of spaced apart parallel extending main structural T-beam members, generally denoted by 10 having flanges 14 and 16 extending laterally from a web 18 and further including spaced apart parallel extending crossing rows of usually shorter transverse structural T-beam members 12, having laterally extending portions like those of the structural main T-beam members 10.
The transverse structural T-beam members 12 extend between the main structural T-beam members 10 to intersect them at right angles thereto and at spaced intervals along the lengths of the main T-beam members 10. Appropriate support means, such as wires 22, support the grid from overlying joists and the like. The illustrated suspended ceiling construction further includes modules such as acoustical panels 20 of a glass or mineral fiber construction. Longitudinal hollow "J" members or trim strips 30 fit on laterally extending flange portions of the structural T-beam members 10 and 12 and are fashioned to run substantially along the lengths of the T-beam members between intersecting T-beam members, as indicated in FIG. 1.
FIG. 2 illustrates an enlarged view of the decorative trim strip 30, generally shown in FIG. 1. The resilient trim strip 30 has a horizontal lower flange 32 substantially equal in width to the total width of both T-beam flanges but slightly wider, an upper horizontal flange 36 slightly less than half of the width of lower flange 32 and a short vertical web 34 extending between said horizontal flange portions and an opposing vertical web 40 forming a channel shaped "J" section including a longitudinal "V" shaped weakening trough extending the entire length of the lower flange 32.
In practice the trim strip 30 is made by an extrusion process. While it has been useful to use polyvinyl chloride plastic to make a semi-rigid trim strip, other suitable materials may be employed. The simple cross-section of the trim strip lends itself to the metal roll forming process. FIGS. 3 and 4 illustrate steps for placing the trim strip 30 in position on a structural T-beam member 10. Initially trim strip 30 is moved so as to have the flange portion 16 of the T-beam 10 pass through the opening 38 created by the upwardly angled end of upper flange 36 and lower flange 32 along a path extending laterally. With such movement the trim strip 30 is placed in a temporary position laterally offset resiliently deflecting apart upper flange 36 and lower flange 32 to permit vertical web 40 to pass under flange portions 14 and 16 of structural T-beam member 10. FIG. 3 represents the trim strip 30 in this temporary position.
Vertical web 40 is more remote from vertical web 34 than the total flange width of any structural T-beam member 10 so lower horizontal flange 32 is permitted to return to rest against the flanges 14 and 16 of the structural T-beam 10, as illustrated in FIG. 4.
FIG. 5 illustrates a conversion of the trim strip 30 for use on structural L-beam perimeter sections. Vertical web 40 is severely deflected so as to cause a fracture in the weakened horizontal lower flange 32 along the trough 42. Once the fracture is started it continues in a controlled manner along the path of trough 42 until the entire vertical web 40 and part of the horizontal lower flange 32 are separated, leaving a "J" section for use on structural L-beam members, as illustrated in FIG. 6. A structural L-beam member 44 is secured with a nail 48 to a wall 46 as is encountered about the perimeter of most ceiling installations. Modified trim strip 33 resiliently engages lower flange 45 of the L-beam member 44 between upper and lower horizontal flanges 32 and 36 of modified trim strip 33.
As illustrated in FIG. 1, trim strips 30 terminate between the intersecting structural T-beam members because of the obstruction to upper horizontal flange 36 and the obstruction to both vertical flanges 34 and 40 at such intersections. The decorative trim strips could be routed at the intersections to provide access for the intersecting T-beam members. However, better results are obtained when the decorative trim strips 30 are cut short of each intersection to allow for expansion of the linear strips and when an intersection cap 50, as illustrated in FIG. 7, is provided to conceal the exposed structural T-beam members at the intersections left exposed by the shortened trim strips 30.
FIG. 7 illustrates the resilient decorative intersection cap 50 comprised of a cross or "X" shaped horizontal flange 52 having spaced apart vertically extending web portions 54 and 56, said web portions being provided with inwardly extending resilient protrusions 58 and 60 at the top ends of said webs, which extend over minor portions of the horizontal flange of the cap to engage decorative trim strip 30 at vertical web portions 34 and 40 thereof. As illustrated in FIG. 8, said decorative trim strip 30 is seated in the recess of the cap so as to engage both vertical sides thereof to maintain the intersection cap 50 in juxtaposition with said trim strip 30 and in juxtaposition with the structural T-beam member, partially covering the trim strip 30 and the exposed flanges 14 and 16 of the T-beam member 10 at each intersection.
It is apparent that within the scope of the invention modifications and arrangements may be made other than as herein disclosed. The present disclosure is merely illustrative, the invention comprehending all variations thereof.
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A decorative trim strip and a suspended ceiling construction employing the trim strip with structural T- and L-beams having laterally extending portions or portion, wherein such trim strip is a resilient longitudinal "J" channel section having a lengthwise opening communicating with the interior thereof through which a laterally extending portion of a structural beam can be inserted internally to engage and maintain the decorative trim strip.
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BACKGROUND OF THE INVENTION
The present invention relates to cardiac pacemakers, and more specifically to a pacemaker having a selectable hysteresis feature which compensates for sinus node malfunction.
It is well known that natural heart activity, including the depolarization of the sinus node provides optimum hemodynamic performance. Atrial or ventricular stimulations induced by such devices as cardiac pacemakers, generally delay or inhibit natural heart activity by preventing the depolarization of the sinus node.
The hysteresis feature was developed to address this concern, by allowing the pacemaker to follow the sensed sinus node depolarization to a certain predetermined rate below the programmed lower rate of the pacemaker. As such, the escape interval in conventional demand pacemakers equipped with hysteresis feature, is longer than the lower rate interval, for enabling the patient's intrinsic rhythm to control the heart as long as the intrinsic rate is maintained above a predetermined minimum rate. However, in selected patients, these conventional pacemakers do not generally allow the natural heart activity to resume normally after pacing.
The following patents provide a brief historical background for the development and use of the hysteresis feature as it relates to cardiac pacing technology. U.S. Pat. No. 4,856,523, entitled “RATE-RESPONSIVE PACEMAKER WITH AUTOMATIC MODE SWITCHING AND/OR VARIABLE HYSTERESIS RATE,” issued to Sholder et al, on Aug. 15, 1989, describes the inclusion of the hysteresis feature in a rate-responsive pacemaker, in an attempt to prevent competition between the pacemaker and the heart's SA node, when the anterograde conduction path is restored. The Sholder patent proposes to vary the hysteresis rate as a function of the pacemaker sensor rate, to a predetermined level upon sensing of the natural heart contraction during the escape interval, as illustrated in FIG. 3B and 4.
U.S. Pat. No. 4,363,325 entitled “MODE ADAPTIVE PACER,” issued to Roline et al, on Dec. 14, 1982, and assigned to Medtronic, Inc., discloses a multiple-mode pacer which automatically switches from an atrial synchronous mode to a ventricular inhibited mode when the intrinsic atrial rate drops below a preset hysteresis rate. The Roline patent is incorporated herein by reference.
While the above cited patents and other publications and studies relating to the hysteresis feature have attempted with varying degrees of success to allow the patient's intrinsic rhythm to control, none was completely successful in causing the natural heart activity to resume optimally after pacing.
SUMMARY OF THE INVENTION
Briefly, the above and further objects and features of the present invention are realized by providing a new and improved pacemaker having a hysteresis feature which permits intrinsic heart activity, controlled by the sinus node to resume optimally after pacing.
The pacemaker has a programmable lower rate and upper rate, a programmable lower hysteresis rate (LRH) corresponding to a lower rate hysteresis interval (LRHI), and a programmable rate (IR) intermediate an upper pacing rate (UR) and a lower pacing rate (LR). A microprocessor measures the average rate of change in the intervals between consecutive ventricular depolarizations M AVG , and compares the last intrinsic escape (RR N ) interval to the lower rate hysteresis interval (LRHI).
If the last intrinsic ventricular interval(RR N ) will be longer than the lower rate hysteresis interval (LRHI), and if the value of M AVG is greater than a first preselected value SL 1 but less than a second preselected value SL 2 , the pacemaker stimulates at the lower rate hysteresis (LRH) and thereafter gradually increases the pacing rate up to the intermediate rate (IR) while the pulse generator is in the demand mode. A time counter maintains a continuous pacing at the intermediate rate (IR) for a predefined period of time, and the pacing rate is gradually decreased down to the lower pacing rate (LR).
The accompanying Table I summarizes the features offered by the present invention, and correlates these features to FIGS. 2A through 6.
TABLE 1
FIG. 2A
FIG. 2B
FIG. 3
FIG. 4
FIG. 5
FIG. 6
(Step)
(Step)
(Region)
(Curve)
(Curve)
(Curve)
220,
I
KL
222
220,
VI
LPQ
224
226,
III
K′L
228,
232
226,
IV
LPQ
228,
230
226,
II
AB
AB
234,
236
226,
V
BCDEF
BB′CDE′R
234,
238-254
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other options, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with accompanying drawings, wherein:
FIG. 1 is a block diagram showing the primary functional blocks of the pacemaker according to the present invention;
FIGS. 2A and 2B are flow charts of a simplified software program suitable for use in the pacemaker of FIG. 1;
FIG. 3 is an illustration of two exemplary generally increasing limit functions SL 1 and SL 2 which determine the behavior of the pacemaker according to the software program of FIGS. 2A and 2B;
FIG. 4 is a response curve illustrating the variation of the pacing rate according to the present invention;
FIG. 5 is another response curve illustrating pacing rate variation according to the present invention; and
FIG. 6 is yet another response curve illustrating pacing rate variation according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and more particularly to FIG. 1 thereof, there is illustrated a block diagram of the components of the pacemaker 100 of the present invention. Block 150 illustrates a microprocessor chip, such as the CDP 1802 microprocessor made by RCA. The microprocessor 150 is connected to a ROM memory 151 and to a RAM memory 152 via a data bus 156 . An address bus 154 interconnects the ROM memory 151 , the RAM memory 152 , and a controller circuit 158 . The controller circuit 158 , in turn, controls a pacer circuit 161 and a pacemaker output stage 160 for stimulating the heart. The pacemaker 100 could be used for single chamber or dual chamber pacing.
FIGS. 2A and 2B together illustrate the flow diagram of a program 200 which is stored in the ROM memory 151 , and which is run once each cycle in the pacemaker 100 . Alternatively, the program 200 could be stored in the RAM memory 152 . The program 200 does not contain all the steps which are carried out by the microprocessor 150 , but it includes those steps that illustrate the operation of the pacemaker 100 according to the present invention. Several variables of the software-controlled operations can be reprogrammed through the RAM memory 152 .
Before proceeding with a more detailed explanation of the present invention, it would be helpful to review the following definitions:
“Intrinsic rhythm” or “intrinsic rate” of the heart is the rate at which the heart naturally beats on its own, without being stimulated by a pacemaker-provided stimulus.
“Hysteresis” means extension of the range of rates at which inhibition of the pacemaker pulses will occur. The base pacing interval is increased by the hysteresis interval. Thus, hysteresis provides a longer escape interval, thereby giving the heart an opportunity to beat on its own before the pacer provides stimulation pulses.
“Pacing Rate” is the rate at which the stimulation pulses are provided from the heart from the pacemaker.
Starting at step 201 , the program 200 is initiated, and the intrinsic ventricular depolarizations are sensed at 202 . While the program 200 uses ventricular events for carrying out the invention, it should be understood that atrial events can alternatively be used.
The program 200 measures, at step 204 , the intrinsic escape interval, such as the RR interval between two successive sensed ventricular events, and calculates, at step 206 , a parameter “D”, as follows:
D=RR i -RR i-1 , (1)
where RR i is the RR interval which has been recently measured at step 204 ; and RR i-1 is the RR interval preceding RR i . It therefore follows that the parameter D is indicative of the rate of change of the RR interval.
In this respect, if D were found to have a positive value, it is an indication that the RR interval is increasing with time, and consequently the intrinsic rate of the heart is dropping. The reverse holds true where D has a negative value, indicating that the RR interval is decreasing and that the intrinsic rate is increasing. Additionally, the absolute value of D represents the rate of change of the intervals of the intrinsic ventricular depolarizations, which is also illustrated by the slope the curve AB in FIGS. 5 and 6, as it will be described later in greater detail.
If at step 208 the value of D is found to be negative, this value will not be used since it represents an increase in the intrinsic ventricular depolarization rate, and the above subroutine, including steps 202 , 204 , 206 and step 208 , is repeated until a positive value of D is found. The dashed line 207 indicates that if the value of D is found to be negative, then the attending physician will have the option to either cause the software to set n=0, at step 203 , or to restart at step 202 . The preferred embodiment of the present invention relates principally to precipitous drops in heart rates, and consequently only positive values of D are added and stored at 212 by the random access memory RAM 152 .
While the preferred embodiment includes adding only those positive values of D, it will become apparent to those skilled in the art that consecutive D values could alternatively be added. The feature of selecting between consecutive and positive D values is a programmable feature, and is selectable by the attending physician.
In order to detect and ascertain the occurrence of precipitous heart rate drops, the software 200 calculates the average rate of increase M AVG of a preselected number “N” of RR intervals. Preferably, M AVG is calculated over a predetermined period of time “T”. If during that period T, the value of M AVG is less than a first limit function SL 1 , then this is an indication that the intrinsic heart rate has not dropped rapidly enough to warrant the use of corrective measures, such as the activation of the hysteresis feature. If on the other hand, the value of M AVG reaches or exceeds the first limit SL 1 , but is less than a second limit SL 2 , the pacemaker is instructed to take appropriate measures, as will be described later in greater detail.
To achieve this function, the program 200 stores the calculated positive values of D, at step 212 , and counts the number of events “n” indicative of a positive D value. When the count reaches a preprogrammed number “N” of stored beats or reaches the time period T, the program 200 calculates the sum “M” of the N stored values D, as follows: M = ∑ j = 1 N D j , ( 2 )
where j is an integer that varies between 1 and N; and where N is the number of stored beats.
The value of M is then averaged at step 217 over the number of stored beats N, as follows: M AVG = M N ( 3 )
In the preferred mode of the present invention the above parameters are assigned the following values:
N=6 beats.
T=15 seconds. It should, however, be understood that different values or ranges of values can alternatively be employed within the scope of the invention.
Digressing from the flow chart of FIG. 2A, and turning to FIG. 3, there is a shown lower limit function SL 1 and an upper limit function SL 2 which are identified by the numeral references 10 and 12 , and which divide the quadrant into six regions: I, II, III, IV, V and VI. Each one of these regions will now be described in greater detail in relation to FIGS. 2A through 5. The horizontal coordinate axis represents time “t”, and the vertical coordinate axis represents RR intervals “RRI”.
As used in this specification, the LRI and LRHI parameters in the following context:
“LRI” means the Lower Rate Interval which corresponds to the lower pacing rate “LR” of the pacemaker, where LRI in milliseconds equals 60,000 divided by LR in beats per minute. LR is typically programmed to 70 beats per minute.
“LRHI” means the Lower Rate Hysteresis Interval that corresponds to the lower rate hysteresis “LRH” which is typically programmed to 50 beats per minute. LRHI in milliseconds equals 60,000 divided by LRH in beats per minute.
By comparing the average rate of change M AVG to the programmable limit functions SL 1 and SL 2 , it would be possible to identify the region which corresponds to the mode of operation of the pacemaker 100 . SL 1 and SL 2 are boundaries between regions defining distinctly different operation of the pacemaker 100 . For clarity purposes, the six regions are defined as follows:
“Region I” is the portion of the quadrant defined by the lower limit function SL 1 and by the RRI and time axes. The pacemaker 100 operates in Region I whenever the value of M AVG is less than SL 1 ; and the last intrinsic ventricular escape interval RR N is shorter than the lower rate hysteresis interval LRHI. Pacing is inhibited in Region I, as illustrated by the curve KL in FIG. 4, and by step 222 of FIG. 2 A. The curve KL shows the heart rate decreasing at a slow rate.
“Region II” is the portion of the quadrant defined by the limit functions SL 1 and SL 2 , and by the lower rate hysteresis interval LRHI axis. The pacemaker 100 operates in Region II whenever the value of M AVG is greater than SL 1 , but less than SL 2 ; and the last intrinsic ventricular escape interval RR N is shorter than LRHI. Pacing is inhibited in Region II, as illustrated by the curve AB in FIGS. 5 and 6, and by step 236 of FIG. 2 B. The curve AB shows the heart rate decreasing at an intermediate rate.
“Region III” is the portion of the quadrant defined by the upper limit function SL 2 , by the LRI axis and by the lower rate hysteresis interval LRHI axis. The pacemaker 100 operates in Region III whenever the value of M AVG is greater than SL 2 ; and the last intrinsic escape interval RR N is shorter than LRHI. Pacing is inhibited in Region III, as illustrated by the curve K′L in FIG. 4, and by the step 232 of FIG. 2 B. The curve K′L shows the heart rate decreasing precipitously, as opposed to curve KL, which represents a more modest heart rate drop in Region I.
“Region IV” is the portion of the quadrant above the lower rate hysteresis interval LRHI axis, and defined by the RRI axis and by the upper limit function SL 2 . The pacemaker 100 operates in Region IV whenever the value of M AVG is greater than SL 2 ; and the last intrinsic escape interval RR N will be longer than LRHI. As illustrated by the curve LPQ in FIG. 4, and by the step 230 of FIG. 2B, pacing is carried out at the lower rate LR. It should however be understood that pacing could be alternatively carried out at the lower rate hysteresis LRH.
“Region V” will be the portion of the quadrant above the lower rate hysteresis interval LRHI axis, between the two limit functions SL 1 and SL 2 . The pacemaker 100 operates in Region V whenever the value of M AVG is less than SL 2 but greater than SL 1 , and the last intrinsic escape interval RR N is longer than LRHI. As illustrated by the curves BCDEF and BB′CDE′R in FIGS. 5 and 6 respectively, and by steps 238 through 254 of FIG. 2B, pacing starts at the lower rate hysteresis rate LRH and gradually increases until the pacing rate reaches an intermediate pacing rate IR. Pacing at IR is maintained for a predetermined period of time, and is thereafter gradually reduced until it reaches the lower rate LR. Pacing is maintained at the lower rate until the intrinsic rate exceeds the pacemaker lower rate, as illustrated by the curve FG in FIG. 5 . The pacemaker operation in Region V is triggered by an intermediate rate of decrease in the intrinsic hear rate.
“Region VI” is the portion of the quadrant defined by the lower limit function and by the lower limit function SL 1 . The pacemaker 100 operates in Region VI whenever the value of M AVG is less than SL 1 ; and the last intrinsic ventricular escape interval RR N will be longer than the lower rate hysteresis interval LRHI. As illustrated by the curve LPQ in FIG. 4, and by the step 224 of FIG. 2A, pacing is carried out at the lower rate LR. It should however be understood that pacing could be alternatively carried out at the lower rate hysteresis LRH.
Returning now to FIG. 2A, the program 200 compares M AVG to SL 1 and step 218 . If M AVG is less than SL 1 , then a further determination is made at step 220 whether the last ventricular intrinsic escape interval RR N is less than or equal to LRHI. If it is, the pacemaker 100 operates in Region I, and pacing is inhibited, as indicated by step 222 in FIG. 2 A and by the response curve KL in FIG. 4 .
If the intrinsic escape interval (RR N ) is determined at step 220 , to be equal to or tend to exceed LRHI, and if there is no sensed event at a shorter interval, while the pacemaker is still in the demand mode, the pacemaker 100 will operate in Region IV, and stimulation is carried out at the lower pacing rate LR, as illustrated by the curve LPQ in FIG. 4 . The curves in FIGS. 4, 5 and 6 which are drawn in dashed lines indicate that pacing is inhibited, while the curves drawn in solid lines indicate that pacing is occurring.
Returning now to step 218 in the flow chart of FIG. 2A, if the program 200 determines that M AVG is greater than or equal to SL 1 then a further determination is made at step 226 whether M AVG is less than or equal to SL 2 . If M AVG is found to be greater than SL 2 then the pacemaker 100 will operate in either Region III or Region IV. A further decision is made at step 228 whether the last intrinsic escape interval RR N is less than or equal to the lower rate hysteresis interval (LRHI).
If the program 200 determines that RR N is less than or equal to LRHI then the pacemaker 100 will operate in Region III, and as indicated by step 232 of FIG. 2B, and by the curve K′L in FIG. 4, pacing will be inhibited. If on the other hand, it is determined at step 228 , that RR N is greater than LRHI, then the pacemaker 100 will operate in Region IV and as indicated by step 230 of FIG. 2B, and by the curve LPQ in FIG. 4, pacing is carried out at the lower pacing rate (LR).
The pacemaker 100 identifies and reacts to intermediate drops in the intrinsic heart rate, whenever M AVG is found to be intermediate the limit functions SL 1 and SL 2 , as follows:
SL 1 ≦M AVG ≦SL 2 (4)
In the above condition, the pacemaker is caused to pace at a gradually increasing pacing rate until it reaches a predetermined intermediate pacing rate (IR) which is lower than, or in certain circumstances, equal to, the upper pacing rate (UR). Demand pacing is maintained at the intermediate pacing rate (IR) for a predetermined period of time, and is thereafter reduced gradually.
With reference to FIG. 2B, the program 200 determines at step 234 whether the last intrinsic escape interval RR N is less than or equal to LRHI. If it is, then the pacemaker 100 will operate in Region II, and as indicated by step 236 , and by the curve AB in FIGS. 5 and 6, pacing is inhibited.
If however, it is determined at step 234 that RR N will tend to be longer than LRHI, then the condition set forth in equation (6) above is satisfied, and the pacemaker 100 will operate in Region V, and will respond by pacing at the lower rate hysteresis (LRH) for a predetermined period of time or a preset number of beats, as illustrated by the dashed line BB′ in FIG. 6, and by step 238 in FIG. 2 B.
It should however be understood that the pacemaker 100 could alternatively bypass step 238 and start pacing along curve BC (FIG. 5 ), with one paced beat at the lower rate hysteresis (LRH). In this respect, pacing is started at point B (FIG. 5) and the pacing rate is incrementally increased until it reaches the intermediate rate (IR). The intermediate rate IR is programmable, and could be changed by the attending physician. The incremental increase in the pacing rate is illustrated by the curves BC in FIGS. 5 and 6. During this period, the pacemaker 100 is in the inhibited mode for single chamber pacemakers, or in the DDD or fully automated mode for dual chamber pacemakers.
The incremental increase of the pacing rate is achieved by steps 240 through 244 , whereby the value of the pacing rate is incrementally increased by a center increment value X (step 240 ), and a determination is made at step 242 whether the pacing rate is less than or equal to IR. Once IR is reached, then, as indicated by step 244 , a time counter is set to maintain the continuous pacing at that intermediate rate (IR) for a preselected programmable period of time, such as for five minutes. This continuous pacing at the intermediate rate is illustrated by curve CD in FIGS. 5 and 6. If during the execution of the subroutine 244 through 248 , an intrinsic rhythm is sensed at 245 , then the intrinsic rate prevails, and pacing is inhibited.
Once the counter time lapses, then, as illustrated by the curves DE and DE′ in FIG. 5 and 6 respectively, the pacing rate is gradually decreased from the intermediate pacing rate (IR), toward the lower pacing rate (LR). This decrement is achieved by the subroutine 250 - 252 , where the pacing rate is decreased by a counter decrement value Y until the pacing rate reaches the lower rate LR.
If decremental pacing is maintained until it reaches the lower rate LR, the pacemaker 100 starts pacing at that lower rate, as illustrated by the curve EF in FIG. 5, and the routine 200 is repeated. If an intrinsic rhythm is sensed at any time during the decremental change (curve DE′) in the pacing rate, then the intrinsic rate prevails, and pacing is inhibited, as illustrated by the curve E′RS in FIG. 6 . The subroutine 200 is thereafter repeated.
It is therefore clear that the new approach described in the present invention teaches away from the conventional hysteresis response feature. In the present invention, whenever an intermediate drop in the heart rate occurs and the hysteresis feature is activated, the natural heart rate resumes and is tracked until it reaches the hysteresis rate. Thereafter, the pacing rate is increased until the intermediate rate (IR) is reached. Pacing at that intermediate rate is maintained for a predetermined period of time, and thereafter allowed to gradually decay toward the lower rate.
It should become apparent to those skilled in the art after reviewing the present description, that the present invention can be made an integral part of single chamber and dual chamber pacemakers which operate in one or more of the programmed modes: SSI, SSIR, DDD, DDDR, DVI, DVIR, DDI and/or DDIR. The present hysteresis feature can be applied to the atrial and/or ventricular channels of a dual chamber pacemaker.
While the following ranges reflect exemplary values of IR, LR, UR, LRH, SL 1 and SL 2 , it should be understood to those skilled in the art that other values and ranges can also be employed and/or programmed.
100 bpm≦UR≦150 bpm.
80 bpm≦IR≦100 bpm.
60 bpm≦LR≦80 bpm.
40 bpm≦LRH≦60 bpm.
2%≦SL 1 ≦10%.
5%≦SL 2 ≦20%.
4 beats≦N≦16 beats.
While particular embodiments of the present invention have been disclosed, it is to be understood that various different modifications are possible and are contemplated within the scope and spirit of the specification, drawings, abstract, and appended claims.
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A pacemaker having a hysteresis feature which permits intrinsic heart activity, controlled by the sinus node to resume optimally after pacing. The pacemaker has a programmable lower rate and upper rate, a programmable lower hysteresis rate (LRH) corresponding to a lower rate hysteresis interval (LRHI), and a programmable rate (IR) intermediate an upper pacing rate (UR) and a lower pacing rate (LR). A microprocessor measures the average rate of change M AVG in the intervals between consecutive ventricular depolarizations, and compares the last intrinsic escape interval RR N to the lower rate hysteresis interval (LRHI).
If the last intrinsic escape interval RR N is longer than the lower rate hysteresis interval (LRHI), and if the value of M AVG is greater than a first preselected value SL 1 but less than a second preselected value SL 2 , the pacemaker stimulates at the lower rate hysteresis (LRH) and thereafter gradually increases the pacing rate up to the intermediate rate (IR). A time counter maintains a continuous pacing at the intermediate rate (IR) for a predefined period of time, and the pacing rate is gradually decreased toward the lower pacing rate (LR).
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FIELD OF THE INVENTION
[0001] The present invention relates to novel devices for golfers, capable of retaining objects such as cigars during a round of golf or anywhere one finds the need to retain an object such that it avoids contact with the ground.
BACKGROUND OF THE INVENTION
[0002] It is common practice for golfers to have objects in need of being stowed as they approach a golf shot on the tee box or anywhere throughout the golf course. Many golfers enjoy smoking cigarettes or cigars while playing golf. When such a golfer prepares to take a golf swing or stroke the ball, the golfer typically lays the lighted cigarette or cigar on the ground, golf cart floor or fender, golf tee, or another item to keep it from contact with the ground. However, this practice may expose the cigar or cigarette to moisture and is unsanitary because the cigar or cigarette may be exposed to poisons or injurious chemicals on the ground, such as fertilizers and other compounds sprayed on the turf, thus exposing the golfer to potential hazards.
[0003] One solution is to use a golf smoke tee, which is a golf tee with a cradle on top for holding objects such as cigars or cigarettes above the ground. U.S. Pat. No. 3,001,529 to Watson discloses such a golf smoke tee, being about 1″ to 2½″ tall, resembling a customary golf tee. One problem with Watson's golf smoke tee is that it is necessary for the golfer to bend low to the ground in order to place the burning cigar or cigarette on the device. This may pose problems for golfers who suffer back problems.
[0004] U.S. Pat. No. 5,706,831 to Whitbeck discloses a ball mark repair tool comprising a cigar support, however, this device also suffers the disadvantage of providing only minimal clearance from the ground, thereby requiring the golfer to bend low to the ground in order to use it.
[0005] Published US Pat. App. 2003/0084911 to McGraw discloses a portable cigar holder in the general form of a golf tee, with a tapered opening comprising a pin upon which a cigar may be placed. This device also suffers from the drawback of protruding only inches from the ground.
[0006] An alternative cigar holder is shown in U.S. Design Pat. No. D385,059 to Jenkins, which suggests a taller vertical shank than Watson, but the Jenkins design does not suggest a means for conveniently driving the device securely into the ground.
[0007] US Pat. App. 2004/0182402 to Cervantes discloses a “cigar caddy” comprising a shaft with a handle and a cradle, the cradle resembling a half-pipe of aluminum conduit upon which a cigar may be rested. The cigar merely rests in the cradle, but is not otherwise secured and is therefore subject to falling to the ground in windy conditions, or upon jostling of the device.
[0008] Other devices available include the offerings of cigarconcierge.com; clubholder.com; holeinonecigarholder.com, and the Grip Clip Cigar Holder. All these devices have disadvantages overcome by the present invention.
[0009] None of the aforementioned devices provide a device to secure objects such as cigars at a distance from the turf in a manner which appears unobtrusively like a golf club in a golf bag. The art, therefore, is in need of improved devices for holding objects, such as cigars and cigarettes, without the disadvantages of current devices.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to devices for securely holding objects, such as cigars, at a convenient distance above the ground. The device of the present invention is suitable for securing a wide variety of items, including, but not limited to, cigars, cigarettes, eyeglasses, sunglasses, scorecards, business cards, writing implements, snack foods, cell phones, and the like. Additionally, the device of the present invention resembles a golf club, and thus appears unobtrusive when stowed in a golf bag, and is conveniently ready for use when the golfer needs to support an object or when approaching a golf shot anywhere on the course.
[0011] In one aspect, the present invention is directed to an object-retaining golf device comprising an elongated shaft, at an upper end of which is a cradle resembling the head of a golf club. The cradle or head has a cavity disposed longitudinally therein (and approximately perpendicular to the shaft) for securing and retaining objects. The opposite end, or lower end, of the shaft features a ground-piercing means, i.e., a point for driving and securing the device into the ground, in the form of a spike or other means such as a taper in the shaft itself. A cap or other protective covering may optionally be fitted to the ground-piercing means to protect the golf bag when the device is placed therein.
[0012] In one aspect, the device of the invention is an object-retaining device comprising an elongated shaft having upper and lower ends, and a cradle coupled to the upper end of the shaft, wherein the cradle has two interior surfaces defining a cavity therebetween capable of securely retaining objects, and wherein the lower end of the shaft comprises ground-piercing means. The objects capable of being retained includes cigars, cigarettes, eyeglasses, sunglasses, scorecards, writing implements, snack foods, cell phones, and the like.
[0013] In another aspect, the ground-piercing means may be a lower end of the shaft which has been tapered, or may be a spike or other means affixed to the lower end of the shaft. The shaft may be a length between about 6 inches and 6 feet, and preferably about 3 feet in length and may be formed of, among others, aluminum or fiberglass
[0014] In another aspect, the cradle resembles a golf club head, and may be formed of, among other things, ABS injection molded plastic, metal, or an alloy thereof.
[0015] Other objects and advantages of the present invention will become apparent to those skilled in the art from a review of the ensuing description and figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order to better appreciate how the above-recited and other advantages and objects of the present inventions are obtained, a more particular description of the present inventions briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0017] FIG. 1 . depicts a side view of a device in accordance with the present invention.
[0018] FIG. 2 . depicts a perspective view of a device in accordance with the present invention.
[0019] FIG. 3 is a photograph of a device in accordance with the present invention.
[0020] FIG. 4 is a photograph of several devices in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A device of the present invention comprises an elongated shaft having an upper and a lower end. The shaft may be formed from any sufficiently sturdy material, including but not limited to fiberglass, aluminum, carbon fiber, other metals and alloys, wood, plastic, and the like. The shaft needs only to be sufficiently sturdy such that it remains in an upright position when the lower end is inserted into the ground.
[0022] The lower end of the shaft, therefore, features a ground-piercing means which allows the shaft to be inserted into the ground and remain in an upright position. The shaft is preferably tapered itself to allow the shaft to be more easily driven into the ground. Alternatively, the lower end of the shaft may be fitted with a ground-piercing means, such as a spike, a nail, or the like.
[0023] In one embodiment, the shaft may optionally have toward the lower end a grip resembling a golf club grip to further enable the device to appear as a golf club, so long as the ground-piercing means is unencumbered. A cap or other protective covering may optionally be fitted to the ground-piercing means to protect the golf bag when the device is placed therein.
[0024] The shaft may be of any length between about 6 inches and about 6 feet, preferably between about 2 and 5 feet, more preferably about 3 feet, approximately waist high. Having a shaft approximately waist high allows a person to drive the shaft into the ground while minimizing back strain. Alternatively, the shaft may be less than 3 feet in length, which allows the cigar wedge to be more easily stored when not in use.
[0025] In another embodiment, the shaft may be formed of telescoping sections, allowing a smaller profile for storage, and permitting the shaft's height to be adjustable to suit a variety of users. Such an adjustable telescoping shaft may have securing means, such as threaded rings which release and exert pressure upon unscrewing and screwing. Such telescoping sectioned shafts are known to those of skill in the art.
[0026] In one embodiment of the present invention, the upper end of the shaft is coupled to an object-retaining cradle or head. The cradle may be crafted to resemble an actual golf club head, so long as it comprises a cavity capable of retaining objects, such as cigars. The cradle has two exterior surfaces and two interior surfaces, such that the cavity is formed by the two interior surfaces of the cradle, as shown in the Figures. The interior surfaces join at the base of the cradle, such that the distance between the two interior surfaces is greatest at the top of the cradle, while the distance decreases to zero at the base of the cradle. The interior angle formed by the surfaces is selected such that the cradle is capable of securely retaining a wide variety of objects and cigar sizes, from the smallest cigarettes to the largest cigar ring size (e.g., Churchills), as well as other objects. The interior angle can range from about 15 degrees to about 60 degrees, preferably from about 25 to about 45 degrees, more preferably from about 30 to about 40 degrees. In one embodiment, either or both of the interior surfaces feature a set of grooves, dimples, ribs, knobs, protrusions, rubber, or the like, to assist in retaining the object. Optionally, a securing device, such as a spring-loaded clip that flexes to the size and shape of the object to be held, may be affixed to one interior surface, and flexibly affixed to the other interior surface, in order to securely retain an object. Other securing devices may be used, such as hook and loop straps, elastic cords, and the like.
[0027] The cradle is coupled to the shaft by any of a variety of means, including but not limited to glue, screws, tube-to-shaft connectors, and the like. The cradle may also serve as a handle allowing the user to remove the device from a golf bag, insert it into the ground, and remove and replace the device in the golf bag when no longer in use.
[0028] The cradle may be formed from at least one of any sufficiently sturdy material, including but not limited to fiberglass, aluminum, other metals and alloys, wood, plastic, carbon fiber, cast iron, cast aluminum, and the like. In a preferred embodiment, the cradle comprises ABS injection molded plastic, or a metal or an alloy thereof, such that it appears to resemble a functional golf club, is sufficiently sturdy to retain objects and also withstand the force necessary to drive the device into the ground, and safely and securely retains objects such as cigars.
[0029] The cradle may also have affixed upon the interior surfaces thereof a material providing greater friction than that from which it is made. For example, a coating of higher frictional material may be applied to at least one of the interior surfaces, or a thin film of rubber, neoprene, porous plastic, or the like may be applied thereon.
[0030] A wide variety of accessories may be removable or fixedly attached to the device of the present invention. For example, a clip suitable for holding a cigar lighter, cigar cutter, or other smoking paraphernalia may be present on an exterior surface of the cradle, or proximal to the cradle on the upper end of the shaft. Likewise, a clip for holding a scorecard or writing implement may be present on the device.
[0031] Additional embodiments within the scope of the invention will be appreciated by those of skill in the art. While embodiments of the present invention have been shown and described, various modifications may be made without departing from the spirit and scope of the present invention, and all such modifications and equivalents are intended to be within the scope of the appended claims. For example, while the device of the present invention has been described with particular application to use by golfers, those of skill in the art will readily appreciate that the device is suitable for other outdoor activities.
EXAMPLES
[0032] The following Examples serve to illustrate the present invention and are not intended to limit its scope in any way.
Example 1
The Cigar Wedge
[0033] FIGS. 1-4 show an example of the present invention, in which an elongated shaft ( 1 ) comprising fiberglass is coupled to a cradle (head) ( 2 ) comprising ABS injection molded plastic. The cradle has two outer surfaces ( 3 ) and two inner surfaces ( 4 ) defining a cavity ( 5 ) in which objects may be retained. The shaft's lower end ( 6 ) is tapered to allow efficient, convenient insertion into the ground. The shaft is approximately 3 feet long, and the cradle adds approximately 3 inches to the length of the device when coupled thereon. The cradle is approximately 4 inches wide, with the largest distance in the cavity between the two interior surfaces being about 3 inches, where the angle between the interior surfaces is approximately 34 degrees.
[0034] When the user of the device has an object, such as a cigar, which needs to be securely retained on the course of play, the user simply removes the device from the golf bag, much as one would remove a desired golf club. Approaching the ball, the user then inserts the device into the ground by holding the cradle and pushing or stabbing the lower end into the ground. The device is then ready for service, and the golfer may place the object or cigar into the cavity of the cradle. While not strictly necessary, applying even gentle pressure when placing the cigar into the cavity further secures the cigar therein. The shape of the cavity and friction with the interior surfaces thereof securely hold the object above the ground at a convenient height.
[0035] The present invention is not to be limited in scope by the specific embodiments described above, which are intended as illustrations of aspects of the invention. Functionally equivalent methods and components are within the scope of the invention. Indeed, various modifications of the invention, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims. All cited references are hereby incorporated by reference.
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The present invention is directed to devices for securely holding elongated objects, such as cigars, above the ground. Generally, a device in accordance with the present invention includes an elongated shaft with ground-piercing means, and a cradle which resembles a golf club head coupled to the upper end of the elongated shaft. The cradle's two interior surfaces define a cavity capable of securely retaining objects such as cigars, cigarettes, sunglasses, and other items needing to be stowed by a golfer on a golf course.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to novel semi-synthetic peptide antibiotics, to processes of their production, and to their use as agents for inhibiting mammalian neoplasms.
2. Description of the Prior Art
Disclosed in our co-pending application U.S. Ser. No. 855,649, filed Apr. 25, 1986, now U.S. Pat. No. 4,692,510, are peptide antibiotics BU-2867T A, B, and C having the formula I ##STR1## wherein E refers to the trans configuration. BU-2867T A, B, and C are produced by fermentation using the novel microorganism Polyangium brachysporum strain K481-B101 (deposited with the ATCC and assigned the culture No. 53,080); they are useful as antitumor and antifungal agents.
The BU-2867T antibiotics yield useful synthetic intermediates when subjected to enzymatic cleavage. For example, when BU-2867T A was treated with the enzyme papain, a compound having the formula II (hereinafter referred to as "Compound II") ##STR2## was obtained. Treatment of BU-2867T A with Pseudomonas acylase yielded a compound having the formula III (hereinafter referred to as "Compound III"). ##STR3##
The present invention takes advantage of the synthetic utility of intermediate compounds II and III to provide novel antitumor semi-synthetic derivatives of antibiotics BU-2867T A, B, and C.
SUMMARY OF THE INVENTION
The present invention provides novel peptide antibiotics of the formula ##STR4## wherein the threonyl unit is L-threonyl, and wherein R is a straight chain alkyl group having 8 to 16 carbon atoms; or a group selected from the group consisting of CH 3 -(CH 2 ) 8 --CH═CH--, CH 3 --(CH 2 ) 13 --CH(OH)--, and p--CH 3 --(CH 2 ) 7 --O--C 6 H 4 --.
In another aspect, the present invention provides peptide antibiotics of the formula ##STR5## wherein R' is selected from the group consisting of ethyl, ##STR6##
Another aspect of the present invention provides a process for the preparation of compounds of the formula IV which comprises acylating compound III or a salt thereof, with a carboxylic acid RCO 2 H, wherein R is as defined above, or an acylating agent corresponding thereto.
Another aspect of the present invention provides a process for the preparation of compounds of the formula IV or V which comprises acylating compound II or a salt thereof, with an acid ##STR7## wherein R and R' are as defined above, or an acylating agent corresponding thereto, to yield IV or V respectively.
A further aspect of the present invention provides an antitumor composition comprising an effective amount of a compound of formula IV or a compound of formula V, and a pharmaceutically acceptable carrier.
Yet another aspect of the present invention provides a method for inhibiting tumors in a mammalian host which comprises administering to said tumor bearing host an effective amount of a compound of formula IV or a compound of formula V.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of the present invention having the general formula IV may be prepared by either route (a) or route (b) depicted in Scheme I.
SCHEME I ##STR8##
Route (a) describes the preparation of compounds of formula IV which involves acylating the amino group of compound III with an appropriate acid or an acylating agent derived therefrom. Alternatively, compounds of formula IV may be prepared by acylating the amino group of compound II with the appropriate acyl-L-threonine or a corresponding acylating agent; this latter process is outlined as route (b). Compounds II and III are enzymatic cleavage products derived from BU-2867T A, and their preparations are described in detail below in "Preparation of Starting Materials". Compound III may also be formed by condensation between L-threonine and Compound II.
Compounds of formula V may be prepared by the procedure outlined in Scheme II using compound II as starting material.
SCHEME II ##STR9##
As shown in Scheme II route (c), compound II when acylated with a 2,4-dodecadienoylamino acid VI yields the corresponding compound V; said compound VI being formed by the condensation of 2,4-dodecadienoic acid with an appropriate α-amino acid. The order of the reaction sequence may be modified so that compound II is first coupled with an appropriate α-amino acid having the desired side chain to give compound VII which may then be further acylated with 2,4-dodecadienoic acid to produce compounds of formula V. This process is outlined as route (d).
Each of the reaction steps described in Schemes I and II involves the acylation of an amino group with a carboxylic acid or a corresponding acylating agent to form an amide bond. Acylation of amino group is a common reaction and may be accomplished by conventional methods well known to those skilled in the art. The amino compound being acylated may be employed as the free base, an acid addition salt thereof, or a reactive derivative of the amino group thereof. The acylating agent may be a symmetrical or mixed acid anhydride; an acid halide such as the acid chloride preferably used in the presence of an acid scavenger such as triethylamine; a reactive ester, e.g. with hydroxybenzotriazole; a reactive amide, e.g. with triazole; or the free acid used in conjunction with a coupling agent such as N,N'-dicyclohexylcarbodiimide.
In carrying out the reactions described above, it may be advantageous to protect certain reactive functional groups other than the reacting ones. In the case when compound II is acylated with an α-amino acid (e.g. Scheme I, Compound II+L-threonine→Compound III), the non-reacting α-amino group of the amino acid is desirably protected with an easily removable group such as t-butoxycarbonyl (t-BOC). The amino protecting group may be removed after acylation using known methods to allow the deprotected amino group to be coupled with a carboxylic acid to form a second amide linkage (e.g. Scheme I, Compound III and RCO 2 H→Compound IV). Other non-reacting hydroxyl, amino, and carboxyl groups may also be conventionally protected; the protective groups may be removed by known methods, if so desired, after the acylation. Techniques for protection and deprotection of reactive groups are described, for example, in J. F. W. McOmie Ed., "Protective Groups in Organic Chemistry", pp. 183 (1973), Plenum Press, N.Y.; S. Patai Ed., "The Chemistry of Functional Groups", pp 505 (1969), Interscience Publ., John Wiley and Sons, Ltd., London. Typical protection techniques are, e.g., acylation and etherification for hydroxy; e.g., acylation, enamine formation, and silyl introduction for amino; and e.g. esterification, amidation, and acid anhydride formation, for carboxy.
The acylation reactions are generally carried out in an inert solvent. Suitable solvents include, but are not limited to, methanol, ethanol, dimethylformamide, tetrahydrofuran, and the like. The reactions may be effected at temperatures ranging from about 0 to about 100° C., but preferably at room temperature.
BIOLOGICAL ACTIVITY
Antitumor activity of representative compounds of the present invention was determined using in vivo murine transplantable P388 leukemia and B16 melanoma models.
In Vivo Models
P388 leukemia: female CDF 1 and male BDF 1 mice were inoculated by intraperitoneal injection of 0.8 ml diluted ascitic fluid containing 10 6 cells.
B16 melanoma; male BDF 1 mice were implanted with 0.5 ml of a 10% tumor brei intraperitoneally.
Drug Administration
Test materials were dissolved in 0.9% saline containing 10% dimethyl sulfoxide and graded doses of them were administered to mice intraperitoneally 24 hrs after tumor implantation. Two dosing schedules were used for the p388 leukemia experiment: once daily on day 1 through day 3 (QD 1→3); and once daily on day 1 through day 9 (QD 1→9). The QD 1→9 schedule was used for the B16 melanoma experiment.
Criteria for Antitumor Activity
Antitumor activity is evaluated as the increase in mediam survival time (MST) of treated (T) and control (C) animals for various dosage regimens expressed as a percentage ratio (T/C %=MST of treated÷MST of control×100). For both in vivo P388 leukemia and in vivo B16 melanoma models, values for percentage ratios of 125 and above indicate significant antitumor effect.
Results of antitumor evaluation are given below in Tables 1-3.
TABLE 1______________________________________Antitumor Effect Against P388 Leukemia MST (% T/C)Compound of dose (mg/kg/day, QD 1 → 3 ip)Example 10 3 1 .3______________________________________1 155 145 1302 64 127 1233 55 132 1274 118 132 1185 132 132 1186 Tox 150 1257 Tox 138 1198 127 114 1009 Tox 132 12310 138 119 114BU-2867TA Tox 145 130C 57 129 124______________________________________
TABLE 2______________________________________Antitumor Effect Against P388 Leukemia(QD 1 → 9 ip) MST (% T/C)Compound of Dose (mg/kg/day, QD 1 → 9 ip)Example 4 2 1 0.5 0.25 0.13 0.63______________________________________1 173 159 150 145 132 1272 155 145 127 123 123 1093 159 150 150 132 132 1186 Tox 155 150 140 120BU-2867TA Tox 190 155 150 130 110B Tox 180 170 145 130 125 130C 65 205 170 155 160 130 115______________________________________
TABLE 3______________________________________Antitumor Effect Against B16 Melanoma MST (% T/C)Compound of Dose (mg/kg/day, QD 1 → 9 ip)Example 4 2 1 .5 .25 .13______________________________________1 155 139 121 113 1073 145 124 116 113 113BU-2867TA Tox 116 113 100 97B Tox 126 118 111 108C Tox 132 113 103 103 103______________________________________
The acute toxicity for compounds of Examples 1, 2, and 3 was determined in ddy mice by single intraperitoneal administration. The LD50 values were 27 mg/kg, 50 mg/kg, and >25 mg/kg, respectively.
It is apparent from the animal test results provided above that compounds of formula IV and V possess effective inhibitory action against mammalian tumors. Accordingly, this invention provides a method for inhibiting mammalian tumors which comprises administering an effective tumor-inhibiting dose of a compound of formula IV or V to a tumor bearing host.
Another aspect of this invention provides a pharmaceutical composition which comprises an effective tumor-inhibiting amount of a compound of formula IV or V and a pharmaceutically acceptable carrier. These compositions may be made up of any pharmaceutical form appropriate for the desired route of administration. Examples of such compositions include solid compositions for oral administration such as tablets, capsules, pills, powders and granules, liquid compositions for oral administration such as solutions, suspensions, syrups or elixirs and preparations for parenteral administration such as sterile solutions, suspensions or emulsions. They may also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, physiological saline or some other sterile injectable medium immediately before use.
Optimal dosages and regimens for a given mammalian host can be readily ascertained by those skilled in the art. It will, of course, be appreciated that the actual dose used will vary according to the particular composition formulated, the particular compound used, the mode of application and the particular situs, host and disease being treated. Many factors that modify the action of the drug will be taken into account including age, weight, sex, diet, time of administration, route of administration, rate of excretion, condition of the patient, drug combinations, reaction sensitivities and severity of the disease.
The following examples serve to illustrate this invention and should not be construed as limiting the scope of the invention.
PREPARATION OF STARTING MATERIALS
Preparation 1
BU-2867T, A, B, and C
Antibiotic Production:
The stock culture of Polyangium brachysporum K481-B101 (ATCC 53080) was propagated at 28° C. for 3 days on agar slant medium composed of 0.5% soluble starch, 0.5% glucose, 0.1% meat extract, 0.1% yeast extract, 0.2% NZ-case (Humko Sheffield Chemical), 0.2% NaCl, 0.1% CaCO 3 and 1.6% agar (pH 7.0). A well grown agar slant was used to inoculate the vegetative medium consisting of 2% corn starch, 3% soybean meal, 0.3% MgSO 4 .7H 2 O and 1% CaCO 3 (pH 7.0, before sterilization). After incubation at 28° C. for 3 days on a rotary shaker (250 rpm), 5 ml of the growth was transferred into a 500-ml Erlenmeyer flask containing 100 ml of the production medium having the same composition as the vegetative medium.
The antibiotic production was monitored by the paper disc agar diffusion method using Candida albicans A9540 as the test organism. The fermentation was continued for 4 days at 28° C. on a rotary shaker and the antibiotic production reached a maximum of 100 mcg/ml.
The fermentation was also carried out in a stir-jar fermenter. A 500-ml portion of the seed culture obtained by flask fermentation was used to inoculate 10 liters of the production medium in a 20-liter vessel. The fermentation was carried out at 28° C. with agitation at 250 rpm and aeration at 10 liters per minute. The antibiotic production reached a maximum of 150 mcg/ml after forty hours' fermentation.
Isolation and Purification of Antibiotic:
The fermentation broth (48 L) was centrifuged with the aid of a Sharpless centrifuge. The mycelial cake was homogenized with 7 L of methanol and the mixture stirred for one hour. After removal of the insolubles by filtration, the methanol extract was evaporated to an aqueous solution which was combined with the broth filtrate and extracted with n-butanol (24 L). The extract was concentrated to 0.5 L which was poured into n-hexane (3.5 L) under stirring to precipitate the crude antibiotic (41 g). This solid was chromatographed on a column of silica gel C-200 (760 ml) eluting with ethyl acetate and an increasing amount of methanol (0-50%). The bioactivity eluted was detected by a paper disc assay using Candida albicans A9540 as the test organism. The active fractions were combined and evaporated to yield a pale yellow powder (13 g) of BU-2867T complex. A 200 mg-portion of this solid was chromatographed on a reverse-phase column (C 18 , 100 ml) using ethanol-water (3:7 to 5:5) as an eluant. The eluate was monitored by anti-funal bioassay and by TLC (Silanized, EtOH:H 2 O=55:45). The first active fractions were combined and evaporated under reduced pressure to afford a pure white solid of BU-2867T A (60 mg) which was crystallized from aqueous methanol to deposit colorless needles (34 mg). Evaporation of the second and third active fractions yielded BU-2867T B (1 mg) and C (11 mg), respectively. BU-2867T B was obtained as a white amorphous powder. BU-2867T C crystallized from methanol as fine colorless needles. Repetition of the above reverse-phase chromatography afforded a total of 3.9 g of BU-2867T A, 44 mg of BU-2867T B and 342 mg of BU-2867T C.
BU-2867T A: mp 259°-261° C.; [α] D 24 ° (C 0.5 MeOH): -111°; EI-MS: m/z 520 (M + ). Anal calc'd for C 27 H 44 N 4 O 6 .1/2H 2 O: C, 61.22; H, 8.56; N, 10.58. Found: C, 60.90; H, 8.65; N, 10.47.
BU-2867T B: mp 232°-234° C.; [α] D 24 ° (C 0.5 MeOH): -92°; EI-MS: m/z 546 (M + ). Anal calc'd for C 29 H 46 N 4 O 6 .3/2H 2 O: C, 60.71; H, 8.61; N, 9.77. Found: C, 60.89; H, 8.31; N, 9.23.
BU-2867T C: mp 273°-275° C.; [α] D 24 ° (C 0.5 MeOH): -104°; EI-MS: m/z 548 (M + ). Anal calc'd for C 29 H 48 N 4 O 6 : C, 63.48; H, 8.82; N, 10.21. Found: C, 63.48; H, 8.91; N, 10.16.
Preparation 2
Compound II
A mixture of BU-2867T A (4 g) and papain (Sigma P-3375, 50 g) in 20 L of 10% aqueous methanol was stirred at 28° C. for 22 hours. The mixture was then acidified to pH 3.3 by acetic acid and extracted with ethyl acetate (10 L). The ethyl acetate extract yielded 2,4-dodecadienoyl-L-threonine. The acid aqueous solution was concentrated to dryness. The residue (36 g) was dissolved in 50 ml of water, adjusted to pH 9.0 and applied on a column of reverse phase silica (C 18 , Merck, 1.6 L) which was developed with water. The fractions containing the title compound were pooled and concentrated in vacuo. The residue was chromatographed on Sephadex LH-20 (250 ml) with 50% aqueous methanol and then on reverse phase silica (C 18 ) with acidic water (pH 3.0 by dil HCl) to afford 747 mg pure II hydrochloride (yield 35%). Mp 190° C. (dec.). [α].sub. D 26 -113° (c 0.5, H 2 O). EI-MS: m/z 241 (M + ). UV: end absorption. IR ν max (KBr) cm -1 : 3400, 1660, 1620, 1530, etc. 1 H-NMR (ppm, 80 MH z , DMSO-d 6 ) δ1.27 (3H, d), 1.4-1.8 (4H), 2.98 (2H, m), 4.52 (1H, m), 6.19 (1H, d), 6.45 (1H, d-d), 7.43 (1H, t, NH), 9.46 (1H, d, NH). Analysis calc'd for C 11 H 19 N 3 O 3 .HCl.H 2 O: C, 44.67; H, 7.50; N, 14.21; Cl, 11.99. Found: C, 45.04; H, 7.82 N, 13.81; Cl, 12.55.
Alternatively, BU-2867T A was subjected to enzymatic degradation with ficin in 0.01M phosphate buffer (pH 7.0). The reaction mixture was acidified to pH 2.2, and extracted with n-butanol to give 2,4-dodecadienoyl-L-threonine. Subsequent extraction of the aqueous solution at pH 10.0 with n-butanol afforded the title compound.
Preparation 3
L-Threonyl-II (Compound III)--Method 1.
Pseudomonas strain Pa-129 was fermented in 10 L of medium containing 2% soluble starch, 0.2% glucose, 3% soybean meal, 1% CaCO 3 and 0.3% MgSO 4 .7H 2 O at 37° C. for 3 days and the cells were collected by centrifugation. After being washed with saline (1 L) two times, the cells were resuspended in 0.75 L of saline. The cell suspension was mixed with a pre-autoclaved suspension (1.5 L) of sodium alginate (75 g) and CM-cellulose (75 g), and the mixture poured into 30 L of 0.1M CaCl 2 solution under stirring. The gel entrapping the cells was stiffened by stirring with 25% glutaldehyde solution and packed in a column (4.0×175 cm). A solution of BU-2867T A (1.5 g) in 20% aqueous methanol (30 L) was passed through the column at a flow rate of 0.4-0.8 L/hour. The pooled effluent was then passed through an Amberlite IRC-50 (70% NH 4 + form, pH 6.7, 300 ml) and a HP-20 column (300 ml) successively. The IRC-50 column was washed with water and then developed with 1.5N NH 4 OH. The ninhydrin positive fractions were pooled, concentrated and lyophilized to give a pale yellow solid (800 mg) which was charged on a column of reverse phase silica (C 18 , 250 ml). The column was developed with water under medium-pressure and the ninhydrin-positive eluates were pooled and concentrated to yield a white solid of L-threonyl-II (III, 612 mg). Yield 62%. Mp 170° C., [α] D 27 -157° (C 0.5, H 2 O). EI-MS m/z 342 (M + ). UV: end absorption. IR ν max (KBr) cm -1 : 3350, 3280, 1650, 1620, 1530 etc. 1 H-NMR (ppm, 80 MH z , DMSO-d 6 ) δ1.05 (3H, d), 1.21 (3H, d), 1.4-2.2 (4H), 4.35 (2H, m), 4.47 (1H, m, OH), 4.62 (1H, d, OH), 6.16 (1H, d), 6.42 (1H, d-d), 7.36 (1H, t, NH), 7.97 (1H, d, NH), 8.62 (1H, d, NH).
Preparation 4
L-Threonyl-II (Compound III)--Method 2.
To a stirred mixture of N-t-butoxy-carbonyl-L-threonine (44 mg), N,N'-dicyclohexylcarbodiimide (40 mg) and 1-hydroxy-1,2,3-benzotriazole (30 mg) in dimethylformamide (4 ml) was added II (40 mg) at room temperature. The mixture was concentrated in vacuo to a residue which was chromatographed on a column of reverse phase silica (C 18 , 40 ml) with methanol and water mixture (ratios: 1:9 to 2:3). The appropriate fractions were pooled, concentrated in vacuo and lyophilized to yield N-BOC-L-threonyl II (=BOC-III). 51 mg Yield, 69%. A mixture of BOC-III (36 mg) and formic acid (1 ml) was stirred for 1 hour at room temperature. This mixture was concentrated, diluted with water (1 ml), adjusted to pH 10.0 and applied to a column of reverse phase silica (C 18 , 20 ml). The column was developed with water and the eluate was monitored with ninhydrin test. Fractions containing the desired compound were combined and freeze-dried to give white solid of III. 25 mg Yield 88%.
EXAMPLE 1
n-Dodecanoyl-III
A mixture of compound III (21 mg, 0.06 mM) and dodecanoic anhydride (24 mg, 0.06 mM) in 1 ml of dimethylformamide (DMF) was stirred overnight at room temperature. The mixture was diluted with 6 ml of MeOH and 4 ml of water and the solution applied on a column of reverse phase silica gel (C 18 , 40 ml). Upon elution with 70% MeOH, fractions containing the desired compound were pooled, evaporated and lyophilized to afford the title compound as a white amorphous solid (28 mg, 89%). Mp 274° C. EI-MS: m/z 524 (M + ). 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) δ: 0.86 (3H, t), 1.02 (3H, d), 6.11 (1H, d), 6.41 (1H, d-d), 7.36 (1H, t), 7.60 (2H, m), 8.55 (1H, d).
EXAMPLE 2
n-Decanoyl-III
Following the procedure described in Example 1, compound III was acylated using n-decanoic anhydride to give the title compound. Mp 244° C. 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) at δ: 0.86 (3H, t), 1.02 (3H, d), 6.10 (1H, d), 6.40 (1H, d), 7.35 (1H, t), 7.58 (1H, d), 7.60 (1H, d), 8.56 (1H, d).
EXAMPLE 3
n-Tetradecanoyl-III
Following the procedure described in Example 1, compound III was acylated using n-tetradecanoic anhydride to give the title compound. Mp 239° C. 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) at δ: 0.86 (3H, t), 1.00 (3H, d), 6.10 (1H, d), 6.40 (1H, d-d), 7.36 (1H, t), 7.58 (1H, d), 7.60 (1H, d), 8.56 (1H, d).
EXAMPLE 4
trans-2-Dodecenoyl-III
A mixture of trans-2-dodecenoic acid (13 mg, 0.064 mM), N,N'-dicyclohexylcarbodiimide (DCC, 10 mg, 0.064 mM) and 1-hydroxy-1,2,3-benzotriazole monohydrate (HOBT, 13 mg, 0.064 mM) in 2 ml of DMF was stirred for 2 hours at room temperature. Compound III (20 mg, 0.058 mM) was added to the solution and the mixture was stirred overnight. After dilution with 60% aqueous MeOH (5 ml), the reaction mixture was chromatographed on a reverse phase silica gel (C 18 , 30 ml) with 70% MeOH elution. Fractions containing the desired compound were pooled, concentrated in vacuo, and lyophilized to give the title compound as a white solid (25 mg, 83%). Mp 232° C. 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) at δ: 0.86 (3H, t), 1.02 (3H, d), 6.05 (1H, d), 6.10 (1H, d), 6.40 (1H, d-d), 6.50 (1H, m), 7.36 (1H, t), 7.66 (1H, d), 7.79 (1H, d), 8.55 (1H, d).
EXAMPLE 5
2-Hydroxy-hexadecanoyl-III
The title compound was obtained following the procedure described in Example 4 using an equimolar amount of 2-hydroxy-hexadecanoic acid in place of trans-2-dodecenoic acid. Mp 229° C. 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) at δ: 0.86 (3H, t), 1.00 (3H, d), 6.11 (1H, d), 6.40 (1H, d-d), 7.35 (1H, t), 7.60 (2H, m), 8.58 (1H, d).
EXAMPLE 6
p-n-Octyloxybenzoyl-III
A mixture of p-n-octyloxybenzoic acid (25 mg, 0.1 mM), N,N'-dicyclohexylcarbodiimide (DDC, 21 mg, 0.1 mM) and 1-hydroxy-1,2,3-benzotriazole monohydrate (HOBT, 16 mg, 0.1 mM) in 3 ml of dimethylformamide was stirred for 2 hours at room temperature. To the solution was added compound III (34 mg, 0.1 mM) and the stirring was continued overnight at room temperature. The mixture was filtered, diluted with 2 ml of 50% aqueous MeOH and loaded on a column of reversed phase silica gel (C 18 , 20 ml). The column was washed with 50% aqueous MeOH (250 ml), followed by elution with 80% aqueous MeOH. The fractions containing the major reaction product were pooled, evaporated and lyophilized to give a white amorphous solid of the title compound (41 mg, 71%). Mp 251° C. 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) δ: 0.86 (3H, t), 1.05 (3H, d), 6.10 (1H, d), 6.40 (1H, d-d), 6.96 (2H, d), 7.36 (1H, t), 7.83 (2H, d), 7.96 (1H, d), 8.57 (1H, d).
EXAMPLE 7
α-(2,4-Dodecadienoylamino)-n-butyryl-II
A mixture of 2,4-dodecadienoic acid (50 mg, 0.26 mM), DCC (58 mg, 0.28 mM) and HOBT (43 mg, 0.28 mM) in tetrahydrofuran (THF, 5 ml) was stirred for one hour at room temperature. The mixture was filtered and the filtrate was added into a vigorously stirred solution of L-α-amino-n-butyric acid (52 mg, 0.5 mM) and triethylamine (0.13 ml) in 50% aqueous THF (2 ml). The reaction mixture was stirred for 4 hours, concentrated to 1 ml under reduced pressure, and the concentrate diluted with 5 ml of water. The solution was washed with ethyl acetate (EtOAc, 5 ml), acidified to pH 2.0 and extracted with EtOAc (5 ml). Evaporation of the extract gave α-(2,4-dodecadienoylamino)-n-butyric acid (64 mg 90%) as a pale yellow solid.
The acid (28 mg, 0.1 mM) was dissolved in 5 ml of DMF containing DCC (21 mg, 0.1 mM) and HOBT (15 mg, 0.1 mM) and the mixture was stirred for one hour. Compound II (24 mg, 0.1 mM) was then added to the solution and the solution was stirred overnight at room temperature. Concentration of the solution in vacuo yielded an oily residue which was loaded on a column of reverse phase silica gel (C 18 , 40 ml). The column was eluted with 80% aqueous MeOH, and fractions containing the reaction product were pooled, concentrated and freeze-dried to give a white solid of the title compound (17.6 mg, 35%), Mp 254° C. EI-MS (m/z): 504 (M + ). 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) δ: 0.86 (3H, t), 0.89 (3H, t), 6.20 (5H, m), 7.00 (1H, m), 7.35 (1 H, t), 7.85 (1H, d), 7.97 (1H, d), 8.54 (1H, d).
EXAMPLE 8
2,4-Dodecadienoyl-L-ω-benzyloxycarbonyl-lysyl-II
The general procedure described in Example 7 was repeated except L-α-amino-n-butyric acid was replaced by an equimolar amount of ω-benzyloxycarbonyl-L-lysine, to give the title compound in 41% yield. Mp 182° C. 1 H-NMR (ppm 80 MHz, DMSO-d 6 ) δ: 0.86 (3H, t), 4.98 (2H, s), 6.20 (5H, m), 6.90 (1H, m), 7.14 (1H, br-s), 7.30 (6H, m), 7.97 (2H, br-d), 8.60 (1H, m).
EXAMPLE 9
2,4-Dodecadienoyl-L-ω-methyl-glutamyl-II
The general procedure described in Example 7 was repeated, except L-α-amino-n-butyric acid was replaced by an equimolar amount of ω-methyl-L-glutamic acid, to give the title compound in 44% yield. Mp 215° C. 1 H-NMR (ppm, 80 MHz, DMSO-D 6 ) δ: 0.86 (3H, t), 3.56 (3H, s), 6.30 (5H, m), 7.00 (1H, m), 7.35 (1H, t), 8.05 (2H, m), 8.55 (1H, d).
EXAMPLE 10
Palmitoyl-L-Threonyl-II
The general procedure described in Example 7 was repeated, except L-α-amino-n-butyric acid was replaced by an equimolar amount of L-threonine, and 2,4-dodecadienoic acid replaced by an equimolar amount of palmitic acid, to give the title compound 18% yield. Mp 216° C. EI-MS (m/z): 580 (M + ). 1 H-NMR (ppm, 80 MHz, DMSO-d 6 ) δ: 0.86 (3H, t), 1.00 (3H, d). 6.10 (1H, d), 6.40 (1H, d-d), 7.35 (1H, t), 7.60 (2H, br-d), 8.56 (1H, d).
The title compound is also produced if the general procedure of Example 1 is followed with dodecanoic anhydride replaced by an equimolar amount of palmitoyl anhydride. Similarly, replacing trans-2-dodecenoic acid of Example 4 with palmitic acid results in the title compound.
EXAMPLE 11
Compounds of Examples 1 to 6 are prepared if the general procedure of Example 7 is repeated with L-α-amino-n-butyric acid replaced by an equimolar amount of L-threonine and 2,4-dodecadienoic acid by an equimolar amount of the acids listed below.
______________________________________ Compound ofAcid Example______________________________________n-Dodecanoic 1n-Decanoic 2n-Tetradecanoic 3trans-2-Decenoic 42-Hydroxydecanoic 5p-n-Octyloxybenzoic 6______________________________________
EXAMPLE 12
Compounds of Examples 7, 8, and 9 are prepared if the general procedure described in Example 4 is repeated with Compound III replaced by an equimolar amount of L-α-amino-n-butyryl-II (VIII), L-ω-benzyloxycarbonyl-lysyl-II (IX), or L-ω-methyl-glutamyl-II (X), respectively; and trans-2-dodecenoic acid replaced by an equimolar amount of 2,4-dodecadienoic acid. Compounds VIII, IX, X are prepared by repeating the procedure of Preparation 4 with N-BOC-L-Thr replaced by an equimolar amount of N-BOC-L-α-amino-n-butyric acid, N-BOC-L-ω-benzyloxycarbonyl-lysine, or N-BOC-L-ω-methyl-glutamic acid, respectively.
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Semi-synthetic derivatives of the BU-2867T antibotics are disclosed. These derivatives are active against experimental mammalian tumors, and may be prepared from enzymatic degradation product(s) of BU-2867T A.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims the benefit of priority under 35 U.S.C. §120 to pending U.S. patent application Ser. No. 12/569,047, filed on Sep. 29, 2009, which claims the benefit of, and priority to, U.S. Provisional Patent Application No. 61/100,796, filed on Sep. 29, 2008, the entire contents of each application incorporated by reference herein in its entirety for all purposes.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to a foldable package. More specifically, the present disclosure relates to a foldable package for the accommodation of medical supplies.
[0004] 2. Related Art
[0005] The packaging of medical supplies presents a particular concern given the general necessity to maintain such supplies in a sterile environment. The packaging must not only preserve the sterility of the medical supplies at all times during transport, but must also protect the medical supplies from damage that may be sustained during handling and/or storage. Any rupturing, piercing, or damage to the packaging may compromise the integrity of the sterile environment, thus resulting in the use of a potentially unsafe product, the communication of undesirable substances or agents to a patient, and perhaps even infection.
[0006] Generally, medical supply packaging will include the instruments that will be used during the course of the procedure, in addition to the corresponding instruction-for-use (I.F.U.). Either prior to, or during the medical procedure, the packaging is opened to expose the instruments, and the I.F.U. is generally removed and set aside for later reference by a practitioner. However, accessing the instruments and the I.F.U. in this way unnecessarily exposes the entire contents of the package to the ambient, and clutters the work environment by separating the medical instruments from the I.F.U. and the packaging. Accordingly, there exists a need in the art for improved packaging that will address these issues.
SUMMARY
[0007] In one aspect of the present disclosure, a medical package is disclosed that is configured and dimensioned to accommodate medical supplies employable during a medical procedure. The medical package has a plurality of panels, including a first panel, a second panel, and a third panel.
[0008] The panels are releasably secured together to establish a first sterile environment between the first panel and the second panel for retention of a first medical supply, and a second sterile environment is established between the second panel and the third panel for retention of a second medical supply. The panels are configured for relative movement such that movement of the first panel relative to the second panel reveals the first medical supply without compromising the second sterile environment, and movement of the second panel relative to the third panel reveals the second medical supply. The panels are arranged for sequential separation in accordance with a plurality of steps performed during the medical procedure that are described in corresponding instructions for use supported on the first panel.
[0009] The first panel is movable relative to the second panel in a first direction, and the second panel is movable relative to third panel in a second direction, wherein the first direction and the second direction are different. To facilitate manual manipulation of the panels, the first panel may include a first tab, the second panel may include a second tab, and the third panel may include a third tab.
[0010] The plurality of panels may be fixedly attached to one another, or alternatively, at least one of the plurality of panels may be removable from the medical package. Additionally, it is envisioned that the plurality of panels may be foldably interconnected, e.g., through a plurality of living hinges.
[0011] In an alternative embodiment, the medical package further includes a fourth panel that is releasably secured to the third panel to establish a third sterile environment therebetween for retention of a third medical supply. To reveal the third medical supply, the third panel is configured for movement relative to the fourth panel in the second direction. The fourth panel may include a fourth tab configured to facilitate manual manipulation of the fourth panel.
[0012] In another embodiment, the medical package further includes a fifth panel that is releasably secured to the fourth panel such that a fourth sterile environment is established therebetween for retention of a fourth medical supply. The fourth panel is configured for movement relative to the fifth panel in the second direction to reveal the fourth medical supply. The fifth panel may include a fifth tab configured to facilitate manual manipulation of the fifth panel. In this embodiment, the third panel is configured for movement relative to the fourth panel to reveal the third medical supply without compromising the fourth sterile environment.
[0013] In another aspect of the present disclosure, a medical package is disclosed that is configured and dimensioned to accommodate medical supplies employable during a medical procedure. The medical package has a plurality of panels including a first panel, a second panel, and a third panel. The first and second panels are releasably secured together to establish a first sterile environment therebetween for retention of a first medical supply, and the second and third panels are releasably secured together such that a second sterile environment is established therebetween for retention of a second medical supply. The first panel is movable relative to the second panel from a first position, in which the first medical supply remains concealed within the first sterile environment, to a second position, in which the first medical supply is revealed, and the second panel is movable relative to the third panel from a first position, in which the second medical supply remains concealed within the second sterile environment, to a second position, in which the second medical supply is revealed. The plurality of panels are arranged for sequential separation in accordance with a plurality of steps performed during the medical procedure.
[0014] In a final aspect of the present disclosure, a medical procedure is disclosed that includes the step of providing a medical package with a plurality of panels including at least a first panel, a second panel, and a third panel. The plurality of panels are releasably secured together to establish a first sterile environment between the first panel and the second panel for retention of a first medical supply, and a second sterile environment between the second panel and the third panel for retention of a second medical supply. The plurality of panels are configured for relative movement such that movement of the first panel relative to the second panel reveals the first medical supply without compromising the second sterile environment, and movement of the second panel relative to the third panel reveals the second medical supply.
[0015] In addition, the method includes the steps of moving the first panel relative to the second panel to reveal the first medical supply, using the first medical supply, moving the second panel relative to the third panel to reveal the second medical supply, and using the second medical supply.
[0016] These and other features of the medical packaging and procedure disclosed herein will become more readily apparent to those skilled in the art through reference to the detailed description of the various embodiments of the present disclosure below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated in, and constitute a part of this specification, illustrate various exemplary embodiments of the present disclosure. Together with the general description given above, and the detailed description of the embodiments given below, the accompanying drawings serve to explain the principles of the medical packaging and method disclosed herein.
[0018] FIG. 1 is a top, perspective view of one embodiment of a medical package, in accordance with the principles of the present disclosure, that includes a top panel, a bottom, panel, and a plurality of intermediate panels positioned therebetween for the accommodation of medical supplies;
[0019] FIG. 2 is a top, perspective view of the medical package of FIG. 1 after lifting the top panel to expose a first intermediate panel, and a swab positioned thereon, for using during a surgical procedure;
[0020] FIG. 3 is a top, perspective view of the medical package seen in FIG. 1 illustrating movement of the first intermediate panel to expose a second intermediate panel;
[0021] FIG. 4 is a top, perspective view of the medical package seen in FIG. 3 illustrating the second intermediate panel, and a first collection of securement tape positioned thereon, for using during the surgical procedure;
[0022] FIG. 5 is a top, perspective view of the medical package seen in FIG. 4 illustrating movement of the second intermediate panel to expose a third intermediate panel;
[0023] FIG. 6 is a top, perspective view of the medical package seen in FIG. 5 illustrating the third intermediate panel, and a dressing positioned thereon, for using during the surgical procedure;
[0024] FIG. 7 is a top, perspective view of the medical package seen in FIG. 6 illustrating movement of the third intermediate panel to expose the bottom panel;
[0025] FIG. 8 is a top, perspective view of the medical package seen in FIG. 7 illustrating the bottom panel, and a second collection of securement tape, together with a label, positioned thereon, for using during the surgical procedure;
[0026] FIG. 9 is a top, perspective view of another embodiment of a medical package, in accordance with the principles of the present disclosure, that includes a plurality of panels for the accommodation of medical supplies;
[0027] FIG. 10 is a top, perspective view of the medical package seen in FIG. 9 after lifting a first panel and illustrating a bottom face of a third panel, and a swab positioned thereon, for use during a surgical procedure;
[0028] FIG. 11 is a top, perspective view of the medical package seen in FIG. 10 illustrating movement of the third panel to expose a top face of a second panel;
[0029] FIG. 12 is a top, perspective view of the medical package seen in FIG. 11 illustrating the top face of the second panel, a first collection of securement tape positioned on the top face of the second panel for use during the surgical procedure, and a bottom face of a fourth panel;
[0030] FIG. 13 is a top, perspective view of the medical package seen in FIG. 12 illustrating movement of the fourth panel to expose a top face of the third panel and a backing panel positioned on a top face of the fourth panel;
[0031] FIG. 14 is a top, perspective view of the medical package seen in FIG. 13 illustrating the top face of the third panel, a dressing positioned on the top face of the third panel for use during the surgical procedure, and the backing panel;
[0032] FIG. 15 is a top, perspective view of the medical package seen in FIG. 14 illustrating movement of the backing panel to expose the top face of the fourth panel; and
[0033] FIG. 16 is a top, perspective view of the medical package seen in FIG. 15 illustrating the top face of the fourth panel, and a second collection of securement tape, together with a label, positioned thereon, for use during the surgical procedure.
DETAILED DESCRIPTION
[0034] Various embodiments of the presently disclosed medical packaging and procedure will now be described in detail with reference to the foregoing figures wherein like reference characters identify similar or identical elements.
[0035] In the figures, and in the description which follows, the various embodiments of the disclosed medical packaging and procedure will be discussed in connection with an intravenous (IV) catheter protection system. However, one skilled in the art will envision that the medical packaging discussed herein below may be used in connection with any medical instruments or supplies, either presently known or later devised. Without departing from the scope and spirit of the present disclosure.
[0036] FIGS. 1-8 illustrate one embodiment of a medical package 100 that houses and accommodates the aforementioned IV catheter protection system in a sterile environment until the medical package 100 is opened by a practitioner. The IV catheter protection system includes a swab 10 ( FIG. 2 ), a first collection of securement tape 12 ( FIG. 4 ), a dressing 14 ( FIG. 6 ), and a second collection of securement tape 16 ( FIG. 8 ) in addition to a label 18 . The method of use corresponding to the IV catheter protection system includes four steps that are outlined for the practitioner on instructions-for-use I.F.U. ( FIGS. 2-8 ) that are supplied with the medical package 100 .
[0037] The medical package 100 may be formed from any suitable material, including but not limited to paperboard, coated papers, polymer films, spunbound polymer fibers (e.g., TYVEK®), metalized polymer films, foils, and the like, either exclusively or in combination, and includes a plurality of panels 102 ( FIG. 1 ) extending from a top edge 104 to a bottom edge 106 to define a length “L.” In the specific embodiment illustrated in FIGS. 1-8 , the medical package 100 includes a top panel 108 , a bottom panel 110 , and plurality of intermediate panels 112 .
[0038] As can be ascertained through reference to FIGS. 1 and 2 , the top panel 108 is connected to the bottom panel 110 along the length “L” through the employ of a living hinge 118 such that the top panel 108 is movable in the direction indicated by arrow 1 . However, in alternative embodiments of the medical package 100 , any binding suitable for the intended purpose of facilitating opening and closing of the medical package 100 may be used. Prior to opening the medical package 100 , the respective top and bottom panels 108 , 110 are releasably secured along the peripheries thereof. The respective top and bottom panels 108 , 110 may be secured together in any manner suitable for the intended purpose of establishing and maintaining a sterile environment therebetween until such time that a practitioner intentionally opens the medical package 100 . For example, it is envisioned that the respective top and bottom panels 108 , 110 may be attached through the use of a medical grade, sterile adhesive (not shown). The top and bottom panels 108 , 110 include tabs 114 T and 114 M , respectively, which are each configured for grasping by the practitioner to facilitate separation of the top panel 108 from the bottom panel 110 , and thus opening of the medical package 100 .
[0039] The top panel 108 defines a bottom face 116 B ( FIG. 2 ) that accommodates the I.F.U. outlining the use of the IV catheter protection system. The I.F.U. may be either removably attached to the bottom face 116 B of the top panel 108 , or alternatively, the I.F.U. may be fixedly or integrally formed therewith. For example, the I.F.U. may be fastened to the bottom face 116 B of the top panel 108 , e.g., through the use of sterile adhesive, or the I.F.U. may be written or inscribed thereon. Positioning the I.F.U. on the bottom face 116 B of the top panel 108 allows the I.F.U. to remain visible to the practitioner at all times during the medical procedure, as will be discussed in further detail below.
[0040] Referring again to FIGS. 1-8 , the aforementioned intermediate panels 112 are positioned between the top panel 108 and the bottom panel 110 . The intermediate panels 112 are arranged such that they are exposed sequentially according to the order in which the steps of the corresponding medical procedure are performed, as outlined in the I.F.U. The intermediate panels 112 support a number of the medical supplies included in the medical package 100 . As such, in the embodiment of the medical package 100 seen in FIGS. 1-8 , the intermediate panels 112 support individual components of the intravenous (IV) catheter protection system. Specifically, the intermediate panels 112 include a first intermediate panel 112 A ( FIG. 2 ) supporting the swab 10 , a second intermediate panel 112 B ( FIG. 4 ) supporting the first collection of securement tape 12 , and a third intermediate panel 112 C ( FIG. 6 ) supporting the dressing 14 . In alternate embodiments of the medical package 100 , however, greater or fewer numbers of intermediate panels 112 may be included depending upon the number of individual medical supplies accommodated by the medical package 100 . The final component of the IV catheter protection system, i.e., the second collection of securement tape 16 and the label 18 , are supported on a top face 116 T of the bottom panel 110 , rather than on an additional intermediate panel 112 , to reduce the overall number of components in the medical package 100 , and thus, decrease manufacturing costs. However, an embodiment of the medical package 100 including a plurality of intermediate panels 112 corresponding in number to the number of components housed by the medical package 100 , i.e., an embodiment wherein the top face 116 T ( FIG. 3 ) of the bottom panel 110 does not support any medical supplies, is not beyond the scope of the present disclosure.
[0041] The first intermediate panel 112 A includes a tab 114 A , the second intermediate panel 112 B includes a tab 114 B , and the third intermediate panel 112 C includes a tab 114 C . As discussed above with respect to the tabs 114 T , 114 M respectively included on the top and bottom panels 108 , 110 , the tabs 114 A , 114 B , 114 C are each configured for grasping by the practitioner to facilitate separation of the respective first, second, and third intermediate panels 112 A , 112 B , 112 C , and thus, exposure of the components of the IV catheter protection system retained within the medical package 100 in accordance with the procedure set forth below.
[0042] When the medical package 100 is assembled, a bottom face 116 B ( FIG. 3 ) of the first intermediate panel 112 A is releasably secured to a top face 116 T of the second intermediate panel 112 B , a bottom face 116 B ( FIG. 5 ) of the second intermediate panel 112 B is releasably secured to a top face 116 T of the third intermediate panel 112 C , and a bottom face 116 C ( FIG. 7 ) of the third intermediate panel 112 C is releasably secured to the top face 116 T of the bottom panel 110 . It is also envisioned that intermediate panel 112 A may be larger in size than intermediate panel 112 B and that intermediate panel intermediate panel 112 B may be larger in size than intermediate panel 112 C such that intermediate panels 112 A , 112 B , 112 C are each releasably secured to the top face 116 T of the bottom panel 110 . As discussed above with respect to the top panel 108 and the bottom panel 110 , the respective first, second, and third intermediate panels 112 A , 112 B , 112 C , and the bottom panel 110 , may be attached in any manner suitable for the intended purpose of establishing and maintaining a sterile environment therebetween, e.g., through the use of a medical grade, sterile adhesive (not shown). In the embodiment of the medical package 100 seen in FIGS. 1-8 , the intermediate panels 112 A , 112 B , 112 C are connected to each other, and/or to the bottom panel 110 , at one or more points along the top edge 104 such that the intermediate panels 112 A , 112 B , 112 C can be moved in the direction indicated by arrow 2 . To facilitate movement of the intermediate panels 112 A , 112 B , 112 C in the direction of arrow 2 , the tabs 114 A , 114 B , 114 C may be positioned in the lower right-hand corners 120 of the respective first, second, and third intermediate panels 112 A , 112 B , 112 C , as seen in FIGS. 2-8 , or in any other suitable location.
[0043] In an alternative embodiment of the medical package 100 , it is envisioned that the intermediate panels 112 A , 112 B , 112 C may be connected to each other, and/or the bottom panel 110 , at one or more points along the bottom edge 106 such that the intermediate panels 112 A , 112 B , 112 C can be moved in the direction of arrow 3 ( FIG. 3 ). In this embodiment, the tabs 114 A , 114 B , 114 C may be respectively positioned on the first, second, and third intermediate panels 112 A , 112 B , 112 C in any suitable location, such as an upper right-hand corner 122 of the intermediate panels 112 A , 112 B , 112 C .
[0044] The connections between the intermediate panels 112 A , 112 B , 112 C , and the bottom panel 110 , may be fixed, such that the intermediate panels 112 A , 112 B , 112 C are simply folded in the direction of arrow 2 , and thus remain integrally formed components of the medical package 100 . Alternatively, however, the connections between the intermediate panels 112 A , 112 B , 112 C , and the bottom panel 110 , may detachable, such that the intermediate panels 112 A , 112 B , 112 C are removable from the medical package 100 after separation from an adjacent panel 102 and/or the bottom panel 110 .
[0045] Referring still to FIGS. 1-8 , use of the medical package 100 will be discussed. To open the medical package 100 , the practitioner grasps the tab 114 T ( FIG. 1 ) included on the top panel 108 , and lifts the top panel 108 in the direction indicated by arrow 1 to thereby separate the top panel 108 from the bottom panel 110 , and expose the swab 10 ( FIG. 2 ). Following separation of the top panel 108 from the bottom panel 110 , it should be appreciated that the integrity of the sterile environment established between the intermediate panels 112 and the bottom panel 110 remains intact, and that the becomes exposed for reference by the practitioner. After opening the medical package 100 , the practitioner can utilize the swab 10 to clean the site where the IV catheter (not shown) will be inserted.
[0046] Following use of the swab 10 and insertion of the IV catheter (not shown), as seen in FIGS. 2 and 3 , the practitioner can grasp the tab 114 A included on the first intermediate panel 112 A , and lift the first intermediate panel 112 A in the direction indicated by arrow 2 to thereby separate the first intermediate panel 112 A from the second intermediate panel 112 B , and expose the first collection of securement tape 12 ( FIG. 4 ). Following separation of the first intermediate panel 112 A from the second intermediate panel 112 B , the sterile environment previously established between the intermediate panels 112 B , 112 C and the bottom panel 110 remains uncompromised.
[0047] By positioning the I.F.U. on the bottom face 116 B ( FIG. 2 ) of the top panel 108 , and moving the first intermediate panel 112 A in the direction of arrow 2 , the practitioner remains in plain view of the I.F.U. such that the practitioner can continually reference the I.F.U. and prepare for the next step in the medical procedure. Thereafter, the practitioner can utilize the first collection of securement tape 12 to limit relative movement between the IV catheter (not shown) and the patient's skin.
[0048] With reference to FIGS. 4 and 5 , the practitioner can then grasp the tab 114 B included on the second intermediate panel 112 B , and lift the second intermediate panel 112 B in the direction indicated by arrow 2 to thereby separate the second intermediate panel 112 B from the third intermediate panel 112 C , and expose the dressing 14 ( FIG. 6 ). Following separation of the second intermediate panel 112 B from the third intermediate panel 112 C , the sterile environment previously established between the third intermediate panel 112 C and the bottom panel 110 remains uncompromised, and the remains visible for reference by the practitioner. Thereafter, the practitioner can position the dressing 14 as desired.
[0049] Finally, referring to FIGS. 7 and 8 , the practitioner can grasp the tab 114 C included on the third intermediate panel 112 , and lift the third intermediate panel 112 C in the direction indicated by arrow 2 to thereby separate the third intermediate panel 112 C from the bottom panel 110 , and expose the second collection of securement tape 16 and the label 18 ( FIG. 8 ). The practitioner can then use the second collection of securement tape 16 to further limit relative movement between the IV catheter (not shown) and the patient's skin, as well as the label 18 .
[0050] With reference now to FIGS. 9-16 , an alternative embodiment of the medical package, referred to generally by the reference character 200 , will be discussed. The medical package 200 is substantially similar to the medical package 100 discussed above with respect to FIGS. 1-8 , and accordingly, will only be discussed with respect to its differences therefrom.
[0051] The medical package 200 includes a plurality of panels 202 extending from a top edge 204 to a bottom edge 206 to define a length “L,” as well as a backing panel 202 BP ( FIGS. 14 and 15 ). In the embodiment of the medical package seen in FIGS. 9-16 , the medical package 200 houses the components of the IV catheter protection system discussed above, and is thus illustrated as including a first panel 202 A , a second panel 202 B , a third panel 202 C , and a fourth panel 202 D , in addition to the aforementioned backing panel 202 BP . However, alternate embodiments of the medical package 200 are also envisioned that may include greater or fewer numbers of panels 202 dependent upon the medical supplies intended to be accommodated thereby.
[0052] The first panel 202 A includes a bottom face 210 B , a top face 210 T , and a tab 212 A , the second panel 202 B includes an bottom face 210 B and a top face 210 T , the third panel 202 C includes a bottom face 210 B having a tab 212 C affixed thereto and a top face 210 T , and the fourth panel 202 D includes a bottom face 210 B having a tab 212 D affixed thereto and a top face 210 T . As seen in FIGS. 14 and 15 , the fourth panel 202 D also includes the aforementioned backing panel 202 BP . The backing panel 202 BP has a tab 212 BP affixed thereto, and is releasably attached to the top face 210 T of the fourth panel 202 D such that a sterile environment is established therebetween, e.g., through the use of a medical grade, sterile adhesive (not shown). The plurality of panels 202 are connected along their length “L” ( FIG. 1 ) through the employ of a plurality of living hinges 214 , which are best seen in FIG. 16 . However, any binding suitable for the intended purpose of facilitating opening and closing of the medical package 200 may be used.
[0053] The bottom face 210 8 of the first panel 202 A accommodates the I.F.U. pertaining to use of the IV catheter protection system, which may be either releasably connected to the bottom face 210 B , or integrally formed therewith, as discussed above with respect to, the medical package 100 illustrated in FIGS. 1-8 . The top face 210 T of the second panel 202 B accommodates the first collection of securement tape 12 ( FIG. 12 ), the top face 210 T of the third panel 202 C accommodates the dressing 14 ( FIG. 14 ), the top face 210 T of the fourth panel 202 D accommodates the second collection of securement tape 16 and the label 18 ( FIG. 16 ), which are positioned beneath the backing panel 202 BP secured to the fourth panel 202 D , and the bottom face 210 B of the third panel 202 C accommodates the swab 10 ( FIG. 10 ).
[0054] As discussed above with respect to the medical package 100 seen in FIGS. 1-8 , the medical package 200 is assembled such that the practitioner will sequentially expose the components of the IV catheter protection system according to the order in which the steps of the corresponding medical procedure are performed, as outlined in the I.F.U. Specifically, in the embodiment of the medical package seen in FIGS. 9-16 , the medical package 200 is assembled such that the bottom face 210 B of the first panel 202 A is releasably attached to the bottom face 210 B of the third panel 202 C , the top face 210 T of the second panel 202 is releasably attached to the bottom face 210 B of the fourth panel 202 D , and the top face 210 T of the third panel 202 is releasably attached to the top face 210 T of the fourth panel 202 D . However, additional arrangements for the medical package 200 are not beyond the scope of the present disclosure.
[0055] The panels 202 may be attached in any manner suitable for the intended purpose of establishing and maintaining a sterile environment between adjacent panels 202 ( FIG. 1 ), e.g., through the use of a medical grade, sterile adhesive (not shown), until such time that the practitioner intentionally separates adjacent panels 202 to open the medical package 200 .
[0056] With continued reference to FIGS. 9-16 , use of the medical package 200 will be discussed. To open the medical package 200 , the practitioner grasps the tab 212 A included on the first panel 202 A , and lifts the first panel 202 A in the direction indicated by arrow 1 ( FIG. 9 ) to separate the bottom face 210 B of the first panel 202 A from the bottom face 210 B of the third panel 202 C , and thereby expose the swab 10 ( FIG. 2 ) and the I.F.U. for reference by the practitioner during the medical procedure. Thereafter, the practitioner can utilize the swab 10 to clean the site where the IV catheter (not shown) will be inserted.
[0057] With specific reference to FIGS. 10 and 11 , following use of the swab 10 and insertion of the IV catheter (not shown), the practitioner can grasp the tab 212 C included on the bottom face 210 B of the third panel 202 C , and use the tab 212 C to move the third panel 202 C in the direction indicated by arrow 2 . Referring now to FIG. 12 as well, movement of the third panel 202 C in the direction of arrow 2 separates the bottom face 210 B of the fourth panel 202 D from the top face 210 T of the second panel 202 B , and exposes the first collection of securement tape 12 without obscuring the practitioner's view of the I.F.U., thereby allowing the practitioner to continually reference the I.F.U., if necessary. The practitioner can then utilize the first collection of securement tape 12 to limit relative movement between the IV catheter (not shown) and the patient's skin.
[0058] After placement of the first collection of securement tape 12 , with reference now to FIGS. 12-14 , the practitioner can grasp the tab 212 D included on the bottom face 210 B of the fourth panel 202 D , and use the tab 212 D to move the fourth panel 202 D in the direction indicated by arrow 2 . Movement of the fourth panel 202 D in the direction of arrow 2 separates the top face 210 T of the third panel 202 C from the top face 210 T of the fourth panel 202 D , and exposes the dressing 14 without obscuring the practitioner's view of the I.F.U. When the third panel 202 C is separated from the fourth panel 202 D , the backing panel 202 BP maintains the sterile environment previously established for the second collection of securement tape 16 and the label 18 . The practitioner can then position the dressing 14 as desired.
[0059] Finally, and with reference to FIGS. 15 and 16 , the practitioner can grasp and use the tab 212 BP ( FIG. 14 ) included on the backing panel 202 BP to move the separate the backing panel 202 BP from the top face 210 T of the fourth panel 202 D to thereby expose the second collection of securement tape 16 and the label 18 . The backing panel 202 BP can be either removably connected to the top face 210 T of the fourth panel 202 D as shown in FIG. 15 such that the backing panel 202 BP can be completely removed from the medical package 200 , or alternatively, the backing panel 202 BP can be fixedly secured to the top face 210 T of the fourth panel 202 D at one or more locations such that the backing panel 202 BP remains attached to the medical package 200 . Following separation of the backing panel 202 BP from the top face 210 T of the fourth panel 202 D , the practitioner can use the second collection of securement tape 16 to further limit relative movement between the IV catheter (not shown) and the patient's skin, for example, as well as the label 18 .
[0060] As illustrated in FIGS. 10-16 , the tabs 212 C , 212 D are respectively attached to the bottom face 210 B of the third and fourth panels 202 C , 202 D at the upper left-hand corner 216 thereof, and the tab 212 BP is attached to the upper left-hand corner 216 of the backing layer 202 BP such that the panels 202 C , 202 D are movable in the direction of arrow 2 . It should be appreciated, however, that the tabs 212 C , 212 D , 212 BP can be alternately positioned in any location suitable for the intended purpose of facilitating movement of the third panel 202 C , the fourth panel 202 D , and the backing panel 202 BP to expose the components of the IV catheter protection system as discussed above.
[0061] While the above is a complete description of the various embodiments of the medical package and method disclosed herein, various alternatives, modifications, and equivalents are also envisioned that do not depart from the scope or spirit of the present disclosure. For example, the features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Those skilled in the art will understand that the embodiments discussed above are intended to be non-limiting and exemplary only, and accordingly, that the present disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.
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The present disclosure relates to medical packaging for the accommodation of medical supplies. The medical packaging discussed herein has a plurality of panels, including a first panel, a second panel, and a third panel, that are releasably secured together to establish a first sterile environment between the first panel and the second panel for the retention of a first medical supply, and a second sterile environment between the second panel and the third panel for the retention of a second medical supply. The panels are configured for relative movement such that movement of the first panel relative to the second panel reveals the first medical supply without compromising the second sterile environment, and movement of the second panel relative to the third panel reveals the second medical supply. The panels are arranged for sequential separation in accordance with the steps of the procedure in which the medical supplies are employed.
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BACKGROUND OF THE INVENTION
The use of amorphous, dense, colloidal silica materials has long been desirable to provide a frictionizing effect on fibers and to increase the strength and performance of fibrous materials, such as textile yarns during weaving. Deposition of the small, dense, amorphous particles on the surface of a fibrous material promotes friction between adjacent fibers to produce an effect which might be compared to placing two pieces of sandpaper face-to-face. Luvisi U.S. Pat. No. 2,787,968, discloses in detail the effect of colloidal silica on various substrates.
However, the use of amorphous, dense, colloidal silica materials as frictionizing agents in water-based processing industries has not been widely accepted due to the inherent chemical nature of the colloidal silica itself. When water based colloidal silica is applied to an article in an aqueous process, the silica particles exist as small, discreet spheres. Upon removal of the process water, or the water carrier for the colloidal silica, the small silica particles follow their water carrier into a diminishing volume of carrier and steadily increasing silica particle concentration. When enough of the water carrier is removed, agglomeration of the colloidal particles occurs with the formation of large, very abrasive, amorphous granules. These large agglomerated silica granules are too large to provide an efficient frictionizing effect between fibers and are so abrasive that adjacent fibers may be severely weakened or cut by their action.
Vossos U.S. Pat. No. 3,629,139, and Kovarik U.S. Pat. No. 3,660,301, disclose a process for the production of organically coated colloidal silica sols which may be dispersed in non-polar organic solvents. The organosols produced by the cited teachings demonstrate the ability to be concentrated to yield dry, free-flowing, coated colloidal silica powders which may be redispersed in an organic media, and which retain the properties of the original colloidal silica. These teachings indicate that the drawbacks of agglomeration may be prevented when the colloidal silica particles have been modified by an organic surface coating and dispersed in an organic solvent. An attempt to exploit this technology in the textile industry was made based upon the teachings of Vossos and Kovarik in the cited patent references. This attempt was not commercially successful but did provide that the organically coated silicas, applied from non-polar solvents, retained their original size and shape as discreet particles without agglomeration. The coated silica particles were shown to be non-abrasive toward fiber, metal or ceramic surfaces which came into contact with the treated yarns. Due to the maintenance of the original size and shape of the colloidal silica particles, one of the most perplexing drawbacks of this treatment was that the frictionizing effect was so efficient that processing of treated fibrous material through subsequent steps was rendered very difficult. Equally important to the lack of acceptance of these materials was their incompatability with existing water based processes and a requirement for designing and installing equipment and process modifications. These changes would have made major capital commitments necessary for the use of these materials. These factors, coupled with an unattractive economic situation with the organosol in oil, made this concept unacceptable to the industry.
SUMMARY OF THE INVENTION
This invention relates to the preparation and application of strength enhancing compositions in and from aqueous media and the fibrous articles treated therewith. In its more specific aspects, this invention relates to the formation and application of organo polymeric-colloidal silica complexes produced in an aqueous media, for application from an aqueous media, to fibrous materials. In the course of the developments of the parameters necessary for the reduction of this invention to practice, it has been found that polymeric polyester resins are the materials of preference for use in the formation of the strength enhancing compositions. While other water soluble or dispersible polymers might find utility in the formation of the polymeric-colloidal silica complex, water soluble or dispersible polyester resins have been shown to provide additional benefits such as adhesion and plasticization of other materials applied to fibrous articles. The polyester resins have demonstrated outstanding utility in providing efficient polymeric-colloidal silica complexes during application of the strength enhancing materials to fibrous articles in wet processes.
Preferably, this invention relates to the application of polymeric organiccolloidal silica complexes to the sizing of textile yarns for the purpose of weaving yarns into textile materials. In this process, it is desirable before weaving to treat the warp yarn with a sizing composition or agent which adheres to and binds the fibrous components of the yarn. This treatment strengthens the textile yarns and renders them more resistant to abrasion during subsequent weaving operations. It is especially important that the sizing process and agent impart both abrasion resistance and added strength to the yarn due to the abrasion and stress encountered during fabric formation. Failure of the yarn during weaving lower both product quality and efficiency of the fabric formation process. It is also important that the sizing composition be easily removed from the fabric by a conventional desize or scouring operation. Removability of the sizing materials allows the desized fabric to be processed through subsequent dyeing and finishing operations without interference from residual materials. Various high number average molecular weight natural and synthetic materials have been suggested and are currently being utilized as sizing agents for yarns. Among such materials are starches of nearly all varieties and modifications, partially and fully hydrolyzed polyvinyl alcohols and copolymers, carboxymethyl cellulose, polymers derived from acrylic monomers, polymers derived from polyvinyl acetate and those derived from vinyl acetate monomers in combination with other monomers incorporated into the polymer via vinyl polymerization. Low and intermediate number average molecular weight polyester resins have also shown utility in yarn sizing applications. Depending upon the specific requirements and desired results, nearly all sizing compositions applied to spun yarns are comprised of the aforementioned materials, or any, or all, of their combinations.
The sizing composition of the present invention includes a complex of colloidal silica particles and polymeric resin in an aqueous medium. Preferably the silica particles are in the 20-50 millimicron range and the resin is an intermediate number average molecular weight (e.g. 3,000 to 7,000) polyester resin. In the preferred embodiment the resin is prepared from isophthalic acid, diethylene glycol and trimellitic anhydride, such as disclosed in Lark U.S. Pat. No. 4,268,645, neutralized conventionally with amine containing materials to render it reducible in water. The ratio of resin to silica particles is sufficiently high to result in substantial encapsulation or occlusion of the silica particles in the resin so that upon drying of the aqueous based composition on the sized material the silica particles will remain substantially discrete rather than agglomerating. The composition is prepared by mixing the colloidal silica and aqueous based resin along with the other components, or the silica and resin may be precomplexed and dried and later dissolution in water to form a sizing composition.
In the preferred embodiment the composition includes other conventional sizing components, such as lubricant, modified starch, and polyvinyl alcohol.
The present invention includes a fibrous product that has been sized with the aforesaid sizing composition.
As a result of the present invention, enhanced strength and performance are obtained for fibrous materials that have been treated with the sizing composition. For example, textile yarns composed of short or staple fibers exhibit enhanced strength and abrasion resistance during weaving as well as being easily cleansed of the composition during conventional desizing or scouring. Also, the sizing composition can be applied to weakened yarns to restore a measure of tensile strength to aid in the more efficient processing of these yarns into fabric.
Further advantages and applications of this invention should become obvious to those skilled in the art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following are examples of preferred embodiments of the present invention as applied to fibrous textile materials and the resulting effects upon the strength and efficiency of the treated materials during subsequent processing steps. These examples re merely illustrative and should not be construed as limiting the scope of the invention. It must be noted that no laboratory procedure has been widely accepted to predict the effect of a size or size additive in the weaving operation. For this reason, the examples involving the effect upon weaving efficiency were performed under mill scale conditions.
In each example, the polyester resin utilized was Pioneer Chemicals, Inc. resin PL 725 or PL401, which is of theoretical intermediate number average molecular weight (5,000-7,000) prepared from isophthalic acid, diethylene glycol and trimellitic anhydride as disclosed in Lark U.S. Pat. No. 4,268,645 and conventionally neutralized with an amine containing material (monoisopropylamine) having an acid number of at least 35 to render it reducible into water. Several different particle size colloidal silicas were utilized in the separate examples, the particle sizes being specified in the examples cited.
EXAMPLE 1
A control sizing composition not incorporating the present invention was prepared by mixing 380 gallons of water, 300 lb. of ethoxylated corn starch, 50 lb. of modified potato starch, 100 lb of polyvinyl alcohol, 200 lb. of aqueous based polyester resin at 25% solids, and 30 lb. of wax. This mixture was cooked under standard conditions and finished to a level of 505 gallons containing 11% total solids. 50/50 polyester/cotton yarn of 35% cotton count was sized through a commercial slasher with this composition. A single end of warp yarn sized with this formulation was collected on a winder located on the front end of the slasher. This yarn was submitted for laboratory strength and elongation testing, the results of which are set out in Table I below under the heading Example 1 Control. Sized warps based upon this formulation were used in weaving on a shuttle loom and exhibited an overall weaving performance of 93.20% over the life of the warps in the looms.
EXAMPLE 2
The size formulation detailed in Example 1 was utilized according to the present invention by the addition of 5.0 lb. of 20 millimicron colloidal silica solids in water. This mixture was processed under standard conditions and finished to 507 gallons of size. A single end of yarn sized with this composition was collected on a winder and submitted for laboratory strength and elongation testing, the results of which are set out in Table I below under the heading Example 2. Two full warps were sized with this composition and used in weaving on a shuttle loom to be compared to the warps from the same yarn set sized with the composition of Example 1 and exhibited an overall weaving performance of 97.45% over the life of the warps in the looms.
A comparison of the results of Example 2 and Example 1 are set out under the heading Percent Difference in Table I.
TABLE 1______________________________________SINGLE END SIZED YARN COMPARISONS EXAMPLE EXAMPLE PERCENT 1 2 DIFFER- CONTROL TEST ENCE______________________________________% Elongation 4.64 4.892 +5.431Std. Deviation 0.70 0.666 -4.86Coeff. of Variation 15.065 13.664 -9.30Elongation RangeHigh 6.115 6.342 +3.29Low 2.83 3.308 +16.89Range 3.285 3.034 -7.64Ave. gm to Break 281.98 303.61 +7.67Std. Deviation 32.62 30.208 -7.394Coeff. of Variation 11.57 9.97 -13.83Strength RangeHigh 367.67 365.876 -0.469Low 205.47 234.332 +14.047Range 162.14 131.554 -18.864No. of Breaks 100 250______________________________________
EXAMPLE 3
The mixture utilized in Example 2 was employed with the following modification. The 200 lb. of polyester resin in water was mixed with 5 lb. of 20 millimicron colloidal silica solids and additional water to maintain the mixed product system at a level of 25% solids. This mixture was stored for a period of 5 days and then cooked with the other ingredients as described in Examples 1 and 2. Two warps were sized with the composition containing the precomplexed polyester-colloidal silica material and used in weaving on a shuttle loom in comparison with warps from the same yarn set sized with the composition of Example 1. In this example, the warps sized with the composition of Example 1 provided a weaving performance of 93.31% in comparison with a performance of 97.42% for the test warps.
EXAMPLE 4
A mixture of 150 lb. of polyvinyl alcohol, 100 lb. of starch, 12 lb. of kettle wax and 2.5 lb. of 20 millimicron colloidal silica solids was cooked and applied to two warps of 65/35 polyester/cotton 35's cotton count yarn. These two warps were woven on projectile looms and compared with warps from the same yarn set sized without the addition of the colloidal silica. Yarns collected from these warps exhibited lower tensile strength in laboratory testing and lower weaving performance than the warps sized with the composition which did not contain the colloidal silica. No polyester-colloidal silica complex of the invention was present. The effects of the abrasive, agglomerated silica were apparent in lowered tensile strength and weaving efficiency.
EXAMPLE 5
The compositions of Example 1 and Example 2 were repeated on 1/2 set of yarn each of 50/50 polyester/cotton 35's cotton count yarn. The two 1/2 sets were woven on shuttle looms and compared directly by both total efficiency and industrial engineering studies. The 1/2 set sized with the composition of Example 1 exhibited a weaving performance of 91.6% and a warp stop level of 0.804/hour. The 1/2 set sized with the composition of Example 2 exhibited a weaving performance of 95.2% and a warp stop level of 0.497/hour.
EXAMPLE 6
200 lb. of carboxymethylated starch and 12 lb. of kettle wax were cooked and applied to 100% cotton yearn, 14's cotton count. Industrial engineering studies of shuttle weaving indicated that a warp stop level of 0.83/hour was obtained with this composition, which did not include the silica/resin complex of the present invention.
EXAMPLE 7
The composition of Example 6 was repeated with the addition of 80 lb. of 25% polyester resin in water. Water was added to maintain the same solids and add-on as in Example 6. Industrial engineering studies of shuttle weaving indicated a warp stop level of 0.69/hour with this composition, which did not include silica and therefore did not include the silica/resin complex of the present invention.
EXAMPLE 8
The composition of Example 7 was repeated with the addition of 2.5 lb. of 50 millimicron colloidal silica and applied to the same 14's 100% cotton count yarn utilized in Examples 6 and 7. Industrial Engineering studies of shuttle weaving indicated that these warps performed at a warp stop level of 0.42/hour.
EXAMPLE 9
A mixture of 100 lb. of polyvinyl alcohol, 100 lb. of ethoxylated corn starch and 12 lb. of kettle wax was cooked and finished to 200 gallons and applied to 100% cotton 20's cotton count yarn and woven on a Jacquard loom. This size composition performed at a warp stop level of 4.2/100,000 picks. This composition did not include the silica/resin complex of the present invention.
EXAMPLE 10
A mixture of 100 lb. of carboxymethyl cellulose, 100 lb. of ethoxylated corn starch and 12 lb. of kettle wax was finished to 200 gallons and applied to the yarn of Example 9 and woven on a Jacquard loom. This composition performed at a warp stop level of 4.4/100,000 picks. It did not include the silica/resin complex of the present invention.
EXAMPLE 11
A mixture of 180 lb. of ethoxylated corn starch, 72 lb. of 25% polyester resin solids, 12 lb. of kettle wax and 2.8 lb. of 25 millimicron colloidal silica solids was finished to 200 gallons and applied to the yearn of Example 9. This sized cotton yarn was woven on a Jacquard loom and performed at a warp stop level of 2.1/100,000 picks.
EXAMPLE 12
400 grams of polyester resin at 25% solids in water was mixed with 10 grams of 25 millimicron colloidal silica solids and the mixture brought to a total a 500 grams with water. This mixture was brought to the boil to remove water from the polyester-colloidal silica complex. After approximately 90% of the water had been removed, the mixture was transferred to a microwave oven and the remaining water removed from the product. The resulting dried film contained no apparent agglomerated silica particles upon examination under a low power microscope. Redispersion of the polymer film was accomplished at 200° F. in water with the aid of small amounts of aqua ammonia. The redispersed polymer in water was cooled and filtered through paper. No agglomerated silica particles were present on the filter paper. This procedure was utilized to establish the ratio of polyester resin solids to silica solids necessary to avoid the formation of agglomerated silica particles upon dry-down of the resin-silica complex.
Further laboratory tests were conducted to determine resin to silica ratios that would provide substantial silica encapsulation. The compositions were dried for observation of possible agglomeration rather than encapsulation and were also filtered to observe the presence of agglomerates. Results are set out in Table II below. These laboratory tests were performed utilizing an theoretical intermediate number average molecular weight polyester resin (approx 5,000-7,000) and a colloidal silica which averages 25 millimicrons. Film preparation of the higher resin/silica complexes (4/1 and 5/1) was also accomplished by mild acidification of the aqueous mixture with dilute acetic acid followed by drying the precipitated complex. The resin/silica ratios determined are based upon the specific particle size colloidal silica utilized. Larger particle size sols will exhibit encapsulation at a lower resin/silica ratio, and smaller particle size sols will require a larger resin/silica ratio due to the significant differences in surface area of the sols. In the same context, lower molecular weight polyester resins allow a lower resin-silica ratio due to the availability of a higher number of polymeric molecules per unit weight. In these tests the residue collected on the filter paper was washed with aqueous ammonia to remove any polyester resin. The agglomerated silica collected was not affected by the ammonia wash. The inorganic nature of the residue collected on the filter paper was confirmed by ignition of the filter paper and granular residue.
TABLE II______________________________________Effect of Polymer/Silica Ratio on Silica EncapsulationParts Parts Dried Film Residue CollectedResin Silica Characteristics on Filter paper______________________________________0.5 1.0 grainy yes - inorganic0.75 1.0 grainy yes - inorganic1.0 1.0 grainy yes - inorganic3.0 1.0 slightly yes - slight inorganic grainy residue on filter4.0 1.0 only a slight none haze in film5.0 1.0 clear none______________________________________
EXAMPLE 13
A yarn package containing 600 grams of bleached 100% cotton yarn, 8's cotton count, was placed in a Gaston County laboratory package dye machine and the pH of the aqueous phase adjusted to 6.5 with dilute acetic acid. The package was subjected to a 35 minute mock dye cycle, followed by a standard drying and conditioning cycle. This yarn exhibited a low end break factor of 450 grams on a Uster single-end tester.
EXAMPLE 14
Water was added to a Gaston County laboratory package dye machine and the pH adjusted to 8.5 by the addition of dilute aqueous ammonia. 7.3 grams of a pulverized dry silica/resin complex containing 6.25 grams of polyester resin solids and 1.05 grams of 25 millimicron colloidal silica solids were added and the mixture circulated for a total of 20 minutes at ambient temperature. At the end of the 20 minute circulation cycle, the pH of the aqueous solution was adjusted to 6.5 with dilute acetic acid. A yarn package containing 600 grams of bleached 100% cotton yarn from the same lot cited in Example 13 was placed in the Gaston County package dye machine and a 35 minute mock dye cycle performed under the same conditions cited in Example 13. After a standard drying and conditioning cycle, the yarn exhibited a low end break factor of 525 grams on a Uster single-end tester. These results were consistent throughout the yarn package, indicating that the complex was exhausted uniformly in the mock dye procedure. A comparison of these results with those of Example 13 clearly indicates the advantage of the present invention, and that silica/resin complex of the present invention will perform in the same efficient manner as the complex formed in situ with the two components.
The present invention may be practiced by forming the composition before application, by preparing the silica/resin complex as a dry powder for in situ application or by forming the composition in situ during an operation such as dyeing.
It is contemplated that the resin used in the present invention may be of a number average molecular weight range other than intermediate and may be neutralized with basic nitrogen containing materials other than amines.
It is expected that colloidal silica particles of sizes different than in the foregoing examples may be used, such as in the range of 3 to 150 millimicrons, provided it is in the classification of a sol. Further, it is contemplated that additives, such as alumina may be usable with silica in the colloidal silica sol.
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.
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A strength enhancing composition for treating textile materials in the sizing or dyeing process has been developed by the encapsulation or occlusion of colloidal silica particles with a water reducible polyester resin of intermediate molecular weight. The complex formation of the resin colloidal silica species is accomplished in an aqueous medium. The resin is prepared from isophthalic acid, diethylene glycol and trimellitic axhydride followed by neutralization with amine containing material to render the resin reducible in water. The composition may be combined with any of the conventional size materials, i.e. polyvinyl alcohol, starches, lubricants, etc., to enhance the performance of the sizing composition. The silica/resin complex may be formed in situ, or may be preformed, dried and pulverized for later use or for mixing with conventional, dry, sizing materials. The composition may be applied to textile yarns using conventional equipment, such as yarn slashers or dye machines, with the treated textile material having enhanced strength and performance characteristics.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an image sensor made in monolithic form intended to be used in shooting devices such as, for example, film cameras, camcorders, cell phones, or again digital photographic cameras.
[0003] 2. Discussion of the Related Art
[0004] FIG. 1 schematically illustrates an example of a circuit of a photosensitive cell of an array of photosensitive cells of an image sensor. With each photosensitive cell of the array are associated a precharge device and a read device. The precharge device is formed of an N-channel MOS transistor M 1 , interposed between a supply rail Vdd and a read node S. The gate of precharge transistor M 1 is capable of receiving a precharge control signal RST. The read device is formed of the series connection of first and second N-channel MOS transistors M 2 , M 3 . The drain of first read transistor M 2 is connected to supply rail Vdd. The source of second read transistor M 3 is connected to an input terminal P of a processing circuit (not shown). The gate of first read transistor M 2 is connected to read node S. The gate of second read transistor M 3 is capable of receiving a read signal RD. The photosensitive cell comprises a photodiode D having its anode connected to a reference supply source GND, for example, the circuit ground, and having its cathode connected to node S via an N-channel charge transfer MOS transistor M 4 . The gate of transfer transistor M 4 is capable of receiving a charge transfer control signal T. Generally, signals RD, RST, and T are provided by control circuits, not shown in FIG. 1 , and may be provided to all the photosensitive cells of a same row of the cell array. Node S behaves a as charge storage region, the apparent capacitance at read node S being formed of the source capacitances of transistors M 1 and M 4 , of the input capacitance of transistor M 2 , as well as of all the stray capacitances present at node S. According to a variation, a specific diode having its cathode connected to node S and having its anode connected to ground may be provided.
[0005] The operation of this circuit will now be described. A photodetection cycle starts with a precharge phase during which a reference voltage level is imposed at read node S. This precharge is performed by turning on precharge transistor M 1 . Once the precharge has been performed, precharge transistor M 1 is turned off. The reference charge state at node S is then read. The cycle carries on with a transfer to node S of the photogenerated charges, that is, those created and stored in the presence of radiation, in photodiode D. This transfer is performed by turning on transfer transistor M 4 . Once the transfer is over, transistor M 4 is turned off, and photodiode D starts photogenerating and storing charges which will be subsequently transferred to node S. Simultaneously, at the end of the transfer, the new charge state at node S is read. The output signal transmitted to terminal P then depends on the channel pinch of first read transistor M 2 , which is a direct function of the charge stored in the photodiode.
[0006] FIG. 2 shows a simplified top view of an image sensor made in monolithic form. FIG. 2 illustrates a conventional example of distribution of the electronic components (photodiodes and transistors) associated with the image sensor. The transistors and the photodiodes associated with the photosensitive cells are generally formed at the center of the image sensor at the level of block 1 (pixels). The transistors of the peripheral circuits which, generally, carry out various processings of the signals associated with the photosensitive cells, are formed all around block 1 . As an example, blocks 2 (readout) correspond to the circuits dedicated to the provision of the control signals of the array of photosensitive cells and to the reading of the signals provided by the photosensitive cells (especially the previously-mentioned processing circuits). Generally, other peripheral circuits may be provided to perform additional functions directly at the level of the image sensor, such as, for example, the correction of faults of the signals read from the read nodes of the photosensitive cells, the image storage, signal processing operations, etc. Thus, block 3 (memory) may correspond to peripheral circuits dedicated to the storage of images. Blocks 4 (digital) may correspond to peripheral circuits dedicated to the performing of signal processing operations. Blocks 5 may correspond to the peripheral circuits dedicated to the processing of input/output interface signals, and especially comprise transistors which are directly connected to the connection pads of the image sensor.
[0007] Conventionally, the electronic components of the image sensor are formed at the level of a substrate of a semiconductor material, for example, a silicon wafer, covered with a stack of insulating layers at the level of which are formed the conductive tracks and vias enabling connection of the electronic components of the image sensor. The stack of insulating layers is covered, at least at its central portion, with colored filters and lenses associated with the photosensitive cells, with the possibility for the colored filters not to be present when the image sensor is a black and white sensor. Such an image sensor is said to be front-lit.
[0008] A disadvantage of a front-lit image sensor is that the straight path of the light rays from each lens to the photodiode of the associated photosensitive cell may be hindered by the tracks and the conductive vias present at the level of the insulating layer stack covering the substrate. It may then be necessary to provide additional optical devices, in addition to the previously-mentioned lenses, to make sure that most of the light rays which reach the front surface of the image sensor reach the photodiodes of the photosensitive cells. This then results in image sensors that may have a relatively complex structure, difficult to form.
[0009] A solution to avoid the use of additional optical devices and/or to improve the light absorption at the level of the image sensor substrate comprises lighting the image sensor through the rear surface of the substrate at the level of which the photodiodes are formed. The image sensor is said to be back-lit.
[0010] FIG. 3 shows an example of conventional monolithic forming of a back-lit image sensor. In the right-hand portion, the photodiode D and the transistor M 4 of a photosensitive cell of the image sensor have been shown and, in the left-hand portion, two MOS transistors M 5 and M 6 associated with the peripheral circuits of the image sensor have been shown. The image sensor comprises a lightly-doped P-type substrate 14 (P − ) comprising a front surface 15 and a rear surface 16 . The photosensitive cell and the transistors of the peripheral circuits are, as an example, delimited by field insulation regions 20 , for example, made of silicon oxide, each surrounded with a P-type region 22 more heavily doped than substrate 14 (P + ). Photodiode D comprises an N-type region 24 formed in substrate 14 . In the case where photodiodes of fully depleted type are used, region 24 is covered with a P-type region 26 more heavily doped than substrate 14 . An N-type region 28 , formed in substrate 14 , corresponds to the drain region of transistor M 4 . An insulating region 30 extends on front surface 16 of substrate 14 , between regions 28 and 24 and corresponds to the gate oxide of transistor M 4 . Insulating portion 30 is covered with a polysilicon portion 32 corresponding to the gate of transistor M 4 . A P-type well 33 , formed in substrate 14 , more heavily doped than substrate 14 (P + ), corresponds to the well of transistor M 5 . Two N-type regions 34 , formed in well 33 , correspond to the power terminals of transistor M 5 . An insulating portion 35 extends between regions 34 and corresponds to the gate oxide of transistor M 5 . A polysilicon portion 36 covers insulating portion 35 and corresponds to the gate of transistor M 5 . An N-type well 37 , forming substrate 14 , corresponds to the well of transistor M 6 . Two P-type regions 38 , formed in well 37 , correspond to the power terminals of transistor M 6 . An insulating portion 39 extends between regions 38 and corresponds to the gate oxide of transistor M 6 . A polysilicon portion 40 covers insulating region 39 and corresponds to the gate of transistor M 6 .
[0011] Substrate 14 is covered with a stack of insulating layers 41 at the level of which are formed metal tracks 44 of different metallization levels and metal vias 46 enabling connection of the components of the photosensitive cells and of the peripheral circuits. Stack 41 is covered with an insulating layer 42 . A reinforcement 43 , for example corresponding to a solid silicon wafer, covers insulating layer 42 . A P-type implantation 44 , more heavily doped than the substrate, is formed of the side of rear surface 16 of substrate 14 . When the image sensor is a color sensor, a colored filter 48 covered with a lens 50 on the side of rear surface 16 of substrate 14 is provided. At the level of the peripheral circuits, an insulating layer 52 covers rear surface 16 of substrate 14 .
[0012] A back-lit image sensor has the advantage that the path of the light rays which reach the sensor on the side of rear surface 16 is not hindered by metal tracks and vias 44 , 46 provided at the level of insulating layer stack 41 .
[0013] Among the peripheral circuits, some exhibit a significant heat dissipation. This concerns, for example, power supply generation circuits, high-frequency output stages, phase-locked loops, etc. A disadvantage is that an image sensor is very sensitive to temperature. Indeed, the operating principle of the image sensor corresponds to the absorption of photons in substrate 14 , which causes the generation of electron/hole pairs, the electrons being captured by the photodiodes of the photosensitive cells. However, thermal electrons are also capable of being captured by the photodiodes. This translates as the occurrence of a thermal noise at the level of the signals measured from the read node of a photosensitive cell which is generally called “dark current”. When present, it is preferable that the dark current be substantially identical for all the photosensitive cells of the image sensor so that the signals measured at the read nodes, in particular in case of a low lighting, have a substantially uniform amplitude. It is thus desirable for the substrate in which the photodiodes of the photosensitive cells are formed to be maintained at as uniform a temperature as possible and, if possible, at a temperature which remains moderate.
[0014] When the image sensor is front-lit, the substrate in which the electronic components of the image sensor are formed generally has a thickness of several hundreds of micrometers. Such a substrate enables a good carrying off of the heat generated by high thermal dissipation circuits. Further, the substrate is generally arranged at the level of a thermally conductive package further easing the heat carrying-off. Thereby, the substrate temperature remains substantially uniform, which enables keeping a relatively constant dark current, when present, through all the photosensitive cells.
[0015] A difficulty appears when the image sensor is back-lit since substrate 14 then has a low thickness, for example, on the order of a few micrometers, and is thermally isolated. It is then difficult to carry off the heat generated by peripheral circuits with a significant heat dissipation. This translates as local temperature variations that may cause a local increase in the dark current.
SUMMARY OF THE INVENTION
[0016] At least one embodiment of the present invention aims at a back-lit image sensor comprising circuits with a significant heat dissipation, which enables maintaining the substrate at the level of which the electronic components of the image sensor are formed at a substantially uniform temperature.
[0017] According to at least one embodiment of the present invention, the image sensor is capable of being formed by a method compatible with CMOS technologies.
[0018] At least one embodiment of the present invention also aims at a method for manufacturing a back-lit image sensor comprising circuits with a significant heat dissipation which enables maintaining the substrate at the level of which the electronic components of the image sensor are formed at a substantially uniform temperature.
[0019] To achieve all or part of these aims, as well as others, an aspect of the present invention provides an image sensor comprising photosensitive cells comprising photodiodes and at least one additional circuit with a significant heat dissipation comprising transistors. The image sensor is made in monolithic form and comprises a layer of a semiconductor material having first and second opposite surfaces and comprising, on the first surface side, regions corresponding to the power terminals of the transistors, the lighting of the image sensor being intended to be performed on the second surface side; a stack of insulating layers covering the first surface; a thermally conductive reinforcement covering the stack on the side opposite to the layer; and thermally conductive vias connecting the layer to the reinforcement.
[0020] According to an embodiment of the present invention, the layer further comprises, on the first surface side, additional regions corresponding to the photodiodes.
[0021] According to an embodiment of the present invention, the regions are arranged at the periphery of the additional regions.
[0022] According to an embodiment of the present invention, the vias are formed at least at the level of said regions.
[0023] According to an embodiment of the present invention, the thickness of the layer is lower than 5 μm.
[0024] According to an embodiment of the present invention, the image sensor further comprises an additional layer of a semiconductor material having third and fourth opposite surfaces and comprising, on the third surface side, additional regions corresponding to the photodiodes, the additional layer being intended to be lit on its fourth surface; and an additional stack of insulating layers interposed between the third surface of the additional layer and the second surface of the layer.
[0025] According to an embodiment of the present invention, the image sensor further comprises at least one insulating portion in the layer; at least one electrically-conductive via crossing the insulating portion and connecting a first electrically-conductive track arranged in the stack and a second electrically-conductive track arranged in the additional stack.
[0026] Another aspect of the present invention provides a method for manufacturing an image sensor comprising photosensitive cells comprising photodiodes and at least one peripheral circuit with a significant heat dissipation comprising transistors. The method comprises the steps of forming a layer of a semiconductor material having first and second opposite surfaces, the lighting of the sensor being intended to be performed on the second surface side; forming in the layer, on the first surface side, regions corresponding to the power terminals of the transistors; covering the first surface with a stack of insulating layers and forming, in the stack, thermally-conductive vias; and covering the stack with a thermally-conductive reinforcement, the vias connecting the layer to the reinforcement.
[0027] According to an embodiment of the present invention, the method further comprises the step of forming in the layer, on the first surface side, additional regions corresponding to the photodiodes.
[0028] According to an embodiment of the present invention, the method further comprises the steps of forming an additional layer of a semiconductor material comprising third and fourth opposite surfaces, the additional layer being intended to be lit on its fourth surface; forming, in the additional layer, on the third surface side, additional regions corresponding to the photodiodes; and covering the third surface with an additional stack of insulating layers, said layer covering, on the second surface side, the additional stack.
[0029] The foregoing and other objects, features, and advantages of the present invention will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 , previously described, shows an electric diagram of a photosensitive cell;
[0031] FIG. 2 , previously described, shows a example of distribution of the components of the image sensor made in monolithic form;
[0032] FIG. 3 , previously described, shows a conventional example of monolithic embodiment of a back-lit image sensor;
[0033] FIGS. 4A to 4E illustrate the successive steps of an example of a method for manufacturing a first embodiment of a back-lit image sensor according to the present invention;
[0034] FIGS. 5A to 5F illustrate the successive steps of an example of a method for manufacturing a back-lit image sensor according to an embodiment of the present invention; and
[0035] FIG. 6 schematically shows a cell phone comprising an image sensor according to the present invention.
DETAILED DESCRIPTION
[0036] For clarity, the same elements have been designated with the same reference numerals in the different drawings and, further, as usual in the representation of integrated circuits, the various drawings are not to scale.
[0037] An aspect of the present invention comprises, for a back-lit image sensor, carrying off the heat generated by circuits with a significant heat dissipation towards the image sensor reinforcement through the stack of insulating layers separating the substrate from the reinforcement.
[0038] FIGS. 4A to 4E illustrate an example of a method for manufacturing a first embodiment of a back-lit image sensor according to the present invention. The elements common with FIG. 3 have been designated with the same reference numerals.
[0039] FIG. 4A shows a solid silicon support 10 covered with an insulating layer 12 , for example, a thermal oxide. Substrate 14 is formed on insulating layer 12 with the possible interposition of a seed layer. Substrate 14 has a thickness of a few micrometers, preferably lower than 5 μm. Such a structure corresponds to an SOI structure (silicon on insulator).
[0040] FIG. 4B shows the structure obtained after having formed all the electronic components of the photosensitive cells and of the peripheral circuits, as well as stack 41 of insulating layers, metal tracks 44 , and vias 46 . For each photosensitive cell, although only photodiode D and transistor M 4 are shown in FIG. 4B , the other cell transistors, that is, transistors M 1 , M 2 , and M 3 , are also formed at the level of substrate 14 . The first embodiment according to the present invention provides forming, at the level of the peripheral circuits, vias 52 crossing the entire insulating layer stack 41 and having one end at the contact of substrate 14 . It is possible to only provide vias 52 at the level of the peripheral circuits with a significant heat dissipation or at the level of all the peripheral circuits. The density of vias 52 at the level of the peripheral circuits with a significant heat dissipation may be greater than for the other peripheral circuits. Vias 52 are made of a material which is a good heat conductor but not necessarily a good electric conductor. As an example, vias 52 may be made of copper or aluminum nitride (AlN).
[0041] FIG. 4C shows the structure obtained after having glued, on the upper surface of insulating layer stack 41 , a strengthening element formed, for example, of the stack of insulating layer 42 and of silicon reinforcement 43 , vias 52 being extended through insulating layer 42 to come into contact with silicon reinforcement 43 . Reinforcement 43 may have a thickness of a few hundreds of micrometers.
[0042] FIG. 4D shows the structure obtained after a “thinning” step which comprises removing, for example, by chemical or chem./mech. etch, support 10 and insulating layer 12 to expose lower surface 16 of substrate 14 . Support 10 and insulating layer 12 may be removed by etching, where the etch stop can be obtained by playing on the selectivity differences between insulating layer 12 and substrate 14 . According to an alternative embodiment, substrate 14 corresponds to a lightly-doped P-type silicon layer formed by epitaxy on a more heavily-doped P-type solid silicon support. In this case, the thinning step comprises removing the silicon support, for example by etching, where the etch stop can be obtained by playing on the selectivity differences between epitaxial layer 14 and the support.
[0043] FIG. 4E shows the structure obtained after having formed P-type region 44 more heavily doped than substrate 14 on the side of rear surface 16 and after having formed, on rear surface 16 , colored filters 48 and lenses 50 associated with the photosensitive cells of the image sensor and insulating layer 52 at the level of the peripheral circuits. Region 44 may be formed by implantation at the level of rear surface 16 of substrate 14 , followed by an activation anneal.
[0044] The first example of an image sensor according to the present invention has the advantage, in operation, that the heat provided by the peripheral circuits with a significant heat dissipation is carried off, via vias 52 , to reinforcement 43 , thus maintaining substrate 14 at a substantially uniform temperature. Further, reinforcement 43 may itself be attached on a conductive package to further improve the heat carrying off.
[0045] FIGS. 5A to 5F illustrate the steps of an example of a method for manufacturing a second embodiment of a back-lit image sensor according to the present invention.
[0046] FIG. 5A illustrates the structure obtained after steps similar to those which have been previously described for the method for manufacturing the first embodiment of the image sensor according to the present invention in relation with FIGS. 4A and 4B . However, conversely to what has been previously described, only photodiode D and transfer transistor M 4 are formed for each photosensitive cell. As to the peripheral circuits, only the components which do not exhibit a significant heat dissipation are formed. Further, vias 52 are not formed. Moreover, vias 58 which extend to the upper surface of stack 41 of insulating layers are provided.
[0047] FIG. 5B shows the structure obtained after having formed on the stack of insulating layers 41 a P-type single-crystal silicon layer 60 , possibly more heavily doped than substrate 14 . The thickness of layer 60 may vary from some twenty nanometers to a few micrometers and is, preferably, lower than 5 μm. Generally, layer 60 may be very thin since the function of absorption of the light reaching the image sensor is not fulfilled with this layer 60 . Layer 60 may be formed by depositing amorphous silicon on stack 41 of insulating layers and by carrying out a step of recrystallization of the amorphous silicon layer by a method which does not cause too high a rise in the temperature of the rest of the image sensor, in particular, of stack 41 of insulating layers. Indeed, an excessive rise in the temperature of stack 41 may cause a deterioration of the materials used to form insulating layers 41 and conductive tracks and vias 44 , 46 . As an example, when metal tracks 44 are made of copper, the temperature of stack 41 should not exceed 400° C. For this purpose, the recrystallization of the amorphous silicon layer may be obtained by a general heating of the image sensor at low temperature or by a local heating of the amorphous silicon layer, for example via a laser.
[0048] FIG. 5C shows the structure obtained after having formed in layer 60 insulating portions 62 resulting in the forming of islands 64 in insulating layer 60 . As an example, insulating portions 62 may be obtained by etching layer 60 across its entire thickness and by filling the obtained openings with an insulating material, for example, silicon oxide. Insulating portions 62 cover the ends of vias 58 . According to a variation of the second example of embodiment, insulating portions 62 correspond to the openings made in layer 60 , which are left as such.
[0049] FIG. 5D shows the structure obtained after having formed MOS transistors at the level of layer 60 and after having covered layer 60 with a stack of insulating layers 70 . As an example, MOS transistors M 1 and M 2 have been shown on the photosensitive cell side, and two MOS transistors M 7 and M 8 have been shown on the peripheral circuit side. Generally, on the photosensitive cell side, all the transistors of photosensitive cell other than transfer transistor M 4 are formed for each photosensitive cell, and on the peripheral circuit side, all the components which have not already been formed at the level of substrate 14 , that is, especially the components of the peripheral circuits with a significant heat dissipation, are formed.
[0050] The methods for manufacturing transistors M 1 , M 2 , M 7 , M 8 are capable of not causing an excessive rise in the temperature of the rest of the image sensor. As an example, materials with a strong dielectric coefficient, for example, Hafnium oxide, which may be deposited by low-temperature methods, may be used to form the transistor gates, or conventional insulating materials which are then deposited at low temperature, for example, by plasma methods, may be used. Further, the transistor gates may be formed by the deposition of a material based on titanium nitride TiN by an atomic layer deposition or ALD method or by a chemical vapor deposition method CVD. Conductive tracks and conductive vias 72 ensuring the interconnection of the transistors are formed at the level of insulating layer stack 70 . In particular, vias 74 are formed at the level of insulating portions 62 to come into contact with the vias 58 provided at the level of the stack of insulating layers 41 . Further, heat drainage vias 76 which cross the entire insulating layer stack 70 and come into contact at one end with semiconductor layer 60 are provided. Vias 76 may be formed at the level of the entire layer 60 , possibly by increasing the density of vias 76 close to the peripheral circuits with a significant heat dissipation. According to a variation, it is possible to only form vias 76 at the level of all the peripheral circuits formed at the level of layer 60 , or only at the level of the peripheral circuits with a significant heat dissipation. Vias 76 are formed of a material which is a good heat conductor but not necessarily a good electric conductor.
[0051] FIG. 5E shows the structure obtained after having covered insulating layer stack 70 with a reinforcement 78 of a thermally conductive material, for example, a solid silicon wafer. Reinforcement 78 may have a thickness of several hundreds of micrometers. Vias 76 come into contact with reinforcement 78 .
[0052] FIG. 5F shows the structure obtained after having performed the thinning step previously described for the manufacturing method of the first embodiment of the image sensor according to the present invention in relation with FIG. 4D and after having formed filters 48 , lenses 50 and insulating layer 52 as described previously for the method for manufacturing the first embodiment of the image sensor according to the present invention in relation with FIG. 4E .
[0053] In operation, the heat generated by the components formed in layer 60 of the peripheral circuits with a significant heat dissipation is carried off to reinforcement 78 via vias 76 . Further, reinforcement 78 may be attached to a thermally conductive package further improving the heat carrying off. Since the circuits with a significant heat dissipation are not present at the level of substrate 14 , the temperature of substrate 14 remains substantially uniform.
[0054] FIG. 6 illustrates an example of use of the image sensor according to the present invention. FIG. 6 very schematically shows a cell phone 80 comprising a package 82 at the level of which are arranged a screen 84 and a keyboard 86 . Cell phone 80 also comprises an image acquisition system 88 comprising an optical system directing the light rays towards an image sensor according to an embodiment of the present invention.
[0055] Of course, the present invention is likely to have various alterations, modifications, and improvements which will readily occur to those skilled in the art. In particular, the present invention also applies to a photosensitive cell for which several photodiodes are connected to a same read node. Further, although the present invention has been described for an image sensor cell in which the precharge device and the read device have a specific structure, the present invention also applies to a cell for which the precharge device or the read device have a different structure, for example, comprise a different number of MOS transistors.
[0056] Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto.
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An image sensor including photosensitive cells including photodiodes and at least one additional circuit with a significant heat dissipation including transistors. The image sensor is made in monolithic form and includes a layer of a semiconductor material having first and second opposite surfaces and including, on the first surface side, first regions corresponding to the power terminals of the transistors, the lighting of the image sensor being intended to be performed on the second surface side; a stack of insulating layers covering the first surface; a thermally conductive reinforcement covering the stack on the side opposite to the layer; and thermally conductive vias connecting the layer to the reinforcement.
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FIELD OF THE INVENTION
The present invention relates to a heat pump/engine system and method, in particular to a heat pump/engine system and method for the air-conditioning of enclosed spaces.
BACKGROUND OF THE INVENTION
Conventional air-conditioners are effective in removing Sensible Heat (SH) and less effective in removing Latent Heat (LH). To remove heat, the evaporator of the air-conditioner must be cold compared with the ambient air which is normally about 26° C. Yet to remove vapor, the evaporator should be cold compared with the dew point temperature, which is about 15° C.
It can be shown that when the LH exceeds the SH, the humidity in a conventionally conditioned enclosed space exceeds 60%, which humidity is the maximum humidity recommended for maintaining a comfortable environment. For this reason, in humid climate air-conditioning systems require an absorption machine which, while removing humidity, heats the enclosed space, and thus, reduces the efficiency of the conditioning system.
In PCT Application Publication No. WO96/33378, there is disclosed a heat pump system and method for air-conditioning utilizing a refrigerant evaporation and a refrigerant condenser for exchanging heat with brine solution. The refrigerant is considered to have an adverse effect on the ozone, and thus, it is recommended to avoid the use thereof.
SUMMARY OF THE INVENTION
Hence, it is a general object of the present invention to provide an environmental friendly heat pump/engine system and method utilizing a water/brine flash evaporator and air/brine heat exchangers.
It is a further object of the present invention to provide a heat pump/engine system and a method for air-conditioning an enclosed space by controlling the heat load in the enclosed space, by regulating the water/brine concentration of a flash evaporator.
It is still a further object of the present invention to provide a heat pump/engine method and a system for air-conditioning an enclosed space by controlling the temperature of the water and or the brine of said flash evaporator.
According to the present invention there is therefore provided a heat pump/engine system, comprising a water/brine flash evaporator in fluid communication with a first air/brine heat exchanger, a brine condenser in fluid communication with a second air/brine heat exchanger, and a vapor compressor/turbine connected on a fluid conduit leading from said flash evaporator to said brine condenser.
The invention further provides a heat pump/engine method, comprising a flash water/brine evaporator in fluid communication with a first air/brine heat exchanger, a brine condenser in fluid communication with a second air/brine heat exchanger, and a vapor compressor/turbine connected on a fluid conduit leading from said flash evaporator to said brine condenser, and regulating the heat load in an enclosed space by controlling the water flow in said flash evaporator in accordance with humidity and heat load in said space.
The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures, so that it may be more fully understood.
With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for the purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is s believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to shown structural details of the invention in more detail that is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a heat pump/engine system according to the present invention;
FIG. 2 is a schematic illustration of a further embodiment of a heat pump/engine system, and
FIG. 3 is a schematic illustration of still a further embodiment of a heat pump/engine system, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is seen a heat pump/engine system, including a water/brine flash evaporator 2 having a housing 4 , a water inlet 6 and a brine outlet conduit 8 leading from the bottom portion of the housing to a drip-type air-brine heat exchanger 10 . The top portion of the housing 4 constituting a vapor chamber 12 communicating with via conduit 14 and vapor compressor 16 with a vapor chamber 18 of a brine condenser 20 . To the vapor chamber 18 there is attached a vacuum pump 22 . The output from brine condensor 20 leads via conduit 24 to a second, air/brine heat exchanger 26 . Both heat exchangers 10 and 26 are similarly structured and are advantageously composed of an inlet 28 in the form of drip or spray nozzles, a brine/air heat exchanging means 30 , e.g., densely folded carton paper or packed particles. The lower portion of the heat exchangers constitute a brine reservoir 32 . For a more effective operation, there is installed an air blower 34 for introducing forced ambient air in the drip portion 35 .
The cold brine accumulated at the reservoirs 32 are recycled back to the brine flash evaporator 2 and to the condensor 20 , via conduits 36 , 38 , respectively, by means of pumps 40 , 42 .
In dry climate areas, the environmental vapor pressure may be lower than the vapor pressure inside the air-conditioned enclosed space. In such a case, the compressor 16 becomes a turbine, i.e., supplies, instead of consumes, energy.
In humid areas where the LH is dominant, ventilation will merely introduce more vapor into the enclosed space. When, however, the water is used to further cool down the brine at the flash evaporator 2 and heat exchanger 10 , dehumidifying and cooling of air at the air/brine heat exchangers 26 , is achieved.
In the event that most of the heat load is SH, the brine will reach a point where it will no longer absorb water vapor. Since the compressor 16 continues to suck vapor from the vapor chamber 12 , for the purpose of cooling, fresh water should be supplied through water inlet 6 .
Referring to FIG. 2, there is illustrated a further embodiment in which there is provided a flash evaporator 44 having two chambers, a brine flash chamber 46 and a water flash chamber 48 . A water conduit 50 having an inlet port 52 located adjacent to the bottom of the chamber 48 leads into the brine flash chamber 46 , meanders therealong, and exits adjacent to the water level 54 in the water chamber 48 . A pump 56 effects the circulation of water through the conduit 50 . Instead of the illustrated conduit 50 , other types of heat exchangers could just as well be used.
Such a two-chamber flash evaporator has a thermodynamic advantage, in that the brine/water solution is only partly cooled by water, having a vapor pressure which is high relative to the solution and therefore the compressor 16 invests relatively less energy in compressing the vapor.
Otherwise, the system operates similarly to the system of FIG. 1 .
In order to avoid excessive dilution of the brine and to improve performance, a per-se known brine concentrator 58 can be added to the system shown in FIG. 3 .
The brine concentrator 58 communicates via conduit 60 with the reservoir 32 of the heat exchanger 26 to receive the diluted brine accumulated therein. The water extracted by the concentrator 58 is driven into the water flash chamber 48 of the water/brine heat exchanger 44 via conduit 62 and pump 64 .
In cold climate areas, the system according to the present invention can be used for space heating by providing a heat source. Accordingly, as further seen in FIG. 3, the water in the water flash chamber 48 of flash evaporator 44 originates from a heated source 66 , e.g., a water aquifer, and is circulated between the heated source 66 and the chamber 48 via conduits 68 and 70 , by means of a pump 72 .
Alternatively, or in addition, the brine in heat exchanger 10 absorbs heat and vapor from outside air and part of this heat is used for flushing the brine and part is transmitted via conduit 50 to the water where it is used for water evaporation. There may also be provided a further heat exchanger 74 , abutting the blower 34 for cooling the air by means of this heat exchanger, communicating via conduits 76 , 78 and circulating pump 80 with the water chamber 48 .
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes 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.
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The invention provides a heat pump/engine system having a water/brine flash evaporator in fluid communication with a first air/brine heat exchanger, a brine condenser in fluid communication with a second air/brine heat exchanger, and a vapor compressor/turbine connected on a fluid conduit leading from the flash evaporator to the brine condenser. Heat/pump methods are also provided herein.
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BACKGROUND OF THE INVENTION
The present invention relates generally to hydraulic mining particularly to an improved hydraulic mining tool and method of hydraulically mining unconsolidated mineral formations such as tar sands.
Recent technology has been developed which permits the recovery of subterranean mineral deposits by use of hydraulic mining techniques. Hydraulic mining techniques basically involve the use of a high velocity liquid stream discharged directly into the subterranean mineral deposit to dislodge minerals from their surrounding mineral bed. The freed minerals and the discharged liquid stream form a resultant slurry that may be pumped by conventional pumping apparatus upward to ground surface for subsequent processing by surface separation systems. As the slurry is removed from the mineral formation, a mining cavity, or void, is formed in the mineral bed which, dependent upon the size and type of the particular formation, may extend to 100 feet in diameter throughout the height of the mineral bed. Examples of such hydraulic mining tools are disclosed in U.S. Pat. No. 3,951,457 issued to Redford and U.S. Pat. No. 3,439,953 issued to Pfefferle and my U.S. Pat. No. 4,275,926, the disclosures of which are hereby incorporated herein by reference.
To date, such hydraulic mining techniques have been primarily utilized to recover minerals such as uranium, coal, or potash, which typically possess sufficient consolidation in their natural formation state so that the mining cavity or void is formed in the subterranean formation, the surrounding mineral bed remains in its stabilized consolidated condition, thereby defining a "clean" mining cavity. Thus, in such consolidated formations, the overburden is continuously supported by the consolidated mineral bed and the hydraulic mining tool may be freely rotated and vertically reciprocated within the borehole and mining cavity throughout the mining process. However, in the hydraulic mining of unconsolidated mineral formations where the overburden is also unconsolidated, unique mining problems exist, which to a great extent have rendered the existing hydraulic mining tool technologyp potentially commercially uneconomical because of the caving of nonmineral-bearing overburden into the cave-in and mixing with the ore, thus decreasing the value of mined materials brought to the surface.
In contrast to the above-mentioned consolidated mineral formations, unconsolidated formations such as tar sands, typically are non-uniform in composition and often fail to possess the necessary degree of integrity and stabilization to maintain a cap over the mining cavity during the hydraulic mining operation. Failure of the unconsolidated overburden formations and, in particular, barren overburden has a serious effect on the economics of subterranean mining when the overburden cavens in and mixes with the ore. The compressive forces generated by the weight of the unconsolidated overburden will cause a cave-in effect as the ore body is being mined. As the subjacent portions of the tar sand mineral bed are removed during the hydraulic mining process, the overburden compressive force balance within the mineral formation is disturbed which, due to only minimal cementation integrity between the individual overburden sand grains, often results in a "cave-in" or "compaction" whereby the surrounding mineral bed catastrophically falls into the mining cavity and around the mining device.
When hydraulically mining in relatively shallow unconsolidated formations approximately 100 feet below ground surface, the removal of the mineral bed often permits the overburden to migrate downward into the borehole and the mining cavity, wherein it mixes with the mined mineral slurry and is subsequently transported upward to ground surface during the mining process. As will be recognized, the mining of the non-mineral bearing overburden reduces the overall efficiency of the mining process. Substantial mining of the overburden decreases the cost effectiveness of the hydraulic mining process to a degree such that the process is commercially infeasible. Further, in those instances where the downward migration of the overburden is acute, a general subsidence of the overburden may be experienced whereby the overburden fails to support the necessary surface mining equipment.
Alternatively, when mining in deep unconsolidated mineral formations (i.e., greater than 500 feet below ground surface), individual sand grains located proximate the borehole often dislodge from the mineral bed by frictional drag forces exerted by the rotating mining tool and drill string. Through prolonged duration, these frictional drag forces often disturb the fragile cementation forces existing between sand grains and result in the entire surrounding mineral bed falling in and compacting around the mining tool. Due to the depth at which the mining operation is occurring, substantial pressure is applied along the entire length of the mining tool. A partial collapse of the overburden could cause a canting of the mining tool, producing pressures on the sides thereof sufficient to prevent rotation of the mining tool, thus requiring intermittent shut-down of the drilling operation. In extreme instances collapses of the overburden have caused a complete structural failure or twist off of the mining tool within the formation. Such intermittent discontinuance of the mining operation significantly decreases overall operating efficiency while a twist-off condition typically results in the mining tool being irretrievably lost within the mineral formation.
The present inventor's copending U.S. patent application, Ser. No. 467,496, filed Feb. 18, 1983, and entitled APPARATUS AND METHOD OF HYDRAULICALLY MINING CONSOLIDATED MINERAL FORMATIONS, now abandoned, hereby incorporated by reference herein, discloses a hydraulic mining tool that includes means for injecting a suitable liquid bonding agent radially outward in the overburden formation from a borehole. The bonding agent cures to form a generally disc-shaped stabilized zone of overburden around the borehole above the mining cavity. The stabilized zone forms a rigid platform that artificially increases the cementation forces existing between the individual particles in the overburden, thereby increasing the suport of the overburden and preventing downward migration of the overburden during the mining operations. However, experience has shown that efficient hydraulic mining of some mineral deposits, particularly certain tar sands deposits, requires even more support of the overburden than is ordinarily possible by injecting a bonding agent from the mining tool radially outward into the mineral formation.
Thus, there exists a substantial need in the art for an improved hydraulic mining method and apparatus specifically adapted for use in unconsolidated mineral formations to prevent downward migration of the overburden, reduce frictional drag forces exerted on the mineral bed, and prevent generation of extremely high torsional forces on the mining tool during the hydraulic mining operation.
SUMMARY OF THE INVENTION
The present invention comprises an improved apparatus and method of hydraulically mining which specifically addresses and alleviates the above-referenced deficiencies associated with the hydraulic mining of unconsolidated mineral formations. More particularly, the present invention provides an apparatus and method for using fluid pressure in the mining cavity and borehole to support an artificially consolidated, stabilized region or zone extending radially outward into the formation in a generally disc-shaped configuration adjacent the overburden mineral bed interface.
In the preferred embodiment, the stabilized zone is formed by injecting a suitable liquid bonding agent radially outward in the formation. After a sufficient curing period, the bonding agent bonds the individual overburden particles together to yield a consolidated, stabilized region above the ore body. By such a procedure, the stabilized region forms a rigid platform having artificially increased cementation forces between the individual formaion particles to increase the support of the overburden and prevent the downward migration of the overburden during mining operations. After the bonding agent has cured, a seal is formed around the mining tool and pressurized fluid is injected into the mining cavity below the stabilized zone. A predetermined pressure is maintained in the mining cavity throughout mining operations to support the overburden and above-ground equipment employed in the mining operations. A blowout prevention device maintains pressurization within the cavity during removal of the mining tool from the cavity and during return of the mining tool into the cavity.
BRIEF DESCRIPTION OF DRAWINGS
These and other features of the present invention will become more apparent upon reference to the drawings, wherein:
FIG. 1 is a cross-sectional view taken through a mineral formation depicting the overburden and mineral bed and illustrating a borehole from a ground surface to a depth adjacent the interface between the overburden and mineral bed; and
FIG. 2 is an enlarged cross-sectional view taken about the interface between the overburden and mineral bed of FIG. 1 and depicting the manner in which the stabilized consolidated region is formed in the formation and the manner in which a fluid pressure is maintained in the mining cavity and borehole.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a mineral formation 10 composed generally of an overburden 12 and a mineral bed 14, which by way of example, may comprise an unconsolidated tar sand formation. The overburden 12 and the mineral bed 14 are shown to have an interface 16 therebetween. Preparatory to the actual hydraulic mining operation, the initial step in the method of the present invention is formation of a borehole 18 which has an open end 20 at ground surface and which preferably extends a short distance beyond the interface 16 between the overburden 12 and the mineral bed 14. The borehole 18 may be formed by any conventional method, but in the preferred embodiment, the borehole 18 is formed by use of a conventional tri-cone bit sized to yield an effective borehole diameter of approximately 26 inches.
Subsequent to the formation of the borehole 18, a tubular drill casing 22 having, in the illustrated embodibment, outside diameter slightly less than the diameter of the borehole 18 is inserted therein to extend from the opening 20 to a position adjacent the lower end of the borehole 18. In a preferred embodiment of the invention, the casing 22 is a standard casing having an inside diameter of approximately 24 inches. The casing 22 is preferably formed of metal or a cement-like material and is maintained stationary within the formation 10 and centered within the borehole 18 by conventional means, such as the centralizer baskets 21 or casing shoes (not shown). Since the casing 22 extends throughout the length of the overburden 12, installation of the casing 22 substantially eliminates problems caused by overburden 12 falling into the borehole 18.
The casing 22 is preferably formed of a plurality of 20-foot casing sections 22a, 22b, 22c, etc. as shown in FIGS. 1 and 2. The 22a, 22b, etc., casings preferably are joined together by threaded interior and exterior flush joints 23. The lowermost joint 23a is preferably reverse threaded from the other joints 23 to permit the upper casing sections to be unscrewed from the lowermost casing section 22a.
After implacement of the casing 22, at least one, and preferably a plurality of conduits 24 are lowered into the borehole 18 outside the casing 22. The conduits 24 extend through the overburden 12 and the upper portion of the mineral deposit 14 into a mining cavity 26. The conduits 24 may be formed of any material such as metal pipes suitable for conducting high pressure fluid into the cavity 26.
Subsequent to the implacement of the casing 22 and the conduits 24, preferably the next step of the present invention is the formation of an artificially stabilized or consolidated zone 28 adjacent the interface 16 between the overburden 12 and mineral bed 14 to provide subjacent support for the overburden 12 during the mining process. Referring to FIGS. 1 and 2, the casing section 22a adjacent its lowermost end has a plurality radially outward of apertures 30 extending therethrough. The apertures 30 may be formed in the casing section 22a either during manufacture of the casing and, hence, prior to insertion of the casing 22 within the borehole 18 or subsequently after the casing section 22a is set in the formation 10 by use of conventional gun perforation or other downhole perforation techniques. As best shown in FIG. 2, the apertures 30 are preferably spaced from the lowermost end of the drill casing 22 and positioned so as to be in the general plane of or slightly above the overburden/mineral bed interface 16.
An expandable packer 32 indicated by the phantom lines in FIG. 2 is inserted downward from ground surface through the length of the casing 22 and rigidly positioned at the lowermost end thereof. The mechanical packer 32 is well-known in the art, and in this particular application, completely closes off, or blocks, the uppermost end of the casing section 22a vertically above the apertures 30. The mechanical packer 32 is lowered into the casing via a suitable tubing 23. Rotation of the mechanical packer 32 in one direction expands it to seal against the wall of the casing section 22a. A cement retainer 25 is placed around the outside of the casing section 22a to prevent material from rising in the borehole above the upper end of the casing section. With the packer 32 implaced within the casing 22, a suitable bonding agent may be pumped under pressure downward from ground surface through the tubing 21 below the mechanical packer 32. The apertures 30 direct the bonding agent radially outward into the formation 10 as indicated by the arrows adjacent the apertures 30 in FIG. 2. With the cement retainer 25 positioned around the casing section 22a as described above, controlling the injection pressure and the volume of the bonding agent introduced into the formation sequeezes the bonding agent radially outward into the formation to form the disc-shaped region 28 substantially co-axial with the borehole 18. A variety of bonding agents may be utilized for this purpose. Suitable bonding agents are characterized by remaining substantially pliable or fluid during the initial injection process to sufficiently migrate radially outward into the formation 10 and subsequently cure or harden to bond the injected formation into the substantially rigid consolidated region 28. Examples of such bonding agents are catalyst-activated silica jells such as that currently sold under the names "SAND FIX", a registered trademark of the Halliburton Company for a multi-step organic chemical resin process, or "SAND SET", a registered trademark of the Halliburton Company for a premixed plastic compound which hardens to form a strong impermeable consolidated zone.
In the preferred embodiment, the effective diameter of the artificially consolidated region 28 and, thus, the amount of bonding agent injected into the formation 10, may be predetermined to insure sufficient support for the overburden 12 to permit removal of the amount of mineral bed 14 desired to be mined in the hydraulic mining process. However, for the majority of hydraulic mining applications, it is anticipated that the effective diameter of the consolidated zone 28 will range from approximately 10 to 60 feet to prevent any downward migration or subsidence of the overburden 12 into the mineral bed 14.
Subsequent to the formation of the consolidated region 28, the mechanical packer 32 is removed from the interior of the drill casing 22 and a conventional drilling apparatus such as a tri-cone bit 39 mounted to a mining tool 36 may be lowered downward within the casing 22 and utilized to drill through the bonding agent in the lowerend of the casing section 22a and extend or drill the borehole 18 a desired depth into the mineral formation 14.
A drill string 34 is fitted with a plurality of annular dynamic seals 35, which each preferably include a collar 36 connected to the drill string 34 to retain a plurality of O-ring seals 37 between the drill string 34 and a protective sleeve 33. The O-ring seals 37 are formed of a suitable low-friction substance for forming a fluid-tight seal between the drill string 34 and the inside of the protective sleeve 33. The dynamic seals 35 are preferably spaced about 15 feet apart along the length of the drill string 34 within the protective sleeve 33 and permit rotation of the drill string 34 within the protective sleeve 33 while retaining fluid pressure in the cavity 26 and the casing 22. The seals 35 permit rotational and vertical movement of the drill string 34 within the protective sleeve 33 while providing sealing adequate to retain desired pressures inside the cavity 26. The drill string 34 with the hydraulic mining tool 38 mounted to the lower end thereof is inserted into the casing 22 and the protective sleeve 33.
Referring to FIGS. 2 and 3, a pair of blowout protector 40 are mounted near the upper end of the casing 22. The blowout protectors 40 each preferably include an expandable device 41 of a type commonly used in oil wells to maintain fluid pressurization control therein. The balloon device 41 is formed to have a generally annular configuration and is positioned around the drill string 34 and the protective sleeve 33 before inflation through a valve 42 and a pipe 44. A collar 43 mounted to the casing 22 retains the balloon device 41 in compression against the casing 22.
The devices 41 are deflated so that the dynamic seals 35 may be moved past the blowout protector 40 as the drill string is lowered or raised within the borehole 18. As best shown in FIG. 3, each blowout protector 40 completely encloses the dynamic seals 35 between the balloon device 41 and the collar 43 as the drill string 34 is raised or lowered in the casing 22. Therefore, vertical movement of the drill string 22 does not cause a loss of fluid pressure in the borehole 18 or the cavity 26.
After insertion of the drill string 34 with the seals 35 thereon into the sleeve 33 and inflation of the blowout protector 40, a pressurized fluid, such as air from a convenient above-ground source (not shown), is injected through the conduits 24 into the mining cavity 26. It has been fund that a pressure of 0.5 pounds per square inch for each vertical foot of overburden supported should be suitable for preventing the overburden from falling into the mining cavity 26. However, a given formation may require a greater or lesser pressure to adequately support the overburden.
The hydraulic mining tool 38 includes at least one nozzle 46, which directs a cutting jet of a suitable high pressure fluid, such as water from an above-ground source (not shown) into the mineral bed 14 to dislodge particles to be mined therefrom. The mining tool 38 may also include a plurality of nozzles such as the nozzle 46. The dislodged particles and the water form a slurry that is drawn into a plurality of orifices 48 for elevation to ground level by conventional pumping means (not shown). Removing the slurry from the cavity 26 increases the volume thereof so that air must be added through the conduits 24 to maintain the desired pressure.
The protective sleeve 33 extends through the casing 22 into the mining cavity 26. The lowermost end of the protective sleeve 33 is preferably 10 to 20 feet above the nozzles 46. The protective sleeve protects the drill string 34 and the mining tool 38 against damage that might result if a portion of the mineral formation 10 should collapse into the mining cavity. The protective sleeve 33 is raised as higher portions of the mineral deposit 14 are mined. The sleeve sections 33a, 33b, etc. are moved past the blowout protectors 40 in a manner similar to that described above for the sections of the drill string 34 with the attached dynamic seals 35.
After mining operations are complete, the drill string 34, mining tool 38 and protective sleeve 33 are removed from the casing 22. The upper casing sections 22b, 22c, etc. are rotated to disconnect them from the lowermost casing section 22a, which is ordinarily permanently set in the earth by the bonding agent. Therefore, the invention provides means for aligning and protecting the drill string 34 and mining tool 38 and requires a sacrifice of only one casing section.
The described embodiment is only exemplary of a presently preferred embodiment. Those skilled in the art may recognize modifications that are within the spirit of the invention. Accordingly, the true scope of the invention is to be determined with reference to the appended claims.
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A pressurized fluid is injected into a subterranean cavity in a mineral deposit to support the overburden during hydraulic mining operations. A dynamic seal between the drill string and a surrounding casing retains fluid pressure within the cavity as the drill string rotates during mining operations. A blowout protector retains fluid pressure within the cavity while the drill string is raised or lowered within the cavity when it is necessary to add or remove drill string sections.
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FIELD OF THE INVENTION
The present invention relates to an automatic focus adjustment apparatus and method used in various video cameras and the like.
BACKGROUND OF THE INVENTION
Auto-focus apparatuses for recent video cameras prevalently adopt a system which attains focus adjustment by detecting sharpness of a frame from a video signal obtained by photoelectrically converting an object image by an image sensing element or the like so as to obtain an AF (auto focus) evaluation value, and controlling a focus lens position so as to maximize the AF evaluation value.
As the AF evaluation value, a high-frequency component level of a video signal, which is extracted by a bandpass filter of a given frequency band, is generally used. That is, when a normal object image is sensed, the high-frequency component level increases as the focus lens position approaches an in-focus position. Hence, a point corresponding to the maximum high-frequency component level is determined as an in-focus position.
An actual video camera that can sense a still image executes AF control as follows. That is, the focus lens is controlled to smoothly maintain an in-focus position during monitoring before sensing a still image. When the user has pressed the release switch to sense a still image, the focus lens is controlled to quickly move to an in-focus position.
However, when the release switch for sensing a still image has half- and full-stroke positions, a blurred image may be recorded depending on the depression timing of the release switch by the user. In order to avoid such blurred image, the AF in-focus time is prolonged.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above situation, and has as its object to execute optimal lens control in response to a user's input especially in sensing a still image so as to prevent a blurred image from being captured.
According to the present invention, the foregoing object is attained by providing a focus adjustment apparatus, which attains focus adjustment by extracting, as a focal point voltage, a predetermined frequency component of a video signal obtained from an image sensor upon sensing an image of an object, and moving a focus adjustment member in an optical axis direction using a moving unit to maximize the focal point voltage, comprising:
a detector that detects two input states including a first input state, and a second input state which is set via the first input state; and
a controller that executes focus adjustment control for the first input state upon detection of the first input state, and selectively enables or disables the focus adjustment control for the first input state in accordance with a time elapsed from detection of the first input state until detection of the second input state, upon detection of the second input state.
According to the present invention, the foregoing object is also attained by providing a focus adjustment method, which attains focus adjustment by extracting, as a focal point voltage, a predetermined frequency component of a video signal obtained from an image sensor upon sensing an image of an object, and moving a focus adjustment member in an optical axis direction using a moving unit to maximize the focal point voltage, comprising:
monitoring a first input state of an input unit which can input two input states including the first input state, and a second input state which is set via the first input state;
executing focus adjustment control for the first input state upon detection of the first input state;
monitoring the second input state; and
selectively enabling or disabling the focus adjustment control for the first input state in accordance with a time elapsed from detection of the first input state until detection of the second input state, upon detection of the second input state.
Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a block diagram for explaining an example of an arrangement of a video camera according to an embodiment of the present invention;
FIG. 2 is a graph showing the relationship between the focus lens position and voltage level in automatic focus adjustment according to the embodiment of the present invention;
FIG. 3 is a flow chart associated with a main AF process in automatic focus adjustment according to the embodiment of the present invention;
FIG. 4 is a flow chart associated with a microstep drive operation in automatic focus adjustment according to the embodiment of the present invention;
FIG. 5 is a graph showing an elapsed time of the focus lens operation in automatic focus adjustment according to the embodiment of the present invention;
FIG. 6 is a flow chart associated with a hill-climbing operation in automatic focus adjustment according to the embodiment of the present invention;
FIG. 7 is a graph showing the relationship between the focus lens position and evaluation value in automatic focus adjustment according to the embodiment of the present invention;
FIG. 8 is a flow chart associated with a general AF operation in sensing a still image;
FIG. 9 is a flow chart associated with a still image AF process according to the embodiment of the present invention; and
FIG. 10 is a flow chart associated with an AF operation in sensing a still image according to the embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described in detail in accordance with the accompanying drawings.
An example of the arrangement of a video camera which can sense a still image according to an embodiment of the present invention will be described first. Referring to FIG. 1 , reference numeral 101 denotes a stationary first group lens; 102 , a zoom lens that attains zooming; 103 , an aperture; 104 , a stationary second group lens; and 105 , a focus compensation lens (to be referred to as a focus lens hereinafter) which has both a function of correcting movement of a focal plane upon zooming, and a focus adjustment function. Reference numeral 106 denotes an image sensing element such as a CCD or the like (to be referred to as a “CCD” hereinafter, but the present invention is not limited to the CCD); and 107 , a correlated double sampling/automatic gain controller (CDS/AGC) for sampling the output from the CCD 106 and adjusting its gain. Reference numeral 108 denotes a camera signal processing circuit for processing the output signal from the CDS/AGC 107 for a signal compatible to a still image recording device 109 (to be described below). Reference numeral 109 denotes a still image recording device which uses a semiconductor memory.
Reference numeral 110 denotes a lens motor as an actuator for moving the focus lens 105 ; and 111 , a lens driver for driving the motor 110 in accordance with a signal from an AF microcomputer 113 (to be described later). Reference numeral 112 denotes an AF evaluation value processing circuit for extracting a high-frequency component used in focus detection from the output signal of the CDS/AGC 107 ; and 113 , an AF microcomputer for controlling the driver 111 on the basis of the output signal from the AF evaluation value processing circuit 112 to drive the focus lens 105 , and switching AF control in accordance with an input from a still image release switch 114 .
Reference numeral 114 denotes the still image release switch, which can detect two states (half stroke, full stroke) in accordance with the degree of depression by the user. In this case, when the user presses the release switch 114 , the first state (to be referred to as a half-stroke state hereinafter) is detected first, and the second state (to be referred to as a full-stroke state hereinafter) is then detected. Reference numeral 115 denotes a monitor device which displays the output signal from the camera signal processing circuit 108 , and is used to monitor a sensed scene.
In the camera system with the arrangement shown in FIG. 1 , the AF microcomputer 113 normally executes automatic focus adjustment by moving the focus lens 105 so as to maximize the output signal level of the AF evaluation value processing circuit 112 , in order to focus on a monitored image (see FIG. 2 ). When the half-stroke state is detected upon depression of the release switch 114 , the AF microcomputer 113 executes an AF operation for still image sensing to search for an in-focus point, and controls the focus lens 105 to stop at the in-focus point. On the other hand, when the full-stroke state is detected, the AF microcomputer 113 stops the focus lens 105 , and issues a recording command to the still image recording device 109 . When the user wants to sense a still image of an object after focus adjustment, he or she need only wait for an in-focus state attained by the AF control while pressing the release switch 114 to its half-stroke position. On the other hand, when the user wants to sense a still image of an object immediately, he or she can press the release switch 114 to its full-stroke position.
The AF control which is done by the AF microcomputer 113 to monitor an image in this embodiment will be described in detail below with reference to FIGS. 3 to 7 .
FIG. 3 explains the overall operation of the monitor AF process. Step S 301 indicates the start of the process. In step S 302 , a microstep drive operation is made to determine whether or not an in-focus point is reached, and to determine a direction in which an in-focus point is present if the in-focus point is not reached. A detailed operation in this step will be described later with reference to FIG. 4 .
If it is determined in step S 303 that the in-focus position is reached in step S 302 , the flow advances to step S 309 to start an in-focus/re-drive determination process (to be described later). If the in-focus position is not reached in step S 302 , the flow advances to step S 304 . If it is determined in step S 304 that the direction is determined in step S 302 , the flow advances to step S 305 to perform hill-climbing drive control; otherwise, the flow returns to step S 302 to continue the microstep drive operation. In step S 305 , the focus lens undergoes high-speed hill-climbing drive control in a direction to increase the evaluation value. A detailed operation in this case will be described later with reference to FIG. 6 .
If it is determined in step S 306 that the evaluation value has exceeded a peak in step S 305 , the flow advances to step S 307 ; otherwise, the flow returns to step S 305 to continue the hill-climbing drive operation. In step S 307 , the focus lens is returned to the focus lens position corresponding to the peak evaluation value during the hill-climbing drive operation. If it is determined in step S 308 that the focus lens is returned to the focus lens position corresponding to the peak evaluation value in step S 307 , the flow returns to step S 302 to execute the microstep drive operation again. If it is determined in step S 308 the focus lens is not returned to the focus lens position corresponding to the peak evaluation value in step S 307 , the flow returns to step S 307 to continue the operation for returning the lens to the peak position.
The in-focus/re-drive determination process which starts in step S 309 will be described below. In step S 309 , the AF evaluation value at the in-focus position fetched during the microstep drive operation in step S 302 is stored, as will be described later. In step S 310 , the latest AF evaluation value is fetched. In step S 311 , the AF evaluation value stored in step S 309 is compared with the latest AF evaluation value fetched in step S 310 to see if a variation of the AF evaluation value is large. If the AF evaluation value varies largely, it is determined that the focal point position has changed due to a change in object position, a change in object to be sensed, or the like. Hence, the flow returns to step S 302 to restart the microstep drive operation. If the AF evaluation value does not vary, the flow advances to step S 312 . In step S 312 , the focus lens 105 is stopped, and the flow returns to step S 310 to continue the in-focus/re-drive determination process.
The microstep drive operation will be described below with reference to FIG. 4 . Step S 401 indicates the start of the process. In step S 402 , the AF evaluation value is fetched from the AF evaluation value processing circuit 112 . If it is determined in step S 403 that the evaluation value fetched in step S 402 is smaller than the previous evaluation value, the flow advances to step S 404 ; otherwise, the flow advances to step S 405 . In step S 404 , the focus lens 105 is driven by a predetermined amount in a direction opposite to the previous drive operation. On the other hand, in step S 405 the focus lens 105 is driven by a predetermined amount in the same direction as the previous drive operation. If it is determined in step S 406 that the same drive direction of the focus lens 105 is successively detected a predetermined number of times, the flow advances to step S 410 ; otherwise, the flow advances to step S 407 .
It is checked in step S 407 if reciprocal movement of the focus lens is repeated within a given area a predetermined number of times. If reciprocal movement is repeated, the flow advances to step S 409 ; otherwise, the flow advances to step S 408 to end the current process. In this case, in the aforementioned process shown in FIG. 3 , since NO in step S 303 and YES in step S 304 , the flow advances to step S 305 to execute the hill-climbing drive operation. On the other hand, it is determined in step S 409 that an in-focus point is detected, and the process ends. In this case, in the aforementioned process shown in FIG. 3 , since YES in step S 303 , the flow advances to step S 309 and subsequent steps to execute the in-focus/re-drive determination process.
FIG. 5 shows a lapse of time of the aforementioned focus lens operation. Evaluation value A corresponding to a change accumulated on the CCD during a period A is fetched at time T A , and evaluation value B corresponding to a charge accumulated on the CCD during a period B is fetched at time T B . At time T B , evaluation values A and B are compared. If A<B, the focus lens 105 is driven in the same direction as the previous focus lens drive direction; if A>B, the focus lens 105 is driven in the opposite direction.
The hill-climbing drive operation will be described below using FIG. 6 . Step S 601 indicates the start of the process. In step S 602 , the AF evaluation value is fetched from the AF evaluation value processing circuit 112 . If it is determined in step S 603 that the evaluation value fetched in step S 602 is larger than the previous evaluation value, the flow advances to step S 604 ; otherwise, the flow advances to step S 606 . In step S 604 , the focus lens 105 is driven by a predetermined amount at a predetermined speed in the same direction as the previous drive operation, and the current process ends. The flow then advances to step S 306 in FIG. 3 . In this case, since NO in step S 306 , the flow returns to step S 305 to repeat the process in FIG. 6 .
On the other hand, if it is determined in step S 606 that the evaluation value is not decreased after a peak, the flow advances to step S 607 ; otherwise, the process ends, and the flow advances to step S 306 in FIG. 3 . In this case, since YES in step S 306 , the flow advances to step S 307 . In step S 607 , the focus lens 105 is driven at a predetermined speed in a direction opposite to the previous drive operation, and the current process ends. Then, the flow advances to step S 306 in FIG. 3 . In this case, since NO in step S 306 , the flow returns to step S 305 to repeat the process in FIG. 6 .
The focus lens operation determined in step S 606 above will be described below with reference to FIG. 7 . In this case, since the evaluation value is decreased at A after passing a peak (YES in step S 606 ), it is determined that an in-focus point is found, and the hill-climbing drive operation ends. After the focus lens 105 is returned to the peak position of the AF evaluation value in steps S 307 and S 308 , the flow returns to step S 302 to start the microstep drive operation. On the other hand, since the evaluation value is decreased at B without passing any peak (NO in step S 606 ), it is determined that the lens is driven in a wrong direction, and the drive direction is reversed, thus continuing the hill-climbing drive operation.
As described above, the focus lens 105 is moved while repeating in-focus/re-drive determination→microstep drive→hill-climbing drive microstep drive→in-focus/re-drive determination. The AF microcomputer 113 of the camera controls to always maximize the AF evaluation value, thereby maintaining an in-focus state of a monitor image.
On the other hand, according to an example of an AF operation in sensing a still image, the focus lens 105 is either stopped at that position or stopped at a peak position after a search for the in-focus position, in accordance with the operation state of the release switch 114 for sensing a still image. This general operation example will be described below with reference to FIG. 8 . This process is also executed by the AF microcomputer 113 . Step S 801 indicates the start of the process. In step S 802 , the aforementioned monitor AF process is executed.
In step S 803 , the release switch 114 is monitored. If the release switch 114 has been pressed to its full-stroke position, the flow jumps to step S 808 and subsequent steps. In step S 808 , the focus lens 105 is stopped at the current position, thus ending the AF process. If the release switch 114 has not been pressed to its full-stroke position, the flow advances to step S 804 . It is checked in step S 804 if the release switch 114 has been pressed to its half-stroke position. If the release switch 114 has been pressed to its half-stroke position, the flow advances to step S 805 . It is checked in step S 805 if a predetermined period of time has elapsed at the half-stroke position (whether the user really wants to hold the release switch at its half-stroke position or the half-stroke state is detected on the way to the full-stroke position). If the predetermined period of time has elapsed, the flow advances to step S 806 to execute a still image AF process. On the other hand, if the release switch has not been pressed to its half-stroke position or the predetermined period of time has not elapsed, the flow returns to step S 802 to continue the monitor AF process. It is checked in step S 807 if an in-focus point is detected in the still image AF process. If an in-focus point is detected, the flow advances to step S 808 to stop the AF control, thus ending the process.
The process in FIG. 9 explains the still image AF process in step S 806 in FIG. 8 . Step S 901 indicates the start of the process. It is determined in step S 902 whether or not the focus lens 105 is at a stop. If it is determined in step S 902 that the focus lens 105 is at a stop, the flow advances to step S 903 . In step S 903 , the focus lens begins to be driven toward the closest distance side, thus ending the current process.
If it is determined in step S 902 that the focus lens is moving, the flow advances to step S 905 to check if the focus lens 105 is moving toward the closest distance side. If it is determined in step S 905 that the focus lens 105 is moving toward the closest distance side, the flow advances to step S 906 . In step S 906 , the AF evaluation value is monitored. If the AF evaluation value is decreased, the flow advances to step S 907 . In step S 907 , the focus lens begins to be driven toward the infinity side, thus ending the current process. If it is determined in step S 906 that the AF evaluation value is not decreased, the current process directly ends.
If it is determined in step S 905 that the focus lens 105 is moving toward the infinity side, the flow advances to step S 908 . In step S 908 , a change in AF evaluation value is monitored. If the AF evaluation value has exceeded a peak, the flow advances to step S 909 . In step S 909 , the focus lens is moved to and stopped at a focus lens position at which the peak of the AF evaluation value is detected in step S 908 , thus ending the still image AF process. If it is determined in step S 908 that the AF evaluation value has not exceeded a peak, the current process ends. In this way, the peak of the AF evaluation value can be detected at high speed.
As described above, during monitoring before sensing an image, the focus lens is controlled to smoothly maintain an in-focus state. Upon depression of the release switch 114 , the focus lens 105 is controlled to reach an in-focus position at high speed, thereby AF control operations suited to individual situations are executed.
The full-stroke state of the release switch 114 for sensing a still image is detected only after the half-stroke state. For this reason, if an AF search operation starts immediately after detection of the half-stroke state, a blurred image is recorded if the release switch 114 is immediately pressed to its full-stroke position. To solve this problem, the control may wait for a predetermined period of time after detection of the half-stroke state, and the AF search operation may start after it is confirmed that the release switch is not pressed to its full-stroke position. However, with this control, since the AF search operation cannot start immediately after detection of the half-stroke state, the AF in-focus time is prolonged.
The control of the camera AF microcomputer according to the present invention will be described in detail below using FIG. 10 . This process is executed by the AF microcomputer 113 . Step S 1001 indicates the start of the process. Step S 1002 corresponds to the aforementioned monitor AF process. In step S 1003 , the release switch 114 is monitored. If the release switch 114 has not been pressed to its half-stroke position, the flow returns to step S 1002 to continue to the monitor AF process. If the release switch 114 has been pressed to its half-stroke position, the flow advances to step S 1004 . In step S 1004 , the current focus lens position is stored in a memory in the AF microcomputer 113 .
In step S 1005 , the aforementioned still image AF process is executed. It is checked in step S 1006 if the release switch has been pressed to its full-stroke position. If the release switch has not been pressed to its full-stroke position, the flow advances to step S 1007 . It is checked in step S 1007 if an in-focus point is detected. If an in-focus point is not detected, the flow returns to step S 1005 to continue the still image AF process. If an in-focus point is detected, the flow advances to step S 1008 to stop the AF process.
If it is determined in step S 1006 that the release switch has been pressed to its full-stroke position, the flow advances to step S 1010 to determine whether or not a predetermined period of time has elapsed after detection of the half-stroke state. This predetermined period of time is experimentally determined based on time periods detected as the half-stroke state upon depressing the release button to its full-stroke position. If the predetermined period of time has not elapsed yet, it is determined that the user originally wants to press the release switch to its full-stroke position, and the focus lens 105 is returned to the focus lens position stored in the microcomputer 113 , since the focus lens position at the beginning of depression of the release switch 114 is optimal. On the other hand, if the release switch 114 has been pressed to its full-stroke position after an elapse of the predetermined period of time or more, it is determined that the user wants to capture the current image, and the focus lens 105 is stopped at the current focus lens position.
In this way, since the AF search operation can start immediately after detection of the half-stroke state in accordance with the release switch 114 for sensing a still image, the AF in-focus time can be shortened. When the full-stroke state is detected within a predetermined period of time after detection of the half-stroke state, it is determined that the user originally wants to press the release switch to its full-stroke position, and the focus lens 105 is returned to the focus lens position saved at the beginning of the AF process. In this way, the AF search operation can be prevented from being erroneously started in response to detection of the half-stroke state on the ways to the full-stroke position and, hence, a blurred image can be prevented from being captured during the search operation. Hence, an appropriate image can be recorded, and the image sensing time can be effectively shortened.
The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore to apprise the public of the scope of the present invention, the following claims are made.
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A focus adjustment apparatus, which attains focus adjustment by extracting, as a focal point voltage, a predetermined frequency component of a video signal obtained from an image sensor upon sensing an image of an object, and moving a focus adjustment member in an optical axis direction using a moving unit to maximize the focal point voltage, has a detector that detects a half-stroke state of a shutter button, and a full-stroke state which is set via the half-stroke state, and a controller that executes focus adjustment control for the half-stroke state upon detection of the half-stroke state, and selectively enables or disables the focus adjustment control for the half-stroke state in accordance with a time elapsed from detection of the half-stroke state until detection of the full-stroke state, upon detection of the full-stroke state.
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TECHNICAL FIELD
[0001] The present invention relates to wireless communication systems and method.
BACKGROUND
[0002] Some mobile network operators are investigating the possibility of providing home and/or small area coverage for a limited number of users using a small base station, commonly called a “femto” base station (or femto NodeB for WCDMA or femto eNodeB (E-UTRAN NodeB) for long term evolution (LTE)). Other common names are Home NodeB (HNB) for WCDMA or Home eNodeB (HeNB) for LTE.
[0003] A femto base station may provide normal LTE/WCDMA coverage for end users in a so called femto cell, and may be connected to the mobile operator's network using some kind of IP based transmission. One alternative is to use fixed broadband access (e.g. xDSL or Cable) to connect the femto base station to the network.
[0004] In some systems (e.g., LTE systems) the coverage area (i.e., femto cell) of a femto base station may overlap with the cell of a large base station, commonly called a “macro” base station, and the femto base station may use the same frequency spectrum (or part of the same frequency spectrum) as the macro base station. Accordingly, at times, the users of the femto and/or macro base station may experience uplink and/or downlink interference. This interference is referred to as “macro-femto interference”. In this document, for purposes of brevity, the overlaying cellular network is always referred as “macro” layer, even though it may consist of both macro, micro and pico cells.
[0005] Thus, there exists a need to reduce this macro-femto interference.
SUMMARY
[0006] In one aspect, the patent provides a method performed by a first base station (e.g., a macro base station) for reducing interference in a communication system comprising the macro base station and a second base station (e.g., a femto base station) located within or near a cell serviced by the macro base station, wherein the macro base station is allocated a frequency spectrum and the femto base station is allocated a frequency spectrum that at least partially overlaps with the frequency spectrum allocated to the macro base station. In some embodiments, the method performed by the macro base station includes: (a) determining a performance metric; (b) comparing the determined performance metric to a predetermined threshold; and (c) determining whether to assign to a user terminal a resource block that is (i) within the frequency spectrum allocated to the femto base station or (ii) within a time slot allocated to the femto base station, characterized in that this determination is based, at least in part, on the result of the comparison of the performance metric with the predetermined threshold.
[0007] The bandwidth of the frequency spectrum allocated to the femto base station may be smaller than the bandwidth of the frequency spectrum allocated to the macro base station and the frequency spectrum allocated to the femto base station may completely fall within the frequency spectrum allocated to the macro base station.
[0008] In some embodiments, at least a portion of the frequency spectrum allocated to the macro base station does not overlap with the frequency spectrum allocated to the femto base station, the performance metric corresponds to an amount of the non-overlapping frequency spectrum that is currently available for use, and the step of determining whether to assign to the user terminal a resource block that is within the frequency spectrum allocated to the femto base station comprises determining whether the amount of the non-overlapping frequency spectrum that is currently available for use is (a) greater than the predetermined threshold or (b) greater than or equal to the predetermined threshold. The macro base station may assign to the user terminal a resource block that is within the frequency spectrum allocated to the femto base station if, and only if, the amount of the non-overlapping frequency spectrum that is currently available for use is (a) less than the threshold or (b) less than or equal to the threshold.
[0009] In some embodiments, steps (a) through (c) are performed in response to receiving a request from a UE. Also, in some embodiments, the macro base station or another node in the network (e.g., a gateway node) may control an active frequency spectrum of the femto base station based, at least in part, on a resource need of the macro base station.
[0010] In some embodiments, the above mentioned performance metric may correspond to the number of available resource blocks that are not within the frequency spectrum allocated to the femto base station, and the step of determining whether to assign to the user terminal a resource block that is within the frequency spectrum allocated to the femto base station comprises determining whether the number of available resource blocks is (a) less than the predetermined threshold or (b) less than or equal to the predetermined threshold.
[0011] In another aspect, the invention provides a communication system in which interference (e.g., macro-femto interference) is reduced. In some embodiments, the communication system includes: a first base station (e.g., a macro base station) servicing a first coverage area, the macro base station being allocated a frequency spectrum for servicing the first coverage area; and a second base station (e.g., a femto base station) servicing a second coverage area, the femto base station being allocated a frequency spectrum for servicing the second coverage area, wherein the second coverage area at least partially overlaps with the first coverage area, the frequency spectrum allocated to the femto base station at least partially overlaps with the frequency spectrum allocated to the macro base station, and the macro base station is configured to avoid using (i) a portion of its allocated frequency spectrum that overlaps with frequency spectrum allocated to the femto base station and/or (ii) time slots allocated to the femto base station, unless performance reasons require the use of one or more of the time slots and/or frequencies allocated to the femto base station.
[0012] In some embodiments, the bandwidth of an active frequency spectrum of the femto base station is controlled based, at least in part, on (1) a capacity need of the femto base station and/or (2) a capacity need of the macro base station. For example, the bandwidth of the active frequency spectrum of the femto base station may be increased upon a determination that (1) the capacity need of the femto base station meets or exceeds a threshold and/or (2) the capacity need of the macro base station is less than or equal to a threshold. The macro base station may be configured to avoid utilizing only the frequencies that fall within the active frequency spectrum of the femto base station. Accordingly, the macro base station may include a storage unit that stores information identifying the femto base station's active frequency spectrum.
[0013] In some embodiments, the macro base station is further configured to: (a) determine a performance metric; (b) compare the determined performance metric to a predetermined threshold; and (c) determine whether to assign to a user terminal a resource block that falls within frequency spectrum allocated to the femto base station, characterized in that this determination is based, at least in part, on the result of the comparison of the performance metric with the predetermined threshold. The performance metric may correspond to the amount of that portion of the frequency spectrum allocated to the macro base station that does not overlap with the frequency spectrum allocated to the femto base station that is currently available for use
[0014] In still another aspect, the invention provides a base station that is configured to reduce the interference (e.g., macro-femto interference). In some embodiments, the base station includes means for reducing interference, characterized in that the means for reducing the interference comprises resource avoiding means for avoiding using only certain resources unless performance reasons require the use of one or more of the certain resources, wherein the certain resources include: (i) frequencies within a frequency spectrum allocated to a second base station and/or (ii) time slots allocated to the second base station.
[0015] The resource avoiding means may include means for: (a) determining a performance metric; (b) comparing the determined performance metric to a predetermined threshold; and (c) determining whether to assign to a user terminal a resource block that is (i) within the frequency spectrum allocated to the second base station or (ii) within a time slot allocated to the second base station, characterized in that this determination is based, at least in part, on the result of the comparison of the performance metric with the predetermined threshold. The determination may be further based on one more downlink CQI values received from the user terminal and/or one or more uplink CQI values estimated by the base station. The performance metric may correspond to a current amount of frequency spectrum that is available for the macro base station to assign to user terminals.
[0016] The above and other aspects and embodiments are described below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements.
[0018] FIG. 1 illustrates a system according to an embodiment of the invention.
[0019] FIG. 2 illustrates different resource blocks.
[0020] FIG. 3 illustrates an example frequency spectrum allocation according to an embodiment.
[0021] FIG. 4 illustrates an example frequency spectrum allocation according to another embodiment.
[0022] FIG. 5 is a flow chart illustrating a process according to an embodiment of the invention.
[0023] FIG. 6 is a flow chart illustrating a process according to an embodiment of the invention.
[0024] FIG. 7 is a functional block diagram of a macro base station according to some embodiments of the invention.
DETAILED DESCRIPTION
[0025] Referring to FIG. 1 , FIG. 1 illustrates a system 100 according to some embodiments of the invention. As illustrated in FIG. 1 , system 100 includes a macro base station 102 having a coverage area 103 and a femto base station 104 having a coverage area 105 . As further illustrated, at least a portion of coverage area 105 (or “cell 105 ”) is within cell 103 .
[0026] Macro base station 102 may be configured to communicate with user equipment (UE) 110 (e.g., UE 110 b and/or 110 c ) using a frequency spectrum having a certain bandwidth. For example, base station 102 may be configured to communicate with UEs 110 using a frequency spectrum having a bandwidth of 20 MHz (e.g., a frequency spectrum of 700 MHz to 720 MHz). Macro base station 102 may be configured to allocate resource blocks (RBs) to a UE (e.g., UE 110 c ) for downlink and uplink communications, as illustrated in FIG. 2 . In the exemplary FIG. 2 , the differently shaded blocks represent different UEs and their allocated RBs in the frequency and time domains. Accordingly, an RB may have a frequency component and a time component. RBs may be allocated to a UE based on signal quality. For example, a UE 110 may report to macro base station 102 a channel quality indicator (CQI) value that represents the quality of a downlink signal. Similarly, base station 102 may estimate a CQI value that represents the quality of an uplink signal received from UE 110 . Base station 102 can use this information to avoid scheduling the UE 110 on RBs that experience bad quality.
[0027] The maximum number of RBs in the frequency domain is dependent on the bandwidth of the available frequency spectrum. For example, with a bandwidth of 20 MHz, the maximum number of RBs in the frequency domain is 100, and with a bandwidth of 10 MHz the maximum number of RBs in the frequency domain is 50.
[0028] Like macro base station 102 , femto base station 104 may be configured to communicate with user equipment (UE) 110 (e.g., UE 110 a ) using a frequency spectrum having a certain bandwidth. For example, femto base station 104 may be configured to communicate with UEs 110 using a frequency spectrum having a bandwidth of 5 MHz (e.g., a frequency spectrum of 715 MHz to 720 MHz). Also, like macro base station 102 , femto base station 104 allocates resource blocks to UEs.
[0029] In those cases where the frequency spectrum used by the femto base station at least partially overlaps with the frequency spectrum used by macro base station 102 , there is a relatively large probability of macro-femto interference. The present invention aims to reduce this interference. In one aspect, the interference is reduced by dynamically using the spectrum available.
[0030] For the sake of illustration, we shall describe an embodiment of the invention in the case where macro base station 102 is allocated a downlink frequency spectrum of 700 MHz-720 MHz, and femto base station is allocated a downlink frequency spectrum of 715 MHz-720 MHz (see FIG. 3 ). Accordingly, in this example, the bandwidth of the spectrum allocated to femto base station 104 is less than the bandwidth of the spectrum allocated to macro base station 102 , and the spectrum allocated to femto base station 104 completely falls within the spectrum allocated to base station 102 .
[0031] In this scenario, macro base station 102 is configured to avoid using the overlapping part of the spectrum (i.e., 715 MHz to 720 MHz). By doing so, the macro base station 102 effectively limits the downlink interference towards underlying femto base stations 104 .
[0032] Macro base station 102 may be configured to avoid using the overlapping part of the spectrum (i.e., the portion of its spectrum that is shared with femto) by configuring macro base station 102 to use such shared portion if, and only if, certain criteria are satisfied. For example, macro base station 102 may be configured to use the shared portion of its spectrum if, and only if, the amount of the non-shared frequency spectrum (e.g., the number of RBs available from the non-shared portion of its spectrum—700 MHz to 715 MHz, in the example shown) is less than or equal to a threshold. For instance, if there are no RBs available from the non-shared portion of the spectrum, then macro base station 102 may use an RB that falls within the shared portion of the spectrum. In such an embodiment, macro base station 102 must know what portion of its spectrum is shared with femto. Accordingly, information identifying the spectrum allocated to femto base station 104 may be stored in a storage unit accessible to macro base station 102 .
[0033] Referring now to FIG. 4 , FIG. 4 illustrates an alternative frequency spectrum allocation between macro base station 102 and femto base station 104 . As in the previous embodiment, macro base station 102 may be allocated a 20 MHz bandwidth frequency spectrum (e.g., 700 MHz to 720 MHz). But in this embodiment, femto base station 104 may be allocated a bandwidth of 10 MHz (e.g., 710 MHz to 720 MHz). Additionally, in this embodiment, femto base station 104 can be dynamically configured to use less than all of the bandwidth allocated to it. That is, femto base station 104 may be configured to not use a portion of its allocated spectrum. The portion of the total allocated spectrum that femto base station 104 is configured to use is referred to as the “active” spectrum. As a specific example, at time t=0, femto base station 104 may have been allocated a frequency spectrum of 710-720 MHz, but also may have been configured to use only the frequency range 712.5-720, which is referred to as the active spectrum.
[0034] In this embodiment, to reduce interference, macro base station 102 is configured to avoid using the portion of the femto base station 104 's active spectrum that overlaps with macro base station's spectrum. In the specific example shown in FIG. 4 , macro base station 102 is configured to avoid using RBs that fall within the 712.5-720 MHz spectrum.
[0035] As before, macro base station 102 may be configured to avoid using the portion of the femto base station 104 's active spectrum that overlaps with the macro base station's spectrum (i.e., the portion of its spectrum that is actively shared with femto) by configuring macro base station 102 to use such actively shared portion if, and only if, certain criteria (e.g., performance criteria) are satisfied. For example, macro base station 102 may be configured to use the actively shared portion of its spectrum if, and only if, there are no RBs available from the non-shared portion of its spectrum (i.e., 700 MHz to 712.5 MHz, in the example shown). In such an embodiment, macro base station 102 must know what portion of its spectrum is actively shared with femto. Accordingly, information identifying the femto's active spectrum may be stored in a storage unit accessible to macro.
[0036] An advantage of this embodiment is that the femto's active spectrum may change over time to accommodate changes in load. For example, the femto's active spectrum may change based on capacity needs of femto base station 104 and/or macro base station 102 . For instance, if the capacity need of macro base station 102 increases greatly, macro base station 102 (or another node) may instruct femto base station 104 to reduce its active spectrum. In order for macro base station 102 to avoid using femto's active spectrum, macro base station 102 should be informed of changes to the femto's active spectrum (e.g., via an interface between base stations, in LTE this could be via the X2 interface) so it can store and use this information to avoid using RBs that fall within the femto's active spectrum.
[0037] When macro base station 102 uses the portion of its allocated spectrum that is shared with femto base station 104 , macro base station 102 may select the UEs to which RBs from the overlapping part of the spectrum are allocated based on downlink CQI values received from the UEs and uplink CQI values estimated by macro base station 102 . For example, when macro base station 102 receives from a UE a bad downlink CQI value for an RB that is within the portion of macro's spectrum that is shared with femto base station 104 , macro base station 102 will not allocate to the UE RBs from the overlapping part of the spectrum because, based on the CQI, it is likely the UE is close to a femto base station 104 .
[0038] Referring now to FIG. 5 , FIG. 5 is a flow chart illustrating a process 500 according to an embodiment of the invention. Process 500 may begin in step 502 , where a frequency spectrum is allocated to macro base station 102 (e.g., 700 MHz-720 MHz). In step 504 , a frequency spectrum is allocated to femto base station 104 (e.g., 715 MHz-720 MHz). Additionally or alternatively, time slots may be allocated to femto base station 104 . In step 506 , macro base station 102 stores in a storage unit (e.g., a database or file system) information identifying the frequency spectrum and/or time slots allocated to femto base station 104 . In step 508 , macro base station 102 is configured to avoid using (a) the frequency spectrum and/or (b) time slots allocated to femto base station 104 . For example, as discussed above, macro base station 102 may be configured to avoid using the overlapping part of the spectrum (i.e., the portion of its spectrum that is shared with femto) by configuring macro base station 102 to use such shared portion if, and only if, certain criteria (e.g., performance criteria) are satisfied. As a specific example, macro base station 102 may be configured to use the shared portion of its spectrum if, and only if, the number of RBs available from the non-shared portion of its spectrum is less than or equal to a threshold. For instance, if there are no RBs available from the non-shared portion of the spectrum, then macro base station 102 may use an RB that falls within the shared portion of the spectrum.
[0039] Referring now to FIG. 6 , FIG. 6 is a flow chart illustrating a process 600 according to an embodiment of the invention. Process 600 may begin in step 602 , where macro base station 102 receives a request from a UE for an RB. In response, macro base station 102 (a) determines a performance metric (e.g., determines the number RBs from the portion of its frequency spectrum not shared with femto) (step 604 ), (b) compares the performance metric to a predetermined threshold (e.g., compares the number of RBs determined in step 604 to the threshold value) (step 606 ); and then decides whether to use a resource (e.g., frequency or time slot) allocated to femto base station 104 based on a result of the comparison (step 608 ). Accordingly, based on the result of the comparison, macro base station 102 performs either step 610 or 612 . In step 610 , macro base station 102 assigns to the UE a resource block that is not within the frequency spectrum and/or time slot assigned to femto, and in step 612 , assigns to the UE a resource block that is within the frequency spectrum and/or time slot assigned to femto base station 104 .
[0040] Although many of the examples used the downlink spectrum allocation to illustrate the invention, the same principles are valid for the uplink direction of communication.
[0041] In an alternative embodiment, rather than configuring macro base station 102 to avoid using resources (e.g., time slots and/or frequency spectrum) that are used by femto, macro base station 102 may be configured so that certain RBs (e.g., RBs from the shared portion of the spectrum) are transmitted with a reduced power.
[0042] Referring now to FIG. 7 , FIG. 7 is a functional block diagram illustrating a macro base station 102 according to some embodiments. As shown in FIG. 7 , macro base station 102 may include a transmitting and receiving circuit 711 for transmitting data to and receiving data from a UE; a storage unit 704 (e.g., a non-volatile data storage) that stores software 708 for implementing the functions and features described above; and a processor 706 (e.g., a microprocessor) for executing software 708 . Storage unit 704 may also store information 709 identifying a resource (e.g., a frequency spectrum and/or time slots) allocated to each femto base station 104 that is located within the coverage area of macro base station 102 .
[0043] While the processes described herein have been illustrated as a series or sequence of steps, the steps need not necessarily be performed in the order described, unless explicitly indicated otherwise.
[0044] Further, while various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
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Systems and methods for reducing macro-femto bas station interference are disclosed. In one aspect, macro-femto interference is reduced by configuring t macro bases station to avoid using resources allocat to the femto base station.
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RELATED APPLICATION
The present application claims the benefit of U.S. Provisional Application No. 60/610,324 filed Sep. 16, 2004, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates generally to the field of movable or portable acoustic shells for use by performers. More specifically, the present invention relates to a movable or portable acoustic shell including electronically enhanced acoustics to provide performers with a variety of selectable acoustic shell tunings depending upon the type of performance and acoustic characteristics of the surrounding environment.
BACKGROUND OF THE INVENTION
Portable acoustic shells provide many advantages to today's performers. One advantage is that performers can be sure of consistent acoustical characteristics as a show travels from location to location. Another advantage is that portable acoustic shells can be used to provide favorable acoustic traits at sites in which the acoustics are generally regarded as poor. A variety of techniques and designs have been used to create portable acoustic shells, for example U.S. Pat. Nos. 3,630,309; 4,241,777; D304,083; 5,524,691; 5,622,011; 5,651,405; and 5,875,591, all of which are commonly assigned to the assignee of the present invention and are all hereby incorporated by reference in their entirety.
While portable acoustic shells provide many advantages, they suffer acoustically in comparison to specially designed acoustical rooms. In an enclosed room, designers can eliminate any acoustical effects of the surrounding environment, resulting in a more consistent and controlled environment. In addition, electronic acoustic systems can be coupled with the enclosed room to emulate any number of acoustical venues to provide more realistic practice and rehearsal conditions. An example of such a system is disclosed in U.S. Pat. No. 5,525,765, commonly assigned to the assignee of the present invention, and hereby incorporated by reference in its entirety.
While portable acoustic shells provide many advantages, it would be desirable to have a portable acoustic shell that provided the type of acoustic flexibility that is available with an enclosed room.
SUMMARY OF THE INVENTION
The portable acoustic shell of the present invention overcomes the acoustical limitations associated with currently available portable acoustic shells. By integrating an electrical acoustic system with a portable acoustic shell, an active sound field can be created that encompasses the performers on stage. The active sound field can be tuned through the placement of speakers throughout the shell structure. By tuning the active sound field, both performers and audience members alike can experience the benefit of a portable acoustic shell that is capable of multiple tuning conditions such that it can be adapted for use by groups with differing numbers of performers, as well as in environments that are not acoustically advantageous.
The active acoustics shell utilizes a moveable (or portable) acoustics shell, which integrates acoustics technology into the shell to provide electronically enhanced acoustics to the performers on stage and to some extent the audience. The benefit of an active acoustics shell is the ability to “tune” the acoustics characteristics of the shell electronically thus allowing various “tunings” depending on the type of music performance being given. Since these are easily changed, multiple tunings could occur during the same event depending on the desires of the groups using the shell. This also allows for a fairly consistent acoustic environment for the musicians to play in, especially when faced with performance spaces that are not conducive to good performance acoustics.
The basic design premise is to create an active sound field from the shells that encompass the performers on the stage. Typically this is done with speakers that are attached to the shell structure. It may also include the addition of speakers located in the overhead reflectors. There is also the need to capture the sound of the performers for processing which is typically (but not restricted to) mounting microphones in the canopy portion of the shells (or could be located in the reflective ceilings above the stage). The sound is captured via the microphones, is equalized based on the transfer function of the shell/stage acoustics (and to some extent the impact of the auditorium area), processed with the acoustics technology and then fed back to the performers on stage via speakers in the shells (and/or overhead reflectors).
In one aspect, the present invention relates to a portable acoustic shell including an electronic acoustical system capable of tuning and projecting an active sound field encompassing performers on stage. Typically, the portable acoustic shell comprises a plurality of vertical panel assemblies placed and attached in proximity with one another to define a performance area. The portable acoustic shell may include an overhead canopy structure to partially enclose the area above the performance area. An electronic acoustic system comprises a microphone assembly, an electronic processing assembly and a speaker assembly. The microphone assembly comprises at least one and preferably, a plurality of microphones positioned above the performance area, often in the canopy, to capture the sound generated by the performers. The electronic processing assembly receives the sounds captured by the microphone assembly and processes the sounds based upon the desired tuning characteristics. The processed sounds are then fed back to the performance area and transmitted through the speaker assembly located within the shell structure resulting in the performers and audience members hearing the tuned version of the performance.
In another aspect, the present invention relates to a method for tuning sounds generated by a performance within a portable acoustical shell. Generally, desired tuning characteristics are inputted into an electronic acoustical system based upon the type and size of a performance, as well as the acoustical characteristics of the surrounding environment. Actual performance sounds are captured by a microphone assembly and are subsequently transmitted to the electronic acoustical system. The electronic acoustical system processes the sounds based on the previously established tuning characteristics. The tuned sounds are retransmitted and broadcast back to the performance area through a speaker assembly located within the acoustic shell structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art portable acoustic shell;
FIG. 2 is a perspective view of a prior art vertical panel assembly;
FIG. 3 is a side view of the vertical panel assembly of FIG. 2 ;
FIG. 4 is a perspective view of a portable acoustic shell system of the present invention;
FIG. 5 is a front view of a vertical panel assembly of the present invention;
FIG. 6 is a perspective, front view of the vertical panel assembly of FIG. 5 ;
FIG. 7 is a side view of the vertical panel assembly of FIG. 5 ;
FIG. 8 is a perspective, rear view of the vertical panel assembly of FIG. 5 ;
FIG. 9 is a front view of an absorber panel of the present invention;
FIG. 10 is a side view of the absorber panel of FIG. 9 ;
FIG. 11 is a side view of the absorber panel of FIG. 9 ;
FIG. 12 is a perspective view of an electronic acoustic system of the present invention; and
FIG. 13 is a flow chart depicting a method of creating an active sound field encompassing a performance area in a portable acoustic shell of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Depicted in FIGS. 1-3 is an acoustic shell 80 of the type commonly known and used by those of skill in the art, such as Wenger® Corporation's Legacy™ Acoustical Shell. Generally, acoustic shell 80 is comprised of a plurality of vertical panel assemblies 82 comprising a plurality of vertical panels; for instance, a kicker panel 84 , a lower panel 86 , an upper panel 88 and a canopy panel 90 , mounted to a vertical frame 92 , which is fixedly attached to base assembly 94 . Base assembly 94 is typically sized to provide stability to the vertical panel assembly 82 . Base assembly 94 typically includes a pair of caster assemblies 96 a , 96 b to allow for easy positioning and transport of the vertical panel assembly 82 . Between the panel sections, for example, between upper panel 88 and canopy panel 90 , vertical frame 92 can include a hinge assembly 98 to allow for rotatable positioning of the canopy panel 90 in comparison to upper panel 88 , as well as to allow for fold-up and storage of the vertical panel assembly 82 . The panel sections are typically comprised of a composite material to provide a stiff, acoustically reflective surface, while the vertical frame 92 and base assembly 94 are constructed of steel and aluminum for durability and strength.
As shown in FIG. 4 , a portable acoustic shell system 100 of the present invention comprises a remote electronic acoustical assembly 102 integrally wired to a portable acoustic shell 104 . Through the combination of electronic acoustical assembly 102 and portable acoustic shell 104 , a performance area 106 can be enveloped with an active sound field. Using electronic acoustical assembly 102 , the active sound field can be tuned or adjusted to provide a desired acoustic sound. The size and shape of performance area 106 can be varied by changing the orientation or number of vertical panel assemblies 120 that make up portable acoustic shell 104 .
A vertical panel assembly 120 of the present invention is further depicted in FIGS. 5 , 6 , 7 and 8 . Generally, vertical panel assembly 120 comprises a plurality of panel sections; for example, a kicker panel 122 ; a lower panel 124 ; a top panel 126 ; and a canopy panel 128 , mounted to a vertical frame 130 , which is fixedly attached to a base assembly 132 . Hanging from canopy panel 128 is a microphone assembly 134 . As shown in FIG. 7 , a hinge assembly 136 is mounted between top panel 126 and canopy panel 128 to provide rotational movement of the canopy panel 128 in relation to the top panel 126 . Hinge assembly 136 can include a biasing arm 138 and a spring assist 140 to allow for easier manipulation of canopy panel 128 .
Absorber panel 142 is depicted in FIG. 9 . As shown in FIGS. 10 and 11 , absorber panel 142 typically includes a pair of speaker assemblies 144 a , 144 b oriented to face the reflective surface of the vertical panel assembly 120 . In an alternative embodiment, a separating element may be provided between speaker assemblies 144 a , 144 b.
Canopy panel 128 and vertical panel assembly 120 define an acoustic reflective zone in the performance area 106 . Sounds made by a performer in the acoustic reflective zone are received by microphone assembly 134 . Absorber panel 142 defines an anechoic zone within the performance area 106 . Speaker assemblies 144 a , 144 b are oriented toward vertical panel assembly 120 so that the sound they produce will reach a performer in the performance area indirectly.
The electronic acoustic system 102 is depicted in FIG. 12 . Generally, electronic acoustic system 102 comprises a microphone preamplifier 152 having a minimum of two channels, an equalizer 154 having a minimum of two channels, a digital signal processor 156 with a minimum of four channels of processing, and an audio amplifier 158 having a minimum of one channel for each channel of the digital signal processor 156 . The components of electronic acoustic system 102 are generally mounted in a frame assembly 160 to provide convenient wiring and operation of the components. Frame assembly 160 can include a plurality of casters to provide for easy transport and positioning of electronic acoustic system 102 . In an alternative embodiment, electronic acoustic system 102 can be located in an enclosure suitable for attachment directly to a vertical panel assembly 120 . In a preferred embodiment, the digital signal processor 156 includes LARES (Lexicon Acoustic Reinforcement and Enhancement System) Digital Signal Processing Technology as manufactured by Lares Associates, Inc., Columbia, Md. Preferably, the components have specifications as described in Table A. However, it should be noted that different and/or additional components with different and/or additional specifications may be used without departing from the spirit or scope of the invention.
TABLE A
Component Specifications
Component
Component
Number
Name
Specifications
134
Microphone
Transducer Type: self-polarized
Assembly
condenser microphone
Frequency Response: 60 to 20,000 Hz
Signal-to-Noise Ratio re 1 Pa
(A-Weighted): 67 dB
Maximum sound pressure level for
1.0% THD: 115 dB SPL
144a,
Speaker
Frequency Response:
144b
Assembly
On Axis (0°) +/− 2 dB from
70-20 kHz
Off Axis (30°) +/− 2 dB
from 70-15 kHz
Sensitivity-room/Anechoic; 89 dB/
86 dB
Maximum input power: 80 watts
Low frequency extension: 48 Hz
(DIN)
152
Microphone
Input Impedance: Greater than 3k
Preamplifier
ohms
Frequency Response: 20-20
kHz, +0, −1 dB
THD: [0.01% (1 kHz, +24 dBm
Gain, 600 ohms, balanced out)
Maximum gain 66 dB, Minimum gain
26 dB
UL ®-Listed
154
Equalizer
Frequency Bands: ⅔ -
Octave ISO Spacing from 25 Hz to
16 kHz
Type: Constant Q
Accuracy: 3% center frequency
Frequency response: 20-60
kHz; +0/−3 dB
THD + Noise: .009%; +/−.002%; +4
dBu, 20-20 kHz
IM Distortion (SMPTE):
.005%, +/−.003%; 60 Hz/7 kHz,
4:1, +4 dBu, 20 kHz bandwidth
Signal-to-Noise: 108/92 dB +/− 2
dB; re +20 dBu/+4 dBu; Slider
Centered, Unity gain
UL ®-Listed and CSA-approved
156
Digital
Frequency response:
Signal
Unprocessed Channels 10 Hz-100
Processor
kHz, +1 dB, −3 dB, Ref. 1 kHz
Processed Channels 10-18 kHz, +1
dB, −3 dB, Ref. 1 kHz
THD + Noise: <0.05% @ 1 kHz
maximum level
Signal-to-Noise ratio: 90 dB min.,
A-weighted, Ref. 1 kHz level
UL ®-Listed, CSA-approved
158
Audio
Output power: 45 watt @ 4 ohms,
Amplifier
20-20 kHz, 0.1% THD
Frequency Response: 20-20
kHz, +0, −1 dB at 1 watt
Slew rate: 6 V/us
Damping factor: Greater than 400 from
DC to 400 Hz
Signal-to-Noise: 106 dB from 20 Hz to
20 kHz @ 45 W
Total Harmonic Distortion
(THD): >0.001% @ 45 W from 20 Hz
to 400 Hz increasing linearly to 0.03%
at 20 kHz
UL ®-Listed, CSA-approved
Generally, the portable acoustic shell system 100 of the present invention is used by first assembling the portable acoustic shell 104 . Based on the desired shape and size of portable acoustic shell 104 , the appropriate number of vertical panel assemblies 120 are positioned in a side-by-side arrangement. Typically, each vertical frame 130 will include a combination attachment/locking mechanism allowing adjacent vertical panel assemblies 120 to be interconnected and locked into position. Once the portable acoustic shell 104 is assembled, the electronic acoustical assembly 102 is wired to the portable acoustic shell 104 such that the electronic acoustical assembly 102 is in electrical communication with the microphone assembly 134 and the speaker assemblies 144 a , 144 b . For purposes of assembling the portable acoustic shell system 100 , the location of electronic acoustical assembly 102 in comparison to the portable acoustic shell 104 is unimportant. Generally, the only requirement for positioning the electronic acoustical assembly 102 is that it be in an electrically safe environment and that a power supply is readily available.
Use of the portable acoustic shell system 100 during a performance is described with reference to FIG. 13 . Once the portable acoustic shell system 100 is assembled, a performance step 160 can commence. Performance step 160 can include any type of performance that includes an audio portion such as speeches, concerts, plays and other forms of performances. Once performance step 160 has begun, a capture step 162 is initiated, whereby the microphone assemblies 134 capture the audio portion of the performance step 160 . Depending upon the size and configuration of the portable acoustic shell 104 , a plurality of microphone assemblies 134 can be used to ensure complete and accurate capture of the audio portions. Once the microphone assembly 134 captures the audio portions, the captured audio signal is amplified by the microphone preamplifier 152 in a preamplification step 164 . The amplified signal is then filtered through the equalizer 154 in a filter step 166 . The filtered signal is then processed by the digital signal processor 156 in a processing step 168 . In processing step 168 , the filtered signal is tuned and adjusted according to the desired audio characteristics that have been input by a user. By changing these desired audio characteristics within digital signal processor 156 , a user can selectively process, modify and/or enhance the filtered signal. The desired audio characteristics can be modified at any time, including between performances, or “on the fly” during an actual performance. The digital signal processor 156 processes the signal into four outputs, which are fed to the audio amplifier 158 in an audio amplification step 170 . Audio amplification step 170 amplifies the four outputs to create four channels of audio amplified signals. The four channels of audio amplified signals are then fed to the speaker assemblies 144 a , 144 b in a transmission step 172 . In transmission step 172 , the audio amplified signals are fed to speaker assemblies 144 a , 144 b in an interleaving pattern, such that adjacent speakers are never on the same audio/processing channel. Finally, the speaker assemblies 144 a , 144 b reflect/diffuse the audio amplified signals back to the musicians/audience in a broadcast step 174 .
Canopy panel 128 and vertical panel assembly 120 define an acoustic reflective zone in performance area 106 . Sounds made by a performer in the acoustic reflective zone are received by microphone assembly 134 . This sound is processed by electronic acoustic system 102 and returned to the performer by way of speaker assemblies 144 a , 144 b . Absorber panel 142 is mounted between the speaker assemblies 144 a , 144 b and performance area 106 so that absorber panel 142 provides a semi-anechoic zone within the reflective zone described above. Speaker assemblies 144 a , 144 b are oriented away from performance area 106 and toward vertical panel assembly 120 and the sound they produce reaches a performer in the performance area indirectly. This configuration and the creation of a semi-anechoic zone between speaker assemblies 144 a , 144 b by way of absorber panel 142 , provides acoustic feedback to a performer in performance area 106 that can be optimized to a particular piece or ensemble, and which is reproducible at different set up sites. Accordingly, a performer practicing in one space, and performing in a different space, will not have to adapt “on the fly” to the varying acoustics of different performance spaces.
Although various embodiments of the present invention have been disclosed here for purposes of illustration, it should be understood that a variety of changes, modifications and substitutions may be incorporated without departing from either the spirit or scope of the present invention. For example, the vertical panel assemblies can include additional speaker assemblies, for example, in canopy panel 128 , to further enhance the performance of the portable acoustic shell system 100 of the present invention. In other embodiments, microphone assemblies 134 can be positioned in alternative locations, such as in front of the portable acoustic shell 104 , within the performance area 106 or even being handheld by the performers themselves.
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An electroacoustic shell system adapted create a performance area where sound created by a performer is received, processed, and returned to the performer in the performance area. The system broadly includes an electroacoustic shell with a vertical panel and a canopy, a microphone and a speaker operably coupled to the shell, and an electronics processing assembly connected to the microphones and speakers for recording, broadcasting, and simulating sound.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a lint cleaner which has been modified to reduce, by substantially one-half, the front-to-rear depth of the air flow path within the lint cleaner past the several grid bars and saw cylinder thereof, with the reduced depth air passage serving to greatly increase the velocity of air flow through the passage and to thereby "air wash" the grid bars as well as the adjacent forward periphery of the saw cylinder to prevent the build up of lint on the grid bars, which build up interferes with generally tangential discharge of trash from the saw cylinder and allows the once removed trash to build up on the side of the lint build up opposing the saw cylinder. After sufficient lint has built up on the grid bars, the trash tends to be sucked back into the saw cylinder and, therefore, is remixed with the cotton lint on the saw cylinder doffed from the saw cylinder by the brush cylinder.
2. Description of Related Art
Various different forms of lint cleaners heretofore have been provided such as those disclosed in U.S. Pat. Nos. 469,559, 910,653, 1,086,204, 1,124,094, 1,168,493, 1,201,901, 2,738,553, 2,834,057, 2,867,850, 2,934,793, 3,121,921, 4,520,529, 4,528,725 and 4,631,781. However, some of these lint cleaners do not include the equivalent of coacting saw cylinders and grid bars and others do not include structure whereby a reduced depth venturi-type throat is provided for passage of air past the several grid bars and the adjacent side of the associated saw cylinder.
SUMMARY OF THE INVENTION
The lint cleaner of the instant invention comprises a modification of a conventional multi-grid bar and saw cylinder equipped lint cleaner of the type including a front wall (having a removable door therein) spaced generally 12 inches forward of the outer periphery of a 16 inch diameter saw cylinder having multiple (in most cases five) grid bars spaced about the forward periphery of the saw cylinder between approximately the 7 and 11 O'clock positions thereof with the grid bars spaced only slightly outwardly of the forward periphery of the saw cylinder. In addition, the conventional lint cleaner includes a mote hopper having a transverse width substantially equal to the length of the saw cylinder and which includes a front-to-rear depth of approximately 15 inches with the forward side of the mote hopper forming a downward continuation of the front wall of the lint cleaner cabinet.
The instant invention includes the provision of a baffle wall (having a door therein) mounted within the lint cleaner cabinet generally one-half the distance between the forward outer periphery of the saw cylinder and the front wall of the cabinet and with the lower portion of the baffle wall being generally vertically disposed and aligned with the front side of a modified mote hopper inlet end spaced approximately 8 inches rearward from the front wall of the hopper, the baffle wall and the reduced front-to-rear depth of the mote hopper serving to accelerate the flow of air past the forward side of the saw cylinder and the grid bars associated therewith, which accelerated air flow prevents the build up of lint on the grid bars.
By substantially eliminating the build up of lint on the grid bars, the small remaining bits of trash to be removed from the cotton lint as it is fed to the saw cylinder is separated from the lint by the saw cylinder and thrown outward between the grid bars, thus preventing the build up of small particles of trash on the side of a lint build up on the grid bars facing the saw cylinder. It has been discovered such trash build up results in a portion of the trash build up being drawn back into the saw cylinder for contamination of the lint being carried thereby, afterwhich the contaminated lint is doffed from the saw cylinder by the brush cylinder. Accordingly, the grid bar air wash system of the instant invention enables the associated lint cleaner to more effectively clean the lint and thus reduce the necessity of lint being passed through tandem lint cleaners.
The main object of this invention is to provide a lint cleaner including structure which will greatly increase the velocity of air flow downwardly along the front side of the saw cylinder opposed by the plurality of associated grid bars and over the latter.
Still another object of this invention is provide a lint cleaner which will direct a larger portion of high velocity air past the three uppermost grid bars and with a major portion of the air flow directed upon the uppermost grid bar.
Yet another object of this invention is to provide a lint cleaner modification in accordance with the preceding objects and which may be readily incorporated into existing lint cleaners.
Another object of this invention is to provide an improved cleaning action lint cleaner which will effect a more thorough cleaning action on lint and thus greatly reduce the necessity of passing cotton through tandem lint cleaners.
A final object of this invention to be specifically enumerated herein is to provide an improved lint cleaner for cotton which will conform to conventional forms of manufacture, be of simple construction and easy to use so as to provide a device that will be economically feasible, long-lasting and relatively trouble free in operation.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary schematic view illustrating a lint cleaner of conventional design disposed in tandem with at least one other lint cleaner;
FIG. 2 is an enlarged fragmentary schematic view of the conventional lint cleaner; and
FIG. 3 is a fragmentary schematic view of a conventional lint cleaner modified in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings the numeral 10 generally designates a conventional form of cotton lint cleaner comprising one lint cleaner connected in series with at least one other lint cleaner. Cotton partially cleaned by a first lint cleaner enters the lint cleaner 10 at 12 and adheres to a revolving screen 14. As the screen 14 rotates the cotton thereon is compressed by the woodroller 16 to a bat approximately 3/4 inch thick and the cotton is then doffed off the screen 14 by a roller 18 and passes between the woodroller 16 and the roller 18 downwardly between rollers 20 and 22 and then between rollers 24 and 26 for compression into a bat of cotton approximately 1/4 inch thickness. The bat of cotton then travels between the feed roller 28 and the feed bar 30 and is compressed to a thickness of 0.010 inch, afterwhich the cotton bat is passed to the saw cylinder 32.
The peripheral speed of the saw cylinder 32 is much greater than the speed of the cotton bat delivered to the saw cylinder 32 and, accordingly, the saw cylinder 32 performs a combing action on the cotton which pulls cotton fibers away from the bat. This in turn allows trash within the cotton fibers and other foreign material to be slung out of the cotton by centrifugal force. The trash then hits the grid bars 34, 36, 38, 40 and 42 and is transferred radially outwardly of the saw cylinder 32 beyond the grid bars. The cotton fibers cling to the saw cylinder and are doffed from the saw cylinder by the brush cylinder 44, afterwhich the cotton lint is then carried away from the lint cleaner 10 and compressed into a marketable bale of cotton, or is passed through a second lint cleaner before being compressed into a bale of cotton.
The above description comprises a description of the structure and operation of a conventional lint cleaner wherein air enters the cabinet of the air cleaner 10 through protective bars 46 and travels through the lint cleaner 10 along the path designated by the arrows 48 before passing into the mote hopper 50 with which an exhaust blower (not shown) is operatively associated.
The forward portion of the cabinet of the lint cleaner 10, in horizontal registry with the grid bars 34, 36, 38, 40 and 42, is provided with a removably mounted access door 52 through which access may be gained to the area of the grid bars.
In a conventional lint cleaner such as the lint cleaner 10 cotton fibers which are not carried about the saw cylinder tend to collect on the grid bars 34, 36, 38, 40 and 42 to a great extent and these collected cotton fibers gradually form bats of cotton fibers which obstruct the openings between the grid bars through which trash is designed to be thrown. When these bats of cotton fiber build up on the grid bars 34-42, the trash thrown outward from the saw cylinder 32 collects on the faces of the cotton bats formed on the grid bars and thus builds up thereon to the extent that some of the trash thrown outward from the saw cylinder is drawn back there toward and into the cotton fibers passing around the saw cylinder and being doffed therefrom by the brush cylinder 44. Thus, the cotton lint (which is to have been cleaned by the saw cylinder 32) is recontaminated with trash and, accordingly, the cotton lint doffed from the saw cylinder 32 by the brush cylinder 44 is not as clean as it should be. Therefore, it is not unusual for multiple lint cleaners 10 to be connected in tandem.
Referring now more specifically to FIG. 3 of the drawings, the numeral 10' generally designates a lint cleaner which has been modified in accordance with the present invention. Various portions of the lint cleaner 10' corresponding to the similar portions of the lint cleaner 10 above described are referred to by corresponding prime numerals. Further, as in the case with the lint cleaner 10, air enters and passes through the lint cleaner 10' along the path indicated by the arrows 48' for movement from the machine 10' through the mote hopper 50'.
The modified lint cleaner 10' may retain the removable front door 52' thereof, or the front door 52' may be removed. However, a baffle wall referred to in general by the reference numeral 56' is installed within the lint cleaner 10' and extends the full length along the saw cylinder 32' with the baffle wall 56' including an arcuate upper section 58' and a vertical lower section 60', the lower section 60' being stationary and the upper section 58' being hingedly supported from the lower section 60' as at 62'. Further, a latch assembly 64' is provided on the upper section 58' for latching the upper section 58' to a stationary transverse brace 66'. The upper section 58' therefore constitutes an access door extending between the lower section 60' and the brace 66'.
The mid and lower portions of the upper section 58' extend along an arc which has its center of curvature generally coinciding with the axis of rotation of the saw cylinder 32' but the upper portion of the upper section 58' is substantially planar and diverges away from those peripheral portions of the saw cylinder 32' horizontally registered therewith. The path of entry of air into the lint cleaner 10' passes in back of the brace 66' and thus the stream of air passing through the lint cleaner 10' is initially directed downwardly upon the uppermost grid bar 34' and thereafter downwardly along the grid bars 36'-42'. Also it will noted that the upper section 58 is disposed generally midway between the removable front door 52' and the forwardmost periphery of the saw cylinder 32'. Thus, the cross sectional area of the flow path 48' of air past the saw cylinder 32' and the grid bars 34'-42' is reduced by generally 50% from the cross section of the air flow path 48 passing through the unmodified lint cleaner 10. In this manner, the air moving along the flow path 48' in not only increased in speed by generally 100%, but it is also directed initially downwardly upon the uppermost grid bar 34'. This increase in air flow velocity, with the same capacity exhaust blower (now shown) operatively associated with the mote hopper 50', ensures that the build up of cotton line bats on the grid bars 34'-42' will be non-existent, or at least minimal, and that if any lint build up occurs such lint build up will not be sufficient to block outward discharge of trash from the saw cylinder.
The lower section 60' is disposed generally one-half the distance from the front of the lint cleaner 10 to the rear wall 70' of the duct 72' opening down into the mote hopper 50', the front wall 74' of the mote hopper 50' also being disposed approximately one-half the distance between the front of the lint cleaner 10 and the rear wall portion 76' of the mote hopper 50. Accordingly, the duct 72' has generally one-half the cross sectional flow area of the duct 72 on the lint cleaner 10 (see FIG. 2) and the mote hopper 50' has generally one-half the cross sectional area of flow of the mote hopper 50 illustrated in FIG. 2. The reduction in size of the duct 72' and the mote hopper 50' from the size of the duct 72 and the mote hopper 50 ensures that the increased air flow velocity immediately rearward of the upper section 58' is maintained throughout movement of the air flow downwardly through the lint cleaner 10 and to the associated exhaust blower (not shown).
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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An arcuate baffle wall is provided within a conventional lint cleaner forward of and horizontally registered with the front side of the saw cylinder of the lint cleaner. The upper and lower extremities of the baffle wall are generally horizontally registered with the upper and lower extremities of the saw cylinder and the baffle wall is spaced generally midway between the forward periphery of the saw cylinder and the front wall section of the lint cleaner to thereby define a venturi passage for air flow at appreciably increased velocity downward over the grid bars of the lint cleaner spaced about the forward peripheral portion of the saw cylinder. The venturi passage greatly increases the velocity of air flow past the grid bars and prevents the build up of cotton lint thereon to the extent that tangential outward displacement of dirt from the saw cylinder is blocked.
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BACKGROUND OF THE INVENTION
THIS INVENTION relates to stands for bench top containers which are used for storing and dispensing drinks. The invention is particularly concerned with cask containers which are widely used for wine and fruit juices. Such casks comprise a rectangular block shaped cardboard container having a plastic bag liner and an outlet tap protruding through the bottom of a side wall. In use, it is necessary to line the cask up on the edge of a support surface, such as a shelf or table top, before it can be emptied as sufficient space must be provided under the tap on the cask for the receptacle into which the contents are to be poured.
The placement of the cask on the edge of a support surface gives rise to a restriction in the mode of use as well as the potential for the cask to be pushed over the edge when the contents are being dispensed, particularly as the cask becomes empty and lightweight. In order to address the former of these problems, one previous solution was to place the cask on a block support, such as on top of another cask lying on its side, or on a box, brick or the like. None of these solutions are particularly practical or aesthetic but, more importantly, they do not address the latter of the aforementioned problems in that they do not give any side support to the cask, with the result that the cask is unstable and is prone to toppling over.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to provide a means for supporting a cask to enable the contents to be readily dispensed without the aforementioned problems.
SUMMARY OF THE INVENTION
According to the present invention there is provided a stand for a rectangular block shaped cask having an outlet tap in a lower region, said stand comprising a platform and elevating means for retaining the cask above a support surface by a sufficient amount to enable a receptacle to be placed under the outlet tap, and associated restraining means to prevent lateral movement of the cask during manipulation of the outlet tap.
DETAILED DESCRIPTION OF THE INVENTION
The stand is suitably dimensioned in most instances to support a cask at least about 120 mm above the support surface. That is, the distance from the base of the cask to the top of the support surface is at least about 120 mm. Preferably, the distance will be within the range of 120 to 200 mm for wine casks, most preferably about 140 mm for two litre casks and about 140 mm for four litre casks. The exact height selected will generally be determined according to the size of the cask but also having reference to the nature of the contents of the cask. Thus, for casks containing fruit juices, a height closer to 200 mm will often be more suitable as the contents may need to be poured into taller glasses than would the case be for wine or port.
The stand can comprise an open framework structure, a closed wall structure, or a combination of both types of structure. From an aesthetic point of view, an open framework structure has been found to be most desirable. Since the stand occupies a relatively large space, an open structure looks less intrusive and is more convenient and less expensive to manufacture. Furthermore, it is a lot easier to see what the label is on the cask if the stand has an open structure. This can be important when there are several casks with different contents being used on adjacent stands.
The open structure framework is conveniently constructed of rigid fabrication materials which can be tubular, rod-profile, square or rectangular section, and so on. The range of construction materials is practically limitless and include such materials as natural products, for instance cane, bamboo and timber; and man-made products such as plastics, composite materials and metals. By far the most preferred are the metals such as iron and steel, including stainless steel, copper and aluminium, and metal alloys such as brass and pewter. The particular material chosen will be based upon the requirements of the consumer. For a high quality finish, the stand will typically be manufactured from hand-forged iron rod which is powder coated for protection and aesthetic requirements. For an even more "up-market" version, the stand will be hand made from high quality stainless steel or brass rod. For the average consumer the stand will be manufactured from heavy gauge steel wire which is processed automatically with spot welded jointing. The resultant product can be zinc platted or dip painted on a continuous production line.
In constructing the stand from heavy gauge steel wire, the framework can conveniently comprise two substantially identical open structured side walls each formed from a continuous piece of steel wire, which are interconnected at an intermediate region by intermediate wire members having the additional function of providing a platform on which the cask rests. One or more extra wires can extend between the intermediate wire members themselves in order to provide further support for the cask, if deemed necessary; and one or more connecting wires can join the lower sections of the framework together to give added rigidity to the structure as a whole.
Preferably, each side wall framework is essentially triangular in side-elevation wherein one of the sides of the triangle forms the base. Most preferably, the triangle is a right-angle triangle wherein the perpendicular side of the triangle forms the rear portion of the stand and the hypotenuse, the front portion of the stand (by "front" it is intended to mean that portion which, in use, faces the user). Further, the hypotenuse may be splayed outwardly below the cask platform, when viewing the stand from the front. Such splaying will provide extra stability for the stand and will also contribute to the aesthetics of the stand.
When a triangular walled structure is adopted, a single connecting wire is sufficient to join the bottom portion of each triangle to one another. All wires, including the intermediate wires, the extra wire or wires joining the intermediate wires, and each side wall framework, are conveniently interconnected by spot-welding. The triangular walls are typically produced by cold bending in a continuous automatic production facility.
In one adaptation of the open structured framework which is specifically designed for use with wine or port casks, it is useful to include means for also holding stemmed wine or port glasses. To this end, a fixed or removable extension can be associated with the stand which projects outwardly from the stand and adjacent to one or both side walls thereof. The extension suitably comprises a pair of spaced arms which are projected horizontally and between which the stem of several glasses can be fitted at an opening between the ends of the arms. The spading between the arms is selected so that the plinth of the glasses cannot pass between the arms and are properly supported by the arms. Preferably, such an extension is located on each side of the stand and the extensions are interconnected by a tie piece. Suitably, the tie piece forms the region for attachment to the stand. Preferably, the tie piece is removable and is connectable to a member lying in the plane of the rear section of the stand. The member can conveniently be an upstanding peg onto which the tie piece is fitted and held in place by friction. To enable this, the tie piece can have a loop which fits over a peg having an outwardly and downwardly tapering end piece.
The restraining means of the cask stand are designed to give side support to the cask to prevent it from movement when in use. To this end, it is preferred that a snug fit is achieved between the cask and the stand. Preferably, the restraining means of the stand will extend at least about two thirds up the side walls of the cask to ensure adequate support is provided.
The stand thus described can be connected with one or more other stands in series so as to support several casks in line. This may be achieved, for instance, by the addition of extra connecting members which are welded or otherwise joined to the rear portion of the stands, and optionally to the base portions thereof.
The invention thus described addresses the problems associated with casks as previously mentioned, and provides the public with a useful choice.
DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the invention will now described with reference to the accompanying drawings, in which:
FIG. 1 is an isometric view of a stand according to the present invention, shown supporting a cask; and
FIG. 2 is an isometric view of a modified stand including glass support means.
In both of the drawings, like reference numerals refer to like parts.
Referring firstly to FIG. 1, the stand 10 is designed to support a two litre wine cask 11. The stand is fabricated from 8 mm iron rod which is painted black. It comprises two mirror image vertically extending structures comprising triangular shaped side walls 12, 13 which are splayed outwardly at their lower front edges 14, 15 for extra stability. The side walls form right-angled triangles when viewed side-on, with perpendicular uprights 16, 17; horizontal support engaging members 18, 19; and hypotenuses 20, 21.
Each side wall is interconnected with the other by tie members 22, 23, 25. An additional connecting member, similar to connecting member 24 in FIG. 2, joins the tie members 22 and 23 to one another and provides a platform for the cask 11 to rest upon.
The wine cask 11 is snugly retained between the perpendicular uprights 16, 17 and the hypotenuses 20, 21 so that lateral movement of the cask relative to the stand is not possible.
It is apparent from the design that a wine glass can easily be located under the tap 26 of the cask for filling.
The FIG. 2 embodiment is basically the same as shown in FIG. 1 with the addition of glass support means 30. The glass support means comprises two pairs of rigid support arms 31, 32 arranged to be located on each side of the wine cask. The support arms are interconnected by an integral member 33 extending in the rear plane of the stand. The support arms and integral member are fabricated from 4 mm iron rod which is also painted black.
The support means 30 is removably fitted to the stand by virtue of an elongated loop 34 formed midway between the ends of the integral member 33. The loop is supported by a rear wall comprising an inverted V-shaped metal peg 35 which is welded to the stand at the intersection of the tie member 22 with the perpendicular uprights 16, 17.
The glass support means can support several glasses on each side of the stand. One glass is illustrated at 36.
Whilst the above has been given by way of illustrative example of the invention, many modifications and variations may be made thereto by persons skilled in the art without departing from the broad scope and ambit of the invention as herein set forth.
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A stand for wine casks having a rectangular block shape and a lower outlet tap. The stand consists of a platform which is elevated above a support surface, and side walls for preventing movement of the cask. A glass support means is removably fitted to the stand.
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FIELD OF THE INVENTION
The present invention relates to housings for planar lightguide circuits and, more particularly, to a thermal housing having temperature control for maintaining a planar lightguide circuit within a fixed temperature range.
BACKGROUND OF THE INVENTION
Optical wavelength division multiplexing (WDM) and dense wavelength division multiplexing (DWDM) have gradually become the standard backbone networks for fiber optic transmission systems. WDM and DWDM systems employ signals consisting of a number of different wavelength optical signals, known as carrier signals or channels, to transmit information on optical fibers. Each carrier signal is modulated by one or more information signals. As a result, a significant number of information signals may be transmitted over a single optical fiber using WDM and DWDM technology.
WDM optical transmission systems employ a variety of different passive components. Such components are increasingly being fabricated on Planar Light-Guide Circuits (PLC). A planar lightguide circuit, also known as an optical integrated circuit, can be readily mass produced because the processing steps are compatible with those used in silicon integrated circuit (IC) technology, which are well known and geared for mass production. One common type of planar lightguide circuit employs doped-silica waveguides fabricated with silicon optical bench technology. Doped-silica waveguides are usually preferred because they have a number of attractive properties including low cost, low loss, low birefringence, stability, and compatibility for coupling to fiber. Such a planar lightguide circuit is fabricated on a carrier substrate, which typically comprises silicon or silica. The substrate serves as a mechanical support for the otherwise fragile lightguide circuit and it can, if desired, also play the role of the bottom portion of the cladding. In addition, it can serve as a fixture to which input and output fibers are attached so as to optically couple cores of an input/output fiber to the cores of the planar lightguide circuit. The fabrication process begins by depositing a base or lower cladding layer of low index silica on the carrier substrate (assuming the substrate itself is not used as the cladding layer). A layer of doped glass with a high refractive index, i.e., the core layer, is then deposited on top of the lower cladding layer. The core layer is subsequently patterned or sculpted into structures required by the optical circuits using photo-lithographic techniques similar to those used in integrated circuit fabrication. Lastly, a top cladding layer is deposited to cover the patterned waveguide core.
One important passive component that can be fabricated on a PLC is an arrayed waveguide grating (AWG) in which two multiport couplers are interconnected by an array of waveguides. AWGs have a variety of different uses and may serve, for example, as multiplexers, demultiplexers and static routers.
One of the problems arising from the use of some planar lightguide circuits such as an AWG is their sensitivity to temperature changes, and to physical stresses that impair their reliability. For example, in an AWG, because the operating wavelengths of the several individual channels differ by such a small degree, any expansion or contraction or bending due to temperature fluctuations will degrade the optical performance and, in the extreme, cause circuit failure. Likewise, temperature fluctuations less than 1° C. may cause degradation or failure. It has been found that degradation or failure can generally be prevented and reliability of the circuit insured if the temperature of the device is maintained at a predetermined temperature in a range of 75° C. to 90° C. This maintenance temperature, specific to the individual circuit, must be controlled to within a few degrees Celsius even though the ambient temperature may vary from, for example, 0° C. to 70° C. Thus, some sort of protective housing must be provided for the planar lightguide circuit.
Housings for maintaining optical components at a constant temperature are well-known. For example, U.S. Pat. No. 5,994,679 shows a housing that comprises a base and a snap-on cover made of a material having a relatively low thermal coefficient of expansion. Within the housing is a layer of fibrous material that is relatively immune to temperature changes. A pair of support members of the same material, but hardened, support a thermal bed, which comprises a substantially U-shaped aluminum member, the legs of which define a slot for receiving the AWG or other planar lightguide circuit. The slot is filled with a thermally conductive grease that suspends the AWG and allows it to float within the slot, substantially completely covered by the legs of the U-shaped bed. Thus, the AWG is in a stress free position in the slot. The thermal grease also increases the thermal conductivity between the thermal bed and the circuit and insures that the temperature is uniform over the entire circuit and that there are no hot spots. On the top surface of one or both legs of the U-shaped bed is a heater, a pair of resistive temperature devices for monitoring the temperature of the bed, and a temperature controller. Leads from the temperature controller pass through electrical lead through pins to the exterior of the housing to supply power to the heater.
One problem with the aforementioned housing is that it requires a relatively large number of components, thereby increasing the complexity and cost of its assembly. Moreover, the housing must be relatively thick to accommodate the U-shaped bed, which diminishes its attractiveness for space-limited applications, such as when the housing is to be mounted on a printed-circuit board.
Accordingly, it would be desirable to provide a housing for an optical component that maintains the component at a constant temperature and which is compact and simple to assemble.
SUMMARY OF THE INVENTION
In accordance with the present invention, a housing is provided for maintaining a planar lightguide circuit at a temperature within a predetermined temperature range independent of ambient temperature. The housing includes a planar heating arrangement supporting and in thermal contact with the planar lightguide circuit. Also included is a frame assembly having a first surface on which the planar heating arrangement is fixed. The frame assembly has at least one opening through which extends at least one optical fiber coupled to the planar lightguide circuit. An overmold, which is molded around the frame assembly, includes at least one strain relief member through which the optical fiber extends.
In accordance with one aspect of the invention, the planar heating arrangement includes a thermally conductive ceramic substrate and a resistive heating element disposed on a first side of the substrate. The planar lightguide circuit may be disposed on a second side of the substrate.
In accordance with another aspect of the invention, the ceramic substrate is formed from aluminum-nitride.
In accordance with yet another aspect of the invention, an elastometric thermal interface pad is provided, which has a first surface in contact with the planar heating arrangement and a second surface in contact with the planar lightguide circuit.
In accordance with another aspect of the invention, the planar lightguide circuit and the substrate have substantially similar temperature coefficient of expansions.
In accordance with another aspect of the invention, the frame assembly includes a frame member and base and cover members secured to one another in an air tight, water resistant manner.
In accordance with yet another aspect of the invention, the strain relief member is integrally formed with the overmold and is configured as a tapered collar surrounding the optical fiber extending therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a thermally stabilized housing for a planar lightguide circuit constructed in accordance with the present invention.
FIG. 2 is a top perspective view and
FIG. 3 is an exploded perspective view of the housing shown in FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 depicts the housing 111 of the present invention as used to house a AWG or other planar lightguide circuit. An input buffered or insulated fiber 117 passes into the housing 111 for carrying optical signals to the AWG within the housing 111 . The signal output of the AWG exits housing 111 in a fiber ribbon 118 , wherein each fiber in the ribbon carries signals of one specific frequency. The ribbon 118 passes into a transition piece 119 wherein each fiber in the ribbon 118 is broken out and exits piece 119 in the form of a single insulated fiber 121 , each having a terminating jack plug 122 at its end. In operation, input fiber 117 carries a combination of signals having different wavelengths, and the AWG within the housing separates the signals by wavelength and applies them to the individual output fibers in ribbon 118 . Thus, each of the fibers 121 carries signals of a different wavelength from any of the other fibers. These wavelengths are typically quite closely spaced. For example, in an eight channel arrangement, the wavelengths maybe 1549.4 nm, 1551.0 nm, 1552.6 nm, 1554.2, 1555.9 nm, 1557.5 nm, 1559.1 nm, and 1560.7 nm. It can be seen that the successive wavelengths increase by only 1.6 nm approximately, a very small incremented difference. Spacings in 32 and 64 channel AWG are as small as 0.4 nm.
FIG. 2 is a top perspective view and FIG. 3 is an exploded perspective view of the housing 211 and the components contained therein. As shown, AWG 210 is located in a framed assembly that comprises aluminum frame 216 , stainless-steel base 218 and stainless-steel cover 220 . A first sidewall of frame 216 includes an opening or cutout 222 through which the fiber ribbon exits the frame assembly. Likewise, a second sidewall of the frame 216 opposing the first sidewall of the frame 216 includes an opening or cutout 224 through which the input fiber exits the frame assembly. A third sidewall of the frame 216 connecting the first and second sidewalls contains an opening or cutout 230 through which an electrical interface or pins 232 extend. The electrical interface provides power and control signals to an internal temperature controller, which is described below.
AWG 210 is mounted on a planar heating arrangement such as an aluminum nitride (AIN) heater 226 . AIN heater 226 includes an AIN substrate, which is a thermally conductive ceramic that has a low temperature coefficient of expansion that is similar to the temperature coefficient of expansion of the silica-based AWG 210 . In this way stress between the AWG 210 and the AIN heater 226 , which can arise from temperature fluctuations, is minimized. A serpentine heater element is screen printed on one side of the substrate using a thick film process. The AWG 210 is mounted on the side of the substrate opposite the heating element. A temperature sensor such as a thermistor or an RTD is also mounted on the side of the substrate on which the heater element is located to provide feedback information to a temperature controller. The temperature controller is also mounted on the side of the substrate on which the heater element is located. In some cases the temperature sensor may be located internal to the temperature controller. AIN heaters that include an integrated temperature controller are commercially available from ThermOptics™ Inc., for example.
A thermal interface pad 228 is disposed between the AWG 210 and the surface of the AIN heater 226 . The thermal interface pad 228 is formed from an elastometric material such as a thermoplastic film filled with AIN particles, which is coated with an adhesive, and serves to provide good heat transfer between the AWG 210 and the AIN heater 226 . A suitable thermal interface pad 228 is available, for example, from Melcor, Inc. The thermal interface pad 228 preferably has a temperature coefficient of expansion that is similar to that of the AWG 228 and the AIN 226 . The elasticity of the thermal interface pad 228 may facilitate a reduction in stress that may arise between any mismatch in the temperature coefficient of expansion of the AWG 228 and the AIN heater 226 .
The frame assembly is assembled in the following manner. Stainless-steel base 218 is fixed to the aluminum frame by any appropriate means such as with an adhesive, for example. In addition, the AWG 210 , thermal interface pad 228 and AIN heater 226 are secured to one another with tape or adhesive. In some cases the thermal interface pad 228 may be supplied with a pressure-sensitive adhesive for mounting the pad to the AIN heater 226 . Next, the AIN heater 226 is secured to the stainless-steel base 218 . In particular, the side of the AIN substrate on which the heater element and controller are located is secured to the stainless-steel base 218 with, for example, double-sided tape that has a thickness in excess of the thickness of the temperature controller. Finally, the frame assembly is completed by securing the stainless-steel cover 220 to the aluminum frame by any appropriate means such as with an adhesive, for example. Prior to securing the stainless-steel cover 220 to the frame 216 , the openings 222 , 224 , and 230 may be filled with foam rubber 238 to eliminate the gaps between the input fiber, fiber ribbon, electrical interface 232 and the respective cutouts through which they extend.
The frame assembly preferably forms an air tight, water resistant package to protect its internal components. This may be achieved by sealing any voids on the exterior surface of the assembly which may exist between the frame 216 , base 218 , cover 220 , the electrical interface 232 extending through cutout 230 , the input fiber extending through cutout 224 , and the fiber ribbon extending through cutout 222 . These voids may be filled with an adhesive such as a fast setting epoxy. Depending on the design specifications that the final device must meet, in some embodiments of the invention it may be desirable for the frame assembly to form a hermetic seal. The hermetic seal may be achieved by providing additional sealing means that are known to those of ordinary skill in the art.
The frame assembly undergoes a molding process in which an overmold is formed around the frame assembly. As seen in the figures, the overmold includes integrally formed strain relief elements through which the input fiber, fiber ribbon and electrical interface 232 respectively extend. The strain relief elements 240 , 242 and 244 , which are respectively aligned with the cutouts 230 , 224 , and 222 in the frame 216 , are protuberances that taper inward as they extend away from the frame assembly, thus each forming a collar about each of the fiber, fiber ribbon and electrical interface to reduce damage that could arise from tension exerted on them. The molding material that forms the overmold may be any material that has a sufficient degree of durability and softness to protect and cushion the internal components. Exemplary materials that may be employed include, for example, urethanes, polymers, and silicone.
Although various embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and are within the purview of the appended claims without departing from the spirit and intended scope of the invention. For example, while housing in accordance with the present invention has been described in terms of housing an AWG, the housing more generally may be employed to housed any planar lightguide circuit. Moreover, the invention is not limited to the particular materials and geometric configurations depicted herein.
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A housing is provided for maintaining a planar lightguide circuit at a temperature within a predetermined temperature range independent of ambient temperature. The housing includes a planar heating arrangement supporting and in thermal contact with the planar lightguide circuit. Also included is a frame assembly having a first surface on which the planar heating arrangement is fixed. The frame assembly has at least one opening through which extends at least one optical fiber coupled to the planar lightguide circuit. An overmold, which is molded around the frame assembly, includes at least one strain relief member through which the optical fiber extends.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a bit holder block and cutter bit therefor of the type used particularly in mining operations. More particularly, the present invention relates to a bit holder block and cutter bit therefor of the aforesaid class which is structured to provide resistance to bit holder block cracking during mining operations.
2. Description of the Related Art:
Typical mining operations, such as the removal of coal along a seam, are performed by a mining apparatus which drives a rotary member provided with a plurality of cutting tips. The cutting tips engage a surface being mined to thereby cause removal of material from the surface. Conventional cutting tips are constructed of a hardened material, such as carbide. The cutting tip is connected to a conical head located at a forward end of an elongated rod, the combination collectively forming a cutter bit. Each cutter bit must be located in a predetermined orientation with respect to the rotary member of the mining apparatus. Because mining operations involve severe wear and tear on the cutter bit, it has become the practice to provide bit holder blocks for replaceably receiving, respectively, each of the cutter bits. It has further become the practice that because of the wear and tear experienced also by the bit holder blocks, that the bit holder blocks are structured for being replaceably connected with respect to the rotary member. Examples of replaceable bit holder blocks and cutter bits are described in U.S. Pat. No. 3,749,449 to Krekeler, U.S. Pat. No. 3,841,708 to Kniff et al., U.S. Pat. No. 3,992,061 to Rollins, U.S. Pat. No. 4,302,055 to Persson, U.S. Pat. No. 4,343,516 to Aden, and U.S. Pat. No. 4,415,208 to Goyarts.
In order for a bit holder block to provide a satisfactory service life, it must be structured so as to adequately handle the forces acting on it as a result of its cutter bit engaging a surface being mined. Ordinarily, the cutter bit is of an elongated cylindrical shape, and the bit holder block is provided with a cylindrical bore into which the cutter bit is received. The cutter bit is ordinarily retained at a predetermined abutting relationship with respect to the bit holder block via a first fastener. The bit holder block is ordinarily provided with surfaces which interface with cooperating surfaces on the rotary member for anchoring the bit holder block thereto in conjunction with one or more second fasteners or weldment.
As exemplified by the disclosure in Goyarts (cited hereinabove) and depicted in FIG. 7A, the conventional theory of force distribution on the cutter bit CB with respect to the bit holder block HB under mining loads was that the resultant cutter bit force F' was directed above the axis A of the cutter bit. This conventional theory presumed that the magnitude of the cutting force F c ' on the cutter bit was larger than the magnitude of the normal force F n ' on the cutter bit. Accordingly, prior bit holder block structures have been provided for accommodating this direction of the resultant cutting bit force F'.
However, applicants have observed the location and development of stress cracks in bit holder blocks after a period of usage. These field observations have led applicants to the realization that the conventional theory of the force distribution is in error because the magnitude of the normal force actually exceeds the magnitude of the cutting force. As indicated in FIG. 7B, it has been determined by applicants that in order to be correct, the theory of force distribution must properly take into account the correct relative magnitudes of the cutting and normal forces F n , F c on the cutter bit. An analysis of the direction and magnitude of these forces has led applicants to the realization that the true resultant cutter bit force F is directed below the axis A of the cutter bit.
Accordingly, the present invention is a bit holder block which provides a structure which takes into account the true resultant cutter bit force F.
SUMMARY OF THE INVENTION
The present invention is an improved bit holder block and cutter bit therefor which takes into proper account the actual forces acting on the bit holder block during mining operations.
The bit holder block according to the present invention is composed of a singular metallic piece, as for example steel. A foot portion thereof is generally V-shaped and is provided with a plurality of surfaces for abutting cooperatively dimensioned and located surfaces of a seat formed in a rotary member. A bore is provided transversely in the foot portion. A bit holder portion of the bit holder block is located opposite the foot portion thereof. The bit holder portion is provided with a bit bore for receiving thereinto the cutter bit according to the present invention. A forward end of the bit holder portion is provided with a bit abutment face. A forward opening of the bit bore is substantially medially located with respect to the bit abutment face. A bit retainer access port is provided in the top of the bit holder portion, spaced with respect to the rear end of the bit holder block. The bit retainer access port communicates with a rear opening of the bit bore.
The cutter bit according to the present invention is provided with a conically shaped head, tipped with a hardened material. The conically shaped head terminates in an annular abutment surface for abutting the aforesaid bit abutment face. An elongate body extends axially from the annular abutment surface for being received within the aforesaid bit bore. An annular groove is provided adjacent the end of the cutter bit opposite the conical head and is located so as project out of the rear end of the bit bore and into the aforesaid bit retainer access port when the elongate body is fully received in the bit bore. A retainer clip is provided for engaging the annular groove to thereby interferingly retain the elongate body seated within the bit bore.
As depicted in FIG. 7B, the true resultant cutting bit force F acting on the bit holder block 12 is directed below the axis A of the cutter bit 14. The true resultant cutting bit force F resolves into two components with respect to the bit holder block, a bit axial force F a and a bit transverse force F x . The bit axial force F a is resisted by the bit abutment face 40 of the bit holder block with respect to the annular abutment surface 58 of the cutting bit. However, the bit transverse force F x creates a bending moment on the cutter bit. As a result of this bending moment, the bit holder block is caused to serve as a fulcrum at point P f of the bit bore 50 with a consequent fulcrum moment force F f acting on the bit holder block at the bit bore adjacent the bit retention access port 52. With this theory in mind, the present invention is a bit holder block providing increased structural strength at a rear segment 64 of the bit holder block extending from the retainer access point 52 to the rear surface 28 thereof in order to provide added regional strength sufficient to resist the fulcrum moment force F f .
Accordingly, it is an object of the present invention to provide a bit holder block for holding a cutting bit having increased structural strength at the rear segment of the bit holder block to adequately resist the fulcrum moment force generated thereat.
It is a further object of the present invention to provide a bit holder block and cutting bit therefor wherein the bit holder block is resistive to forces generated on the cutter bit during operation, specifically fulcrum moment force and cutter bit axial force.
These and additional objects, features and benefits will become clear from the following description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a plurality of bit holder block and cutter bit combinations according to the present invention, shown installed with respect to a rotary member of a mining apparatus.
FIG. 2 is a perspective, exploded view of the bit holder block and cutter bit combination according to the present invention.
FIG. 3 is a partly sectional side view of the bit holder block and cutter bit combination according to the present invention, shown installed with respect to the rotary member of the mining apparatus of FIG. 1.
FIG. 4 is a partly sectional view of the bit holder block and outer bit combination according to the present invention, seen along line 4--4 in FIG. 3.
FIG. 5 is a front elevational view of the bit holder block according to the present invention.
FIG. 6 is a left side elevational view of the bit holder block according to the present invention.
FIGS. 7A and 7B are side views of a bit holder block and cutting bit combinations according to the present invention, wherein FIG. 7A shows theoretical forces acting thereupon during operation thereof according to conventional theory, and wherein FIG. 7B shows actual forces acting thereupon during operation according to the present theory set forth herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Drawing, FIG. 1 generally depicts a plurality of bit holder block and cutting bit combinations 10 according to the present invention, shown in a typical environment of operation in which each bit holder block 12 and cutter bit 14 thereof are connected to a rotary member 16 of a conventional mining apparatus (not shown). It will be noted that the rotary member 16 has a periphery 16' at which is provided a plurality of seats 18 recessed thereinto, wherein each seat receives a respective bit holder block 12. The cutter bits 14 are each provided with a predetermined orientation with respect to the periphery 16' so that as the rotary member 16 rotates about a center axis C in the direction of arrow R, the cutting tip 20 of each of the cutter bits 14 will engage a surface (not shown) to be mined or otherwise worked.
Referring now additionally to FIGS. 2 through 6 and 7B, the structure and function of the bit holder block and cutter bit combination 10 according to the present invention will be detailed with greater specificity.
As depicted in FIG. 2, the bit holder block 12 and cutter bit 14 of each bit holder block and cutter bit combination 10 is structured[such that the cutter bit is releasable from the bit holder block, the releasability of which, as described hereinbelow, is controlled by a retainer clip 22.
The bit holder block 12 according to the present invention is composed of a singular metallic piece. An example of a suitable construction material is steel, preferably AISI 864OH, but other suitably strong and durable materials can also be used. The bit holder block 12 is structured in a predetermined configuration which provides strength at locations of known stress caused by the forces acting on the cutter bit 14 during operation, as will be discussed in detail hereinbelow.
A foot portion 24 of the bit holder block 12 is generally V-shaped and is provided with a plurality of surfaces, as follows: a flat front surface 26, a flat rear surface 28 located opposite the front surface, a flat left surface 30, a flat right surface 32 located opposite the left surface, and a bottom surface 34 located contiguous the aforementioned surfaces, as shown in FIGS. 5 and 6, for abutting cooperatively dimensioned and oriented surfaces of a respective seat 18 formed in a rotary member 16. The bottom surface 34 has a flat central portion 34a and contiguous the left and right surfaces 30, 32, the bottom surface is provided, respectively, with chamfered side portions 34b, the chamfer angle being preferably forty-five degrees with respect to the central portion. Similarly, the bottom surface 34 contiguous the front surface 26 is preferably provided with a chamfered front portion 34c, the chamfer angle being preferably forty-five degrees with respect to the central portion 34a. Each of the left and right surfaces 30, 32 are mutually diverging with increasing distance from the bottom surface 34. A preferred angle of each of the left and right surfaces 30, 32 with respect to the central portion 34a of the bottom surface 34 is seventy-eight degrees, wherein the left and right surfaces mutually diverge at an angle of 24 degrees. The front surface 26 is angled substantially at ninety degrees with respect to the front portion 34c of the bottom surface 34; that is, substantially at forty-five degrees with respect to the central portion 34a of the bottom surface. The rear surface 28 is oriented parallel with respect to the front surface 26. Bore 36 extends through the bit holder block 12 having openings thereof at each of the left and right surfaces 30, 32 substantially near the rear surface 28, the exact location of which will be explained hereinbelow.
A bit holder portion 38 of the bit holder block 12 is located opposite the foot portion 24 thereof. The bit holder portion 38 is provided with a bit abutment face 40 which contiguously meets the front surface 26 at an angle of preferably fourteen degrees with respect thereto, as generally shown in FIG. 2. The bit holder portion 38 further has a radiused top surface 42 which smoothly curves over one-hundred-eighty degrees, the apex 44 of which forms a line along its length that is at an angle of preferably fifty degrees with respect to the central portion 34a of the bottom surface 34. The top surface 42 meets the bit abutment face 40 and the rear surface 28, and meets the left and right surfaces 30, 32, respectively, via left and right sidewalls 46, 48 which are progressively increasing in size toward the bit abutment face 40. A bit bore 50 is provided in the bit holder portion 38, wherein the forward opening 50a thereof is located substantially medial with respect to the bit abutment surface 40. The bit bore 50 extends interiorly in perpendicular relation to the bit abutment surface 40, and terminates at a rear opening 50b. A bit retainer access port 52 is provided in the top surface 42 of the bit holder portion 38, a rear sidewall 52b thereof being spaced from, but substantially near, the rear end 28. In this regard, the bit retainer access port 52 communicates with the rear opening 50b of the bit bore 50 at a front sidewall 52a thereof. Further in this regard, bore 36 adjoins the bit retainer access port 52, wherein the bore communicates with the bit retainer access port 52 so as to provide, as shown in FIG. 4, clearance for the retainer clip 22. Preferably, the rear section 42a of the top surface 42 is provided with a chamfer between the retainer access port 52 and the rear surface 28.
The cutter bit 14 according to the present invention is provided with a conically shaped head 54 to which is connected a hardened material tip 20, such as, for example, carbide. The conically shaped head 54 connects with an elongated body 56 having a cross-section less than that of the conically shaped head at the connection therebetween. The difference in cross-sections of the elongated body 56 and the conically shaped head 54 define an annular abutment surface 58. In this regard, the elongated body 56 is dimensioned to be received within the bit bore 50, wherein, when fully received thereinto, the annular abutment surface 58 abuts the bit abutment face 40 of the bit holder block 12. An annular groove 60 is provided adjacent the end 64 of the elongated body 56 opposite the conical head 54. The annular groove 60 is located so that when the elongated body 56 is fully received into the bit bore 50, the elongated body projects out of the rear opening 50b and into the bit retainer access port 52, whereupon the annular groove is situated within the bit retainer access port. The retainer clip 22 is placed through the bit retainer access port 52 and engaged in a selectively removable manner with the annular groove 60. The retainer clip 22 interferingly abuts the front sidewall 52a of the bit retainer access port 52 adjacent the rear opening 50b of the bit bore 50, thereby preventing extraction of the cutter bit 14 therefrom.
In operation, the bit holder block 12 is welded to the rotary member 16 along surfaces 34a, 34b, 34c and surface 28. The cutter bit 14 is installed by placing the elongated body 56 into the bit bore 50 until the annular abutment surface 58 abuts the bit abutment face 40. Then the retainer clip 22 is placed onto the annular groove 60 by passage thereof through the bit retainer access port 52. In this regard, the end 64 of the elongated body 56 adjacent the annular groove 60 does not contact the rear sidewall 52b of the bit retainer access port 52 when the annular abutment surface 58 abuts the bit abutment surface 40, as shown in FIG. 3.
It will be noted that to replace cutter bits, all that needs to be done is to remove the retainer clip from the retainer access port and then extract to cutter bit from the bit bore.
As indicated in FIG. 7B, a major aspect of the present invention is to provide a bit holder block 12 which is structured to take into account the true resultant force F acting on the cutter bit 14 as it is operatively engaging a surface. Since the magnitude of the cutter bit normal force F n exceeds the magnitude of the force F c , the resultant cutter bit force F acting on the bit holder block 12 is directed below the axis A of the cutter bit 14. The resultant cutter bit force F resolves into two components with respect to the bit holder block 12, these being a bit axial force F a and a bit transverse force F x . The bit axial force F a is resisted by the bit abutment face 40 of the bit holder block with respect to the annular abutment surface 58 of the cutter bit 14. However, the bit transverse force F x creates a bending moment on the cutter bit. As a result of this bending moment, the bit holder block 12 is caused to serve as a fulcrum at point P f of the bit bore 50 with a consequent fulcrum moment force F f acting on the bit holder block at the bit bore adjacent the bit retention access port 52.
With this theory of force distribution in mind, the present invention provides a bit holder block with increased structural strength at the rear portion of the bit holder block to thereby resist the fulcrum moment force F f .
In this regard, as depicted in FIG. 3, the bit holder block 12 is provided with a rear segment 66 located between the front sidewall 52a of the bit retainer access port 52 and the rear surface 28. In this regard, the rear segment 66 includes a rear wall 68, a left wall 70 extending from the rear wall to the front sidewall 52a, and a right wall 71 opposite the left wall and extending also from the rear wall to the front sidewall. The thickness of the rear wall 68 is on the order of at least the thickness 90 (FIG. 5) of the bit holder' block between the bit bore 50 and the apex 44, whereas the left and right walls 70, 71 have a thickness on the order of at least one-half the bit bore to apex distance 90. Accordingly, the rear segment 66 provides, adjacent the retainer access port 52, regional structural strength for the bit block holder 12 at the general location of the application of the fulcrum moment force F f . As a result, a long life of the bit holder block 12 can be expected, without structural fatigue, cracking or distortion occurring.
It should noted that since the cutter bit 14 is located in the bit bore 50 by operation of an abutting relationship between the annular abutment surface 58 and the bit abutment face 40, there is no need for locating structure rearward of the rear opening 50b of the bit bore. It is thus made clear that the present invention provides the rear segment 66 in order to assuage the fulcrum moment force F f in accordance with applicants' theory of force distribution as enunciated hereinabove.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. For example, the exact angles and dimensions of the surfaces of the bit holder block may be varied, but nonetheless a rear segment would be included therewith as generally defined herein. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited by the scope of the appended claims.
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A bit holder block is provided composed of a foot portion for being received in a seat of a rotary member and a bit holder portion for releasably holding a cutter bit with respect to a bit bore therein. The bit bore has a forward opening at a bit abutment face of the bit holder block. The cutter bit is provided with an annular abutment surface for abutting the bit abutment face. A bit retainer port is provided in the bit holder block located at, and communicates with, a rear opening of the bit bore for therein securing a retainer clip to an annular groove in the cutter bit. A rear segment of the bit holder block provides a strong reinforcing structure for the area around the rear opening of the bit bore which counters a fulcrum force generated at the rear opening of the bit bore, the fulcrum force arising during operation due to a resultant force acting on the cutter bit being directed below the axis of the cutter bit, rather than above it, as was previously believed in the art.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional Application for a U.S. Patent claims the benefit of priority of MY PI 2015 702511 filed Jul. 31, 2015, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a lubricant. The invention particularly relates to a lubricant suitable for use in magnetic recording medium mounted in magnetic storage devices for computers, laptops and the like. More specifically, the present invention relates to a lubricating layer disposed over a protective layer of a magnetic recording medium. 2.Background of the Related Art
[0004] Magnetic storage devices such as hard disk drives (HDD) comprise a magnetic recording medium (MRM, or magnetic disk) rotating at high speeds, and a magnetic head facing the MRM. Data are written to the MRM and data written on the MRM are read by the magnetic head flying just above the surface of the MRM. The data recording density becomes greater (and therefore more data is stored given the same surface area) when the magnetic spacing is reduced. The magnetic spacing is defined by the distance between the magnetic recording layer of the MRM and the reading portion of the magnetic head.
[0005] Recently, the magnetic spacing has been reduced to extreme low levels to satisfy the demands for ever increasing hard disk drive capacity, and the chance of the magnetic recording medium (MRM) making contact with the magnetic head increases as a result. To protect the magnetic layer of the MRM from wear and damage due to contact with the magnetic head, a protective overcoat layer (also known as protective layer) is laminated over the magnetic recording layer, and to allow the magnetic head to smoothly glide off the MRM whenever they inevitably make contact with each other, a lubricating layer is further laminated over the protective overcoat layer.
[0006] Perfluoropolyether (PFPE) lubricant is the type of lubricant most commonly used for this purpose as it has high wear resistance, high stability and other features that make it most suitable for lamination over the protective overcoat layer. As the magnetic spacing is further reduced over time, various improvements of PFPE lubricants have been studied and devised to accommodate the ever narrowing distance between the MRM and the magnetic head.
[0007] Various types of functional groups are known to be added to an end group (also known as a terminal group) of a PFPE. They include, for example: the —OH group, the —COOH group, the —NH 2 group, and a phenyl (C 6 H 5 ) group. The characteristics of the lubricant differ greatly not only by the type of functional group used, but also by the number of functional group(s) that exist within each molecule of the lubricant. Therefore, various functional groups (and combinations of them) have been added to a PFPE, including for example adding one —OH to one of the PFPE's end group, two —OH to one of the PFPE's end group, or one —OH to both of the PFPE's end groups, and so on to produce lubricants of vastly different characteristics.
[0008] Another method of producing PFPE lubricants with the desired characteristics is to mix different types of PFPE-based lubricants. For example, U.S. Pat. No. 8,980,449 discloses a mixture of two types of PFPE lubricants. One of them is a PFPE lubricant with two —OH groups in each of its end groups. The other has a PFPE main chain and two —OH groups within one end group and a cyclic triphosphazene group within the other end group. The resultant mixture was a lubricant with the advantages of both originating PFPE lubricants.
[0009] A further method of producing PFPE lubricants with the desired characteristics is to use two PFPE lubricants containing highly reactive molecules. U.S. Pat. No. 5,498,457 discloses a chemical reaction after two types of PFPE lubricants with highly reactive end groups are mixed. The lubricant mixture eventually formed a stable and bulky network after the lubrication layer has been applied to the magnetic recording medium. The two types of molecules provided by the two PFPE lubricants underwent ionic interaction at their functional groups. According to one of the examples of U.S. Pat. No. 5,498,457, when the lubricant mixture is made up of one lubricant molecule having carboxyl group at both ends, and another lubricant molecule having amino group at both ends, the carboxyl groups and the amino groups of the two lubricant molecules would eventually react to give rise to ammonium carboxylate salt. The reaction propagates across the entire lubricant layer until all the reactive end groups have reacted with each other, eventually forming a large molecular network. Furthermore, if the lubricant molecules have excess functional groups, these function as groups adsorbable onto the disk surface.
[0010] Owing to the efforts as described earlier, PFPE lubricants have been improved. However, the never ending reduction of the magnetic spacing necessitates further improvements to the lubricants used to protect the magnetic recording medium. Hard disk drives are demanded to be made smaller with each passing year, while at the same time their storage capacities are being demanded to double or triple in size to accommodate vast amounts of digital data.
[0011] Essentially, a lubricant layer laminated over the protective overcoat layer of a magnetic recording medium (MRM) has to improve over time in the following four areas.
[0012] (1) The lubricant layer deposited over the protective overcoat layer must become increasingly thinner in order to allow the magnetic head to fly closer to the magnetic layer. This improves read/write performance, and also increases the capacity of the magnetic recording medium.
[0013] (2) The lubricant molecules must develop stronger affinity to the MRM disk surface to minimize scattering by centrifugal force. The stronger the affinity, the longer the lubricant molecules will stay attached to the MRM. This in turn provides the hard disk drive with a longer service life. The molecules' strong affinity to the MRM disk surface also allow the MRM to spin faster (higher RPM), thus improving read/write speed of the hard disk drive.
[0014] (3) The lubricant molecules must form an increasingly uniform film over the protective overcoat layer (or protective layer) with better surface coverage. The more uniform the molecules are spread over the protective overcoat layer, the closer the magnetic head can fly over the MRM without making contact with the MRM surface.
[0015] (4) The lubricant molecules must become increasingly durable in terms of MRM weariness. Hard disk drives become hot when in use, and lubricant molecules when heated to a certain degree will start to evaporate. Also, wear and tear will be faster as the ever reducing magnetic spacing causes the magnetic head to make contact with the MRM more often when they are in use.
[0016] Also, lubricant molecules with a lower coefficient of friction are always desired. The ability of these molecules to self-replenish is also desired. The contacts between the MRM with the magnetic head will undoubtedly sometimes remove some lubricant molecules from the MRM surface. When this happens, adjacent molecules redistribute, and fill whatever gaps on the MRM surface the contact has left behind.
[0017] In cases such as those of U.S. Pat. No. 5,498,457, however, the reaction that propagates across the entire lubricant layer until a large molecular network is formed prevents or hinders this self-replenishing ability.
[0018] Therefore, there remains an unfulfilled need for an improved lubricating compound capable of being laminated over a magnetic recording medium so that the resultant hard disk drives can become smaller and lighter, while able to store more and more digital data, are durable and reliable, and at the same time is still able to perform as efficiently as, if not better, than presently available hard disk drives.
[0019] Thus, the principal object of the present invention is to provide a new type of perfluoropolyether lubricant. The lubricant is especially useful for a magnetic recording medium (MRM). When applied over the MRM's protective overcoat layer, the resultant lubricating surface adds minimal additional thickness to the MRM, and at the same time maintains a uniform coverage across the MRM's surface, reduces wear and tear and friction between the MRM and the magnetic head, thereby resulting in better reliability and durability of the hard disk drive.
SUMMARY OF THE INVENTION
[0020] For the purpose of this description, the magnetic recording medium of the hard disk drive is also abbreviated as MRM, and whenever a MRM is mentioned, it is understood that the MRM is comprised of at least a substrate, a magnetic recording layer, a protective layer (e.g., a carbon layer) and a lubricating layer. Other variations of an MRM exist, but they essentially serve the same function, which is to store digital data within a hard disk drive, and shall be considered the same for the purpose of this description.
[0021] According to one aspect of the invention, there is provided an ionic lubricant compound having a perfluoropolyether main chain, wherein each end of the perfluoropolyether main chain is terminated by an end group; and at least one of the end groups comprises an ionic bond and at least one functional group.
[0022] Two reactants, with one providing the perfluoropolyether (PFPE) main chain of the lubricant according to an embodiment of the present invention, are chemically reacted to give rise to an ionic PFPE lubricant.
[0023] According to one preferred feature, the ionic bond is between a carboxylic acid group and a basic amino group.
[0024] The carboxylic acid group donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms an ammonium ion.
[0025] In one embodiment, the end group comprises hydrocarbon chain.
[0026] The physical and chemical characteristics of a typical hydrocarbon chain, including insolubility in water and solubility in certain organic solvents, become a part of the physical and chemical characteristics of the resultant PFPE lubricant.
[0027] In another embodiment, the end group comprises a fluorocarbon chain.
[0028] Similarly, the physical and chemical characteristics of a typical fluorocarbon chain, including insolubility in water and most organic solvents, become a part of the physical and chemical characteristics of the resultant PFPE lubricant.
[0029] In a further embodiment, the end group comprises from 3 to 6 carbon atoms.
[0030] In yet another embodiment, the functional group is a hydroxyl group.
[0031] In another embodiment, the functional group is a phenyl group.
[0032] The functional group allows the lubricant molecule to anchor/adhere itself to the protective overcoat layer/protective layer, which contains carbon. As hydroxyls are highly reactive, with the electronegativity of the oxygen atom substantially greater than the hydrogen atom, the hydroxyl group anchors/adheres the lubricant molecule to the protective overcoat layer.
[0033] Similarly, a functional group comprising phenyl is highly reactive, enabling it to anchor/adhere the lubricant molecule to the protective overcoat layer. Phenyls, however, possess an additional advantage over hydroxyls in that they are also structurally flatter than hydroxyls, thus can adhere closer to the protective overcoat layer.
[0034] In another embodiment, the ionic bond is at least two chemical bonds from the end of the perfluoropolyether main chain.
[0035] In a further embodiment, the perfluoropolyether main chain is represented by chemical formula (A) as follows
[0000]
[0000] where m, n are positive integers.
[0036] Formula (A) represents the back bone of the preferred PFPE molecule according to one of the embodiments of the present invention.
[0037] In yet another embodiment, the perfluoropolyether main chain is represented by chemical formula (B) as follows:
[0000] —O—(CF 2 —CF 2 —CF 2 —O) m — (B),
[0000] where m is a positive integer.
[0038] As an alternative to formula (A), formula (B) is able to replace the preferred PFPE main chain according to one of the embodiments of the present invention.
[0039] In a further embodiment, the perfluoropolyether main chain is represented by chemical formula (C) as follows:
[0000] —O—(CF—CF 2 —O) m — (C),
[0000] where m is a positive integer.
[0040] Similarly, as an alternative to formula (A), formula (C) is able to replace the preferred PFPE main chain according to one of the embodiments of the present invention.
[0041] In yet another embodiment, the perfluoropolyether main chain is represented by chemical formula (D) as follows:
[0000] —O—(CF(CF 3 )—CF 2 —O) m — (D),
[0000] where m is a positive integer.
[0042] As yet another alternative to formula (A), formula (D) is able to replace the preferred PFPE main chain according to one of the embodiments of the present invention.
[0043] According to one embodiment, an ionic lubricant is represented by chemical formula (1) as follows:
[0000]
[0000] where m and n are positive integers.
[0044] The lubricant represented by formula (1) has an ionic bond and a hydroxyl group located at each end of the perfluoropolyether main chain. The ionic bonds and the hydroxyl groups are located in the end groups.
[0045] In another embodiment, an ionic lubricant is represented by chemical formula (2) as follows:
[0000]
[0000] where m and n are positive integers.
[0046] The lubricant represented by formula (2) has an ionic bond and a hydroxyl group located at each end of the perfluoropolyether main chain. The ionic bonds and the hydroxyl groups are located in the end groups, and the hydroxyl groups branches from the linear PFPE molecule.
[0047] According to a further embodiment, an ionic lubricant is represented by chemical formula (3) as follows:
[0000]
[0000] where m and n are positive integers.
[0048] The lubricant represented by formula (3) has an ionic bond and a hydroxyl group located at each end of the perfluoropolyether main chain. The ionic bonds and the hydroxyl groups are located in the end groups.
[0049] In yet another embodiment, an ionic lubricant is represented by chemical formula (4) as follows:
[0000]
[0000] where m and n are positive integers.
[0050] The lubricant represented by formula (4) has an ionic bond and two hydroxyl groups located at each end of the perfluoropolyether main chain. The ionic bonds and the hydroxyl groups are located in the end groups.
[0051] In a further embodiment, an ionic lubricant is represented by chemical formula (5) as follows:
[0000]
[0052] The lubricant represented by formula (5) has an ionic bond and a phenyl group located at each end of the perfluoropolyether main chain. The ionic bonds and phenyl groups are located in the end groups.
[0053] According to another aspect, the invention provides a magnetic recording medium, comprising a substrate and at least a magnetic layer, a protective layer, and a lubricating layer provided in the order recited over the substrate, wherein the lubricating layer is comprised of: a single lubricant compound having a perfluoropolyether main chain; each end of the perfluoropolyether main chain is terminated by an end group; and at least one of the end groups comprises an ionic bond and at least one functional group.
[0054] In one embodiment, the ionic bond is at least two chemical bonds from the end of the perfluoropolyether main chain.
[0055] In another embodiment, the end group comprises a hydrocarbon chain.
[0056] In another embodiment, the end group comprises a fluorocarbon chain.
[0057] In a further embodiment, the end group comprises from 3 to 6 carbon atoms.
[0058] In yet another embodiment, the functional group is a hydroxyl group.
[0059] In yet a further embodiment, the functional group is a phenyl group.
BRIEF DESCRIPTION OF THE DRAWING
[0060] The invention will be described in conjunction with a single drawing which is only for the purpose of illustrating the embodiments of the present invention, and not for the purpose of limiting the present invention.
[0061] FIG. 1 is a cross-sectional view of a magnetic recording medium according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0062] The invention is described in detail in reference to the Examples below and the accompanying FIG. 1 .
[0063] The invention relates to an ionic type perfluoropolyether lubricant. The lubricant is especially suited for the lubrication of a magnetic recording medium (MRM). The lubricant is applied as a lubricating layer 4 over the top surface of the magnetic disk, which is typically a carbon coated protective overcoat layer 3 . Due to its molecular structure, the lubricant can easily achieve a thin but uniform coverage over the entire surface of the MRM, which is preferred for example in an ultra compact portable hard disk drive with high storage capacities, for example, in the range of 1 to 3 terabytes (TB). The ultra thin lubrication layer 4 allows the MRM to rotate closer to the magnetic head, reduces wear and tear of the MRM, thus achieving high capacity storage while keeping the portable hard disk drive reliable and durable, despite its ultra compact dimensions.
[0064] In an example of the present invention, the lubricant is PFPE type consisting of a main chain and two end groups each terminating the main chain. The main chain has the following chemical formula (A):
[0000]
[0000] where m, n are positive integers.
[0065] The lubricant molecule has only one main chain of formula (A). This feature is preferable in obtaining the desired low viscosity of the lubricant. Formula (A) is the main chain of a common PFPE, commercially known as Fomblin® PFPE. Fomblin® lubricants are fluorinated lubricants most suitable in aggressive chemical environments, high temperatures or where wide working-temperature ranges are involved.
[0066] Notwithstanding the above PFPE main chain, other types of PFPE main chain may also be used, such as —O—(CF 2 —CF 2 —CF 2 —O) m — (Demnum®), —O—(CF—CF 2 —O) m —, or —O—(CF(CF 3 )—CF 2 —O) m —.
[0067] Preferably, each end group of the lubricant molecule has at least one ionic bond and at least one functional group.
[0068] The ionic bond furnishes the lubricant with unique characteristics. The presence of ionic bond as a result of the strong electrostatic interaction between the cation and the anion in the salts could raise the boiling point of the ionic lubricant. Conventional lubricants which consist of mainly covalent bond may suffer the disadvantage of undergoing evaporation with time at high operating temperatures, hence reducing their protection effects over the MRM surface. The use of low-volatility ionic lubricant will help to reduce the evaporation rate and prolong the life of the MRM.
[0069] The example of ionic bond is O − N + derived from carboxylic acid group (—COOH) and amino group. Carboxylic acid can donate a hydrogen ion (H+) to the nitrogen lone pair of the amino group.
[0070] The lubricant has at least one functional group in the end group. The first preferred functional group in an embodiment of the present invention is a hydroxyl group (—OH). A second preferred functional group in an embodiment of the present invention is a phenyl group. It is of course to be appreciated that other functional groups may be used as well. The functional group will interact with the elements, such as carbon, of the protective overcoat layer 3 and anchor the lubricant molecule to the protective overcoat layer 3 . This will give the lubricant molecules an adhesive force to latch onto the protective overcoat layer 3 . The adhesive force will help to prevent the lubricant molecules from being scattered when the MRM is in use. Most hard disk drives spin their magnetic recording medium up to 7200 RPM when in use. Therefore, this adhesive characteristic is obviously advantageous when the lubricant molecules are subjected to such high centrifugal force by the spinning MRM.
[0071] The examples of the end groups are represented by formula (E) to (I) which follow.
[0000]
[0072] The number of carbons in the end group may be changed from the above examples. The preferred number of carbon atoms in the end group according to an embodiment of the present invention is from 3 to 6 carbon atoms. By increasing the carbon atoms of non-polar component (in case of the figures above, carbons disposed at right side of the ionic bond) in the end group, this could improve the solubility of the ionic salt in organic solvent. Apart from that, by introducing hydrocarbon chain into the lubricant is also beneficial in order to achieve a balance of the hydrophobic and hydrophilic properties of the lubricant to ensure better coverage and low friction coefficient of the lubricants.
[0073] It is possible to adopt two or more functional groups in the lubricant.
EXAMPLE 1
[0074] The lubricant material was obtained by reacting the Fomblin® Z DIAC PFPE lubricant (manufactured by Solvay Specialty Polymers) with the amino-alcohol molecule. The mixture of Z DIAC and a 5% excess of the long chain amino-alcohol is warmed to 80-90° C. with constant stirring until complete dissolution is obtained. The salt formed after the reaction is then rinsed with hexane in order to remove the excess amino-alcohol. The chemical structure of the synthesized ionic salt can be characterized by infrared spectroscopy (FT-IR).
[0075] Scheme 1 below illustrates the synthetic scheme for the proposed ionic lubricant formula (1). Fomblin Z DIAC, i.e., COOHCF 2 O[CF 2 CF 2 O]m[CF 2 O]nCF 2 COOH, and 4-amino-1-butanol are used. The carboxylic acid end group (—COOH) donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms ammonium ion. Both end groups have long chain hydrocarbon with an ester, amide, alcohol and carboxylate ammonium salt. The hydroxyl group (—OH) in 4-amino-1-butanol anchors or adhere the resultant molecule to MRM's protective overcoat layer 3 , which comprises carbon.
[0000]
[0000] where m, n are positive integers.
EXAMPLE 2
[0076] The lubricant material was obtained by reacting the Fomblin® Z DIAC PFPE lubricant (manufactured by Solvay Specialty Polymers) with 4-amino-2-propanol. The mixture of Z DIAC and a 5% excess of the long chain 4-amino-2-propanol is warmed to 80-90° C. with constant stirring until complete dissolution is obtained. The salt formed after the reaction is then rinsed with hexane in order to remove the excess amino-alcohol. The chemical structure of the synthesized ionic salt can be characterized by infrared spectroscopy (FT-IR).
[0077] Scheme 2 which follows illustrates the synthetic scheme for the proposed ionic lubricant formula (2). Fomblin Z DIAC, i.e., COOHCF 2 O[CF 2 CF 2 O]m[CF 2 O]nCF 2 COOH, and 4-amino-2-propanol are used. The carboxylic acid end group (—COOH) donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms ammonium ion. Both end groups have long chain hydrocarbon with an ester, amide, alcohol and carboxylate ammonium salt. The hydroxyl group (—OH) in 4-amino-2-propanol anchors or adhere the resultant molecule to MRM's protective overcoat layer 3 , which comprises carbon. The hydroxyl group acts as the branched group from the linear PFPE ionic molecule.
[0000]
[0000] where m, n are positive integers.
EXAMPLE 3
[0078] The lubricant material was obtained by reacting the Fomblin® Z DIAC PFPE lubricant (manufactured by Solvay Specialty Polymers) with 4-amino-1-fluorobutanol. The mixture of Z DIAC and a 5% excess of the long chain 4-amino-1-fluorobutanol is warmed to 80-90° C. with constant stirring until complete dissolution is obtained. The salt formed after the reaction is then rinsed with hexane in order to remove the excess amino-alcohol. The chemical structure of the synthesized ionic salt can be characterized by infrared spectroscopy (FT-IR). Replacing the hydrocarbon chain (—CH 2 —) with a fluorocarbon chain (—CF 2 —) improves the wettability and solubility of the resultant lubricant. The resultant lubricant is also chemically and thermally more stable than its hydrocarbon counterpart.
[0079] Scheme 3 which follows illustrates the synthetic scheme for the proposed ionic lubricant formula (3). Fomblin Z DIAC, i.e., COOHCF 2 O[CF 2 CF 2 O]m[CF 2 O]nCF 2 COOH, and 4-amino-1-fluorobutanol are used. The carboxylic acid end group (—COOH) donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms ammonium ion. Both end groups have long chain fluorocarbon with an ester, amide, alcohol and carboxylate ammonium salt. The hydroxyl group (—OH) in 4-amino-1-fluorobutanol anchors or adhere the resultant molecule to MRM's protective overcoat layer 3 , which comprises carbon.
[0000]
[0000] where m, n are positive integers.
EXAMPLE 4
[0080] The lubricant material was obtained by reacting the Fomblin® Z DIAC PFPE lubricant (manufactured by Solvay Specialty Polymers) with the amino-alcohol molecule. The mixture of Z DIAC and a 5% excess of the long chain amino-alcohol is warmed to 80-90° C. with constant stirring until complete dissolution is obtained. The salt formed after the reaction is then rinsed with hexane in order to remove the excess amino-alcohol. The chemical structure of the synthesized ionic salt can be characterized by infrared spectroscopy (FT-IR)
[0081] Scheme 4 which follows illustrates the synthetic scheme for the proposed ionic lubricant formula (4). Fomblin Z DIAC, i.e., COOHCF 2 O[CF 2 CF 2 O]m[CF 2 O]nCF 2 COOH, and the diol of NH 2 CH 2 CHOHCH 2 OH (3-aminopropan-1,2-ol) are used. The carboxylic acid end group (—COOH) donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms ammonium ion. Both end groups have long chain hydrocarbon with an ester, amide, alcohol and carboxylate ammonium salt. The hydroxyl group (—OH) in 3-aminopropan-1,2-ol anchors or adhere the resultant molecule to MRM's protective overcoat layer 3 . It is note that the terminal ends have two hydroxyl groups, and thereby providing stronger anchoring/adhesive power to the MRM's protection layer, which comprises carbon.
[0000]
[0000] where m, n are positive integers.
EXAMPLE 5
[0082] The lubricant material was obtained by reacting the Fomblin® Z DIAC PFPE lubricant (manufactured by Solvay Specialty Polymers) with 4-phenylbutylamine. The mixture of Z DIAC and a 5% excess of the long chain 4-phenylbutylamine is warmed to 80-90° C. with constant stirring until complete dissolution is obtained. The salt formed after the reaction is then rinsed with hexane in order to remove the excess phenylbutylamine. The chemical structure of the synthesized ionic salt can be characterized by infrared spectroscopy (FT-IR). Replacing the hydroxyl group (—OH) with phenyl group (—C 5 H 5 ) improves lubricant coverage, as phenyl rings are flatter than hydroxyls. This results in a thinner lubrication layer, and thus reduces the magnetic spacing further.
[0083] Scheme 5 which follows illustrates the synthetic scheme for the proposed ionic lubricant formula (5). Fomblin Z DIAC, i.e., COOHCF 2 O[CF 2 CF 2 O]m[CF 2 O]nCF 2 COOH, and 4-phenylbutylamine are used. The carboxylic acid end group (—COOH) donates a hydrogen ion (H+) to the nitrogen lone pair of the amino group and forms ammonium ion. Both end groups have long chain hydrocarbon with an ester, amide, benzene and carboxylate ammonium salt. The phenyl group (C 6 H 5 ) in 4-phenylbutylamine can lie flatter and adhere the resultant molecule to MRM's protective overcoat layer 3 , which comprises carbon.
[0000]
EXAMPLE b 6
[0084] The magnetic recording medium with the cross-sectional view as shown in FIG. 1 with the lubricant represented by the formulae (1) through (5) is prepared.
[0085] The substrates used are 65 mm diameter rigid magnetic disks 5 composed of glass substrates 1 . A magnetic layer 2 comprised of chromium and cobalt-based recording layer is sputter-deposited onto the substrate followed by the deposition of protective nitride carbon overcoat layer 3 through plasma-enhanced chemical vapor deposition (PECVD) process. The lubricant 4 is applied onto the protective overcoat layer 3 by using a dip-coating method. Each of the ionic lubricant material of formulae (1) through (4) is mixed with fluorinated solvent. The solvent was Vertrel/methanol (manufactured by Dupont). The concentration of the lubricant material in the solution was 0.5% by weight. The film thickness after dipping was quantified using FT-IR spectroscopy method (grazing angle). Each sample showed satisfactory results.
[0086] The number of main chains in every embodiment of the present invention is kept to a minimum, which resulted in small, uncomplicated lubricant molecules. The presence of an ionic bond at the end group gives the lubricant physical properties that are typical of ionic bonds including high boiling point, and partial solubility in water when combined with the hydrophobic properties of the hydrocarbon and fluorocarbon end groups. The presence of the functional group, hydroxyl, anchors/adheres the lubricant molecule to the carbon-based protective overcoat layer 3 (protective layer), and this maintains the lubricant molecules firmly over the protective overcoat layer 3 .
[0087] Therefore, it can be surmised that ionic PFPE lubricants of the kind represented by the five types of ionic PFPE lubricants described in examples 1 through 5 of the description have the potential to provide advantageous results and properties over existing PFPE lubricants, in terms of distribution uniformity, protection/operation longevity, and improved recording density as a result of reduced magnetic spacing when applied to a magnetic recording medium (MRM).
[0088] It is understood that the invention may be embodied in numerous other ways without departing from the scope of the invention.
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An ionic lubricant includes a single lubricant compound having a perfluoropolyether main chain, wherein each end of the perfluoropolyether main chain is terminated by an end group, and at least one of the end groups includes an ionic bond and at least one functional group. The ionic perfluoropolyether lubricant has unique characteristics that allows its ultra-thin and uniform distribution over a protective overcoat layer of a magnetic recording medium, while at the same time providing its molecules with strong adhesion power to the protective overcoat layer of the magnetic recording medium compared to existing lubricants, so as to provide shorter magnetic spacing between the magnetic recording medium and the magnetic head, and enable longer operation hours for the magnetic recording medium.
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TECHNICAL FIELD
The present invention relates to organic light-emitting devices.
BACKGROUND ART
An organic light-emitting device is a device that includes an anode, a cathode, and an organic compound layer interposed between the anode and the cathode. Holes and electrons injected from the respective electrodes of the organic light-emitting device are recombined in the organic compound layer to generate excitons and light is emitted as the excitons return to their ground state. The organic light-emitting device is also called an organic electroluminescent device or organic EL device. Recent years have seen remarkable advances in the field of organic light-emitting devices. Organic light-emitting devices offer low driving voltage, various emission wavelengths, rapid response, and small thickness and are light-weight.
Phosphorescence-emitting devices are a type of device that includes an organic compound layer containing a phosphorescence-emitting material, with triplet excitons contributing to emission. Creation of novel organic compounds has been actively pursued to provide high-performance phosphorescence-emitting devices.
PTL 1 discloses a compound 1 used as a host material of a phosphorescence-emitting device. The compound 1 is a xanthone derivative having carbazolyl groups.
Since the excited triplet (T 1 ) energy of this compound is low, this material is not suitable as a host material of an emission layer of a blue or green phosphorescence-emitting device or as a material for forming a carrier transport layer.
CITATION LIST
Patent Literature
PTL 1: International Publication No. 2006/114966
SUMMARY OF INVENTION
The present invention provides an organic light-emitting device that uses a xanthone derivative having a high T 1 energy and good electron injectability so that an organic light-emitting device having high emission efficiency and low driving voltage is provided and used as a blue or green phosphorescence-emitting device.
According to an aspect of the present invention, an organic light-emitting device includes an anode, a cathode, and an emission layer composed of an organic compound and interposed between the anode and the cathode. The emission layer contains a phosphorescence-emitting material. The organic light-emitting device contains a xanthone compound represented by general formula [1]:
In general formula [1], R 1 to R 8 are each independently selected from a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a substituted or unsubstituted phenyl group, a substituted or unsubstituted naphthyl group, a substituted or unsubstituted phenanthryl group, a substituted or unsubstituted fluorenyl group, a substituted or unsubstituted triphenylenyl group, a substituted or unsubstituted chrysenyl group, a substituted or unsubstituted dibenzofuranyl group, and a substituted or unsubstituted dibenzothienyl group.
According to the present invention, an organic light-emitting device having high emission efficiency and low driving voltage can be provided by using a xanthone derivative having high T 1 energy and good electron injectability.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic cross-sectional view of an organic light-emitting device and a switching element connected to the organic light-emitting device.
DESCRIPTION OF EMBODIMENTS
An organic light-emitting device according to an embodiment of the present invention includes an anode, a cathode, and an emission layer composed of an organic compound and interposed between the anode and the cathode. The emission layer contains a phosphorescence-emitting material. The organic light-emitting device contains a xanthone compound represented by general formula [1]:
In formula [1], R 1 to R 8 are each independently selected from a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a substituted or unsubstituted phenyl group, a substituted or unsubstituted naphthyl group, a substituted or unsubstituted phenanthryl group, a substituted or unsubstituted fluorenyl group, a substituted or unsubstituted triphenylenyl group, a substituted or unsubstituted chrysenyl group, a substituted or unsubstituted dibenzofuranyl group, and a substituted or unsubstituted dibenzothienyl group.
Examples of the alkyl group having 1 to 4 carbon atoms include a methyl group, an ethyl group, a normal propyl group, an isopropyl group, a normal butyl group, a secondary butyl group, an isobutyl group, and a tertiary butyl group.
Examples of the substituents that may be included in the phenyl group, the naphthyl group, the phenanthryl group, the fluorenyl group, the triphenylenyl group, the chrysenyl group, the dibenzofuranyl group, and the dibenzothienyl group are as follows.
Examples of the substituents are a methyl group, an ethyl group, a normal propyl group, an isopropyl group, a normal butyl group, a secondary butyl group, an isobutyl group, and a tertiary butyl group; a phenyl group, a methylphenyl group, a dimethylphenyl group, a trimethylphenyl group, a pentamethylphenyl group, a triisopropylphenyl group, a tertiary butylphenyl group, a di-tertiary butyl phenyl group, a naphthylphenyl group, a phenanthrylphenyl group, a fluorenylphenyl group, a triphenylenylphenyl group, a chrysenylphenyl group, a dibenzofuranylphenyl group, a dibenzothienylphenyl group, and a 9,9′-spirobi[fluoren]-ylphenyl group; a biphenyl group, a di-tertiary butyl biphenyl group, a naphthylbiphenyl group, a phenanthrylbiphenyl group, a fluorenylbiphenyl group, a triphenylenylbiphenyl group, a chrysenylbiphenyl group, a dibenzofuranylbiphenyl group, and a dibenzothienylbiphenyl group; a naphthyl group, a di-tertiary butylnaphthyl group, a phenylnaphthyl group, and a biphenylnaphthyl group; a phenanthryl group, a phenylphenanthryl group, and a biphenylphenanthryl group; a fluorenyl group, a phenylfluorenyl group, a biphenylfluorenyl group, and a 9,9′-spirobi[fluoren]-yl group; a chrysenyl group, a phenylchrysenyl group, and a biphenylchrysenyl group; a triphenylenyl group, a phenyltriphenylenyl group, and a biphenyltriphenylenyl group; a dibenzofuranyl group, a tertiary butyldibenzofuranyl group, a di-tertiary butyldibenzofuranyl group; a phenyldibenzofuranyl group, a biphenyldibenzofuranyl group, a naphthyldibenzofuranyl group, a phenanthryldibenzofuranyl group, a fluorenyldibenzofuranyl group, a chrysenylbenzofuranyl group, and a triphenylenyldibenzofuranyl group; and a dibenzothienyl group, a tertiary butyldibenzothienyl group, a di-tertiary butyldibenzothienyl group, a phenyldibenzothienyl group, a biphenyldibenzothienyl group, a naphthyldibenzothienyl group, a phenanthryldibenzothienyl group, a fluorenyldibenzothienyl group, a chrysenyldibenzothienyl group, and a triphenylenyldibenzothienyl group.
Properties of Xanthone Compound
Since a xanthone skeleton contains a carbonyl group, it has high electron affinity. Since a xanthone skeleton is a planar skeleton, molecular overlap easily occurs and intermolecular electron migration occurs highly efficiently in a solid state. The xanthone compound having such properties is suited to carrying out injection and transport of electrons from the cathode or the adjacent organic layer when it is used in an organic light-emitting device. In other words, a xanthone compound is suited for use in an electron injection/transport layer and as a host in an emission layer.
Another feature of the xanthone skeleton is its high T 1 energy. A phosphorescent spectrum of a diluted toluene solution of unsubstituted xanthone (compound represented by formula [1] above with R 1 to R 8 each representing a hydrogen atom) was taken at 77 K, and the T 1 energy was determined from a 0-0 band. The T 1 energy was 3.02 eV (410 nm), which is sufficiently higher than that of blue (maximum peak wavelength in an emission spectrum is 440 nm to 480 nm). Accordingly, the xanthone compound may be used as a host of an emission layer or in a carrier transport layer adjacent to the emission layer in a phosphorescence-emitting device using a blue to red (600 nm to 620 nm) phosphorescence-emitting material.
In sum, a xanthone compound is suitable for use as a host of an emission layer and/or in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device.
When the xanthone compound is used as a host material of an emission layer of a phosphorescence-emitting device, the xanthone compound easily receives electrons from an electron transport layer and efficiently transports the electrons within the host (low voltage). Thus, the xanthone compound can give high T 1 energy generated by recombination of electrons and holes to the phosphorescence-emitting material without loss (high efficiency).
When the xanthone compound is used in an electron transport layer adjacent to the emission layer, the xanthone compound easily receives electrons from the cathode or an electron injection layer and transports the electrons to the emission layer (low voltage). Since the T 1 energy of the phosphorescence-emitting material in an excited state does not migrate to the xanthone compound in the electron transport layer adjacent to the emission layer, the T 1 energy is confined in the emission layer, thereby increasing the efficiency of the phosphorescence-emitting device. When the xanthone compound is used as a host of an emission layer and in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device, the lowest unoccupied molecular orbital (LUMO) energy barrier between the emission layer and the electron transport layer disappears and the effect of decreasing the voltage can be enhanced.
Regarding Substituents to be Introduced into Xanthone Compound
Introducing an alkyl group or an aromatic ring group into a highly planar compound such as a xanthone skeleton improves the solubility in a solvent, the sublimation property during vacuum deposition, and the amorphous property in a thin film state. However, since the sublimation property is degraded when an alkyl group has too many carbon atoms, the number of carbon atoms in the alkyl group may be 1 to 4.
In order to use the xanthone compound as a host of an emission layer and/or in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device, the xanthone compound desirably has a T 1 energy higher than that of the phosphorescence-emitting material. In other words, when the emission color of the phosphorescence-emitting material is blue to red (440 nm to 620 nm), it is important that the T 1 energy of the xanthone compound be decided according to the emission color of the phosphorescence-emitting material. In general, alkyl substituents little affect the T 1 energy but aromatic ring substituents greatly affect the T 1 energy of the compound as a whole. Thus, in deciding the T 1 energy of the xanthone compound, the T 1 energy of the aromatic ring substituent bonded to one of R 1 to R 8 in general formula [1] is extensively studied.
Table 1 shows the T 1 energy (on a wavelength basis) of each of major aromatic rings. Of these, preferred structures of the aromatic ring are benzene, naphthalene, phenanthrene, fluorene, triphenylene, chrysene, dibenzofuran, dibenzothiophene, and pyrene.
When the phosphorescence-emitting material has a blue to green range (440 nm to 530 nm) by utilizing the high T 1 energy property of the xanthone skeleton, preferable aromatic ring structures bonded to one of R 1 to R 8 of the xanthone compound are benzene, naphthalene, phenanthrene, fluorene, triphenylene, chrysene, dibenzofuran, and dibenzothiophene.
The substituents of the aromatic ring structures described above may further contain substituents as long as the T 1 energy of the xanthone compound is not significantly lowered.
TABLE 1
T 1 energy
on a
wavelength
Structural formula
basis
Benzene
339 nm
Naphthalene
472 nm
Phenanthrene
459 nm
Fluorene
422 nm
Triphenylene
427 nm
Chrysene
500 nm
Dibenzofuran
417 nm
Dibenzothiophene
415 nm
Anthracene
672 nm
Pyrene
589 nm
Note that the compound 1 described above is a compound having a xanthone skeleton into which an N-carbazolyl group is introduced. In order to predict the T 1 energy of the compound 1, a molecular orbital calculation of the B3LYP/6-31G* level was performed based on a density functional theory. The calculation was also conducted on the xanthone compound represented by general formula [1] above, and the results are compared with the phosphorescent spectrum measurement results of a diluted toluene solution. Table 2 shows the results.
TABLE 2
T 1 energy
T 1 energy
on a
on a
wavelength
wavelength
basis
basis
Structure
(calculated)
(observed)
Example Compound A-4
423 nm
439 nm
Example Compound A-15
444 nm
487 nm
Example Compound A-12
467 nm
502 nm
Compound 1
486 nm
—
The difference between the calculated value and the observed value of the T 1 energy of the three xanthone compounds of embodiments of the present invention was from 16 to 35 nm. Example Compound A-12 exhibited a T 1 energy observed value equal to the limitation value at which the compound can be used as a host in an emission layer or in an electron transport layer adjacent to the emission layer in a green phosphorescence-emitting device. In contrast, the compound 1 exhibited a calculated value 19 nm longer than that of Example Compound A-12; therefore, the observed value is assumed to be about 520 to 530 nm. The host of the emission layer or the material used in a carrier transport layer adjacent to the emission layer may have an energy about 20 nm higher than that of the emission material in terms of wavelength. However, since the compound 1 has a T 1 energy about the same as the emission wavelength (500 to 530 nm) of a green phosphorescence-emitting material, the energy of the green phosphorescence-emitting material may migrate to the compound 1 and the emission efficiency of the phosphorescence-emitting device may be lowered. Accordingly, the compound 1 is not suited for use as a host in an emission layer or in a carrier transport layer adjacent to the emission layer of a phosphorescence-emitting device for a wavelength shorter than green, and is thus not favored due to its narrow application range.
The reasons therefor is investigated by focusing on the electron distribution determined by a molecular orbital calculation. In the compound 1, the highest occupied molecular orbital (HOMO) is localized on the N-carbazolyl group and the LUMO is localized on the xanthone skeleton. This causes the compound 1 to enter a charge-transfer (CT) excited state and significantly decreases the excited singlet (S 1 ) and T 1 energies. In order for the xanthone skeleton to maintain a high T 1 energy, introduction of substituents, such as a carbazolyl group, that have a high HOMO energy level is avoided.
It is not desirable to introduce an electron-donating substituent such as an amino group since the electron acceptability of the xanthone skeleton may be degraded.
The position into which the substituent is to be introduced is at least one selected from R 1 to R 8 in general formula [1] to obtain desired physical property values.
The chemical stability of the compound can be further enhanced by introducing a substituent into a high-electron-density carbon atom on an aromatic ring. In the xanthone skeleton, the para position from the position at which an ether oxygen atom is bonded is susceptible to electrophilic reaction and has a high electron density. Thus, an alkyl group or an aromatic ring group is preferably introduced to at least one of R 2 and R 7 and more preferably to both R 2 and R 7 with the rest of Rs, i.e., R 1 , R 3 to R 6 , and R 8 , being hydrogen atoms. Most preferably, the R 2 and R 7 are the same substituents.
Examples of the Xanthone Compound
Examples of the xanthone compound are described below in Groups A to C.
Properties of Example Compounds
Of the example compounds, those of Group A have an axis of symmetry within a molecule and two substituents of the same kind are respectively introduced into two benzene rings in a symmetrical manner. Thus, the electron distribution in the xanthone skeleton is unbiased and is thus stable.
Example compounds of Group B each have two or more substituents introduced into the xanthone skeleton and no axis of symmetry. These compounds achieve higher stability in an amorphous state. The physical property values can be finely adjusted by changing the position and type of the substituents.
Example compounds of Group C each have one substituent introduced therein. Since the high T 1 energy of the xanthone skeleton remains relatively undegraded, these compounds are particularly suited for use in blue or green phosphorescence-emitting devices.
Description of Synthetic Route
An example of a synthetic route for an organic compound is described. The reaction scheme therefor is presented below.
First, a halide, a triflate, and a boronic acid ester can be synthesized by using widely commercially available xanthone and its derivatives.
The halide, triflate, and boronic acid ester is used in a Suzuki coupling reaction. As a result, an alkyl group or an aromatic ring group can be introduced into the xanthone skeleton.
A Friedel-Crafts reaction may be employed to introduce an alkyl group into a xanthone skeleton.
Alternatively, a dehydration condensation reaction may be conducted using a dihydroxybenzophenone derivative already having a reactive functional group or an aromatic ring group and the xanthone skeleton is formed later.
Desired substituents can be introduced into desired positions selected from among R 1 to R 8 in general formula [1] by freely combining the above-described basic reactions.
Regarding the Properties of Organic Light-Emitting Device
Next, the organic light-emitting device is described.
The organic light-emitting device according to an embodiment of the present invention includes a pair of opposing electrodes, namely, an anode and a cathode, and an organic compound layer interposed between the electrodes. A layer containing a phosphorescence-emitting material in the organic compound layer is the emission layer. The organic compound layer of the organic light-emitting device contains a xanthone compound represented by general formula [1].
An example of the structure of the organic light-emitting device is an anode/emission layer/cathode structure on a substrate. Another example is an anode/hole transport layer/electron transport layer/cathode structure. Still other examples include an anode/hole transport layer/emission layer/electron transport layer/cathode structure, an anode/hole injection layer/hole transport layer/emission layer/electron transport layer/cathode structure, and an anode/hole transport layer/emission layer/hole-exciton blocking layer/electron transport layer/cathode structure. These five structures of the multilayer organic light-emitting device are basic device structures and the structure of the organic light-emitting device containing a xanthone compound is not limited to these. Various other layer configurations may be employed, e.g., an insulating layer may be provided at the interface between an electrode and an organic compound layer, an adhesive layer or an interference layer may be provided, and the electron transport layer or the hole transport layer may be constituted by two layers having different ionization potentials.
The device may be of a top emission type that emits light from the substrate-side electrode or of a bottom emission type that emits light from the side opposite the substrate. The device may be of a type that emits light from both sides.
The xanthone compound can be used in an organic compound layer of an organic light-emitting device having any layer structure. Preferably, the xanthone compound is used in an electron transport layer, a hole-exciton blocking layer, or an emission layer. More preferably, the xanthone compound is used in at least one of the host material of an emission layer, a hole blocking layer, an electron transport layer, and an electron injection layer.
In general, a “hole blocking layer” is a layer that blocks holes. In the present invention, a layer adjacent to the cathode-side of the emission layer is referred to as a “hole blocking layer”. The reason for this is as follows. The main purpose of using the xanthone compound is not to block holes but to use the xanthone compound in an electron transport layer. However, the xanthone compound is used in a layer located at the same position as a general hole blocking layer. Thus, in order to avoid confusion as to the position with the electron transport layer, the layer is referred to as a “hole blocking layer” from the position of the layer.
The emission layer of the organic light-emitting device may be constituted by two or more organic compounds, namely, a host material and a guest material. A guest material is an organic compound that emits light. One or more host materials may be used. In other words, the emission layer may contain two or more host materials in addition to the phosphorescence-emitting material. When only one host material is used, the xanthone compound may be used as this host material. When two or more host materials are used, the xanthone compound may be a host material having a smaller weight ratio than other host materials. In such a case, other host materials may have a hole transport property. This is because the xanthone compound has high electron transport property. When a material having a high hole transport property and a material having a high electron transport property are used together, the host material exhibits a substantial bipolar property in the emission layer.
The hole transport property of the emission layer may be enhanced by a guest material having a high hole transport property even when the hole transport property of the host material other than the xanthone compound is low. In such a case also, the xanthone compound may be used as a host material to adjust the carrier balance of the emission layer. Of the organic light-emitting devices shown in Table 3 below, the emission layer of the organic light-emitting device that has a host material 2 exhibits a high hole transport property due to properties of the host material 1 and the guest. The term “weight ratio” is a ratio relative to the total weight of the compounds constituting the emission layer.
The hole transport property and the electron transport property are regarded as “high” when the mobility is 10 −4 cm 2 /(V·s) or higher. The mobility can be measured by a time-of-flight (TOF) technique.
When two or more host materials are used, the xanthone compound having a smaller weight ratio than other host materials is referred to as a “host material” or, in some cases, an “assisting material”.
The concentration of the guest material relative to the host material is 0.01 to 50 wt % and preferably 0.1 to 20 wt % relative to the total amount of the constituent materials of the emission layer. The concentration of the guest material is most preferably 10 wt % or less to prevent concentration quenching. The guest material may be homogeneously distributed in the entire layer composed of a host material, may be contained in the layer by having a concentration gradient, or may be contained in particular parts of the layer, thereby creating parts only the host material is contained. The emission color of the phosphorescence-emitting material is not particularly limited but may be blue to green with the maximum emission peak wavelength in the range of 440 to 530 nm.
In general, in order to prevent a decrease in emission efficiency caused by radiationless deactivation from T 1 of the host material of a phosphorescence-emitting device, the T 1 energy of the host material needs to be higher than the T 1 energy of the phosphorescence-emitting material which is a guest material.
The T 1 energy of the xanthone skeleton that functions as the center of the xanthone compound is 410 nm, which is higher than the T 1 energy of a blue phosphorescence-emitting material. Thus, when the xanthone compound is used in an emission layer or a nearby layer of a blue to green phosphorescence-emitting device, a phosphorescence-emitting device having a high emission efficiency can be obtained.
The xanthone compound has a low LUMO level. When the xanthone compound is used not only as an electron injection material or an electron transport material, or in a hole blocking layer but also as a host material of the emission layer, the driving voltage of the device can be lowered. This is because a low LUMO level decreases the electron injection barrier from the hole blocking layer or the electron transport layer adjacent to the cathode-side of the emission layer.
When a xanthone compound is used as an assisting material of the emission layer, the lifetime of the device can be extended when the xanthone compound has a LUMO level lower than that of the host material having a larger weight ratio. This is because electrons are trapped in the xanthone compound, thereby creating delocalized electronic distribution and delocalized recombination regions in the emission layer and thereby avoiding deterioration of the material occurring intensely in one portion of the emission layer.
When the xanthone compound is used as an electron transport material, an assisting material, or a host material in a phosphorescent light-emitting layer, a phosphorescence-emitting material used as a guest material is a metal complex such as an iridium complex, a platinum complex, a rhenium complex, a copper complex, an europium complex, or a ruthenium complex. Among these, an iridium complex having a high phosphorescent property is preferred. Two or more phosphorescence-emitting materials may be contained in the emission layer to assist transmission of excitons and carriers.
Examples of the iridium complex used as the phosphorescence-emitting material and examples of the host material are presented below. These examples do not limit the scope of the present invention.
If needed, a low-molecular-weight or high-molecular-weight compound may be used in addition to the xanthone compound. For example, a hole injection or transport compound, a host material, a light-emitting compound, or an electron injection or transport compound may be used in combination.
Examples of these compounds are presented below.
The hole injection/transport material can be a material having a high hole mobility so that holes can be easily injected from the anode and the injected holes can be easily transported to the emission layer. Examples of the low- and high-molecular-weight materials having hole injection/transport property include triarylamine derivatives, phenylenediamine derivatives, stilbene derivatives, phthalocyanine derivatives, porphyrin derivatives, poly(vinyl carbazole), poly(thiophene), and other conductive polymers.
Examples of the light-emitting material mainly contributing to the light-emitting function include the phosphorescent light-emitting guest materials described above, derivative thereof, fused compounds (e.g., fluorene derivatives, naphthalene derivatives, pyrene derivatives, perylene derivatives, tetracene derivatives, anthracene derivatives, and rubrene), quinacridone derivatives, coumarin derivatives, stilbene derivatives, organic aluminum complexes such as tris(8-quinolinolato)aluminum, organic beryllium complexes, and polymer derivatives such as poly(phenylenevinylene) derivatives, poly(fluorene) derivatives, and poly(phenylene) derivatives.
The electron injection/transport material may be selected from materials to which electrons can be easily injected from the cathode and which can transport the injected electrons to the emission layer. The selection may be made by considering the balance with the hole mobility of the hole injection/transport material. Examples of the electron injection/transport material include oxadiazole derivatives, oxazole derivatives, pyrazine derivatives, triazole derivatives, triazine derivatives, quinoline derivatives, quinoxaline derivatives, phenanthroline derivatives, and organic aluminum complexes.
The anode material may have a large work function. Examples of the anode material include single metals such as gold, platinum, silver, copper, nickel, palladium, cobalt, selenium, vanadium, and tungsten or alloys thereof, and metal oxides such as tin oxide, zinc oxide, indium oxide, indium tin oxide (ITO), and indium zinc oxide. Conductive polymers such as polyaniline, polypyrrole, and polythiophene may also be used. These anode materials may be used alone or in combination. The anode may be constituted by one layer or two or more layers.
The cathode material may have a small work function. Examples of the cathode material include alkali metals such as lithium, alkaline earth metals such as calcium, and single metals such as aluminum, titanium, manganese, silver, lead, and chromium. The single metals may be combined and used as alloys. For example, magnesium-silver, aluminum-lithium, and aluminum-magnesium alloys and the like can be used. Metal oxides such as indium tin oxide (ITO) can also be used. These cathode materials may be used alone or in combination. The cathode may be constituted by one layer or two or more layers.
Layers containing the xanthone compound and other organic compounds in the organic light-emitting device are formed by the following processes. Typically, thin films are formed by vacuum vapor deposition, ionization deposition, sputtering, plasma, and coating using an adequate solvent (spin-coating, dipping, casting, a Langmuir Blodgett method, and an ink jet method). When layers are formed by vacuum vapor deposition or a solution coating method, crystallization is suppressed and stability over time can be improved. When a coating method is employed, an adequate binder resin may be additionally used to form a film.
Examples of the binder resin include, but are not limited to, polyvinylcarbazole resins, polycarbonate resins, polyester resins, ABS resins, acrylic resins, polyimide resins, phenolic resins, epoxy resins, silicone resins, and urea resins. These binder resins may be used alone as a homopolymer or in combination of two or more as a copolymer. If needed, known additives such as a plasticizer, an antioxidant, and an ultraviolet absorber may be used in combination.
Usage of Organic Light-Emitting Device
The organic light-emitting device of the embodiment may be used in a display apparatus or a lighting apparatus. The organic light-emitting device can also be used as exposure light sources of image-forming apparatuses and backlights of liquid crystal display apparatuses.
A display apparatus includes a display unit that includes the organic light-emitting device of this embodiment. The display unit has pixels and each pixel includes the organic light-emitting device of this embodiment. The display apparatus may be used as an image display apparatus of a personal computer, etc.
The display apparatus may be used in a display unit of an imaging apparatus such as digital cameras and digital video cameras. An imaging apparatus includes the display unit and an imaging unit having an imaging optical system for capturing images.
FIG. 1 is a schematic cross-sectional view of an image display apparatus having an organic light-emitting device in a pixel unit. In the drawing, two organic light-emitting devices and two thin film transistors (TFTs) are illustrated. One organic light-emitting device is connected to one TFT.
Referring to FIG. 1 , in an image display apparatus 3 , a moisture proof film 32 is disposed on a substrate 31 composed of glass or the like to protect components (TFT or organic layer) formed thereon. The moisture proof film 32 is composed of silicon oxide or a composite of silicon oxide and silicon nitride. A gate electrode 33 is provided on the moisture proof film 32 . The gate electrode 33 is formed by depositing a metal such as Cr by sputtering.
A gate insulating film 34 covers the gate electrode 33 . The gate insulating film 34 is obtained by forming a layer of silicon oxide or the like by a plasma chemical vapor deposition (CVD) method or a catalytic chemical vapor deposition (cat-CVD) method and patterning the film. A semiconductor layer 35 is formed over the gate insulating film 34 in each region that forms a TFT by patterning. The semiconductor layer 35 is obtained by forming a silicon film by a plasma CVD method or the like (optionally annealing at a temperature 290° C. or higher, for example) and patterning the resulting film according to the circuit layout.
A drain electrode 36 and a source electrode 37 are formed on each semiconductor layer 35 . In sum, a TFT 38 includes a gate electrode 33 , a gate insulating layer 34 , a semiconductor layer 35 , a drain electrode 36 , and a source electrode 37 . An insulating film 39 is formed over the TFT 38 . A contact hole (through hole) 310 is formed in the insulating film 39 to connect between a metal anode 311 of the organic light-emitting device and the source electrode 37 . A single-layer or a multilayer organic layer 312 that includes an emission layer and a cathode 313 are stacked on the anode 311 in that order to constitute an organic light-emitting device that functions as a pixel.
First and second protective layers 314 and 315 may be provided to prevent deterioration of the organic light-emitting device.
The switching element is not particularly limited and a metal-insulator-metal (MIM) element may be used instead of the TFT described above.
EXAMPLES
The present invention will now be described by using Examples which do not limit the scope of the invention.
Example 1
Synthesis of Example Compound A-4
The following reagents and solvents were placed in a 100 mL round-bottomed flask.
Xanthone (Tokyo Chemical Industry Co., Ltd.): 5.0 g (26 mmol) Bromine: 16 g (102 mmol) Iodine: 50 mg (0.20 mmol) Acetic acid: 20 mL
The reaction solution was refluxed for 5 hours at 100° C. under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, chloroform and a saturated aqueous sodium sulfite solution were added to the reaction solution and stirring was continued until the color of bromine was lost. The organic layer was separated, washed with a saturated aqueous sodium carbonate solution, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (toluene: 100%). As a result, 2.9 g (yield: 41%) of 2-bromoxanthone and 2.2 (yield: 25%) g of 2,7-dibromoxanthone were obtained.
The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2,7-Dibromoxanthone: 0.70 g (2.0 mmol)
4,4,5,5-Tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane: 1.9 g (4.8 mmol)
Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol)
Toluene: 10 mL
Ethanol: 2 mL
2M Aqueous sodium carbonate solution: 5 mL
The reaction solution was refluxed for 5 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the organic layer was separated, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (chloroform:heptane=1:1). The resulting crystals was vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 300° C. As a result, 0.90 g (yield: 63%) of high-purity Example Compound A-4 was obtained.
The compound was subjected to matrix-assisted laser desorption ionization-time-of-flight mass spectroscopy (MALDI-TOF-MS), and 724.4 which was M + of this compound was confirmed.
The structure of the compound was confirmed by proton nuclear magnetic resonance spectroscopy ( 1 H-NMR).
1 H-NMR ((CD 3 ) 2 NCDO, 500 MHz) δ (ppm): 8.13 (2H, d), 7.63-7.44 (10H, m), 7.32 (4H, d), 7.15 (4H, d), 1.43 (18H, s), 1.25 (18H, s)
The T 1 energy of Example Compound A-4 was measured by the following process.
A phosphorescence spectrum of a diluted toluene solution (1×10 −5 M) of Example Compound A-4 was measured in an Ar atmosphere at 77K and an excitation wavelength of 350 nm. The T 1 energy was calculated from the peak wavelength of the 0-0-band (first emission peak) of the obtained phosphorescence spectrum. The T 1 energy was 439 nm on a wavelength basis.
Example 2
Synthesis of Example Compound A-5
Example Compound A-5 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 3-biphenylboronic acid.
M + of this compound, 500.2, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.66 (2H, d), 8.06 (2H, dd), 7.91 (2H, bs), 7.72-7.66 (6H, m), 7.66-7.60 (4H, m), 7.57 (2H, t), 7.49 (4H, t), 7.39 (2H, t)
The T 1 energy of Example Compound A-5 was measured as in Example 1. The T 1 energy was 446 nm on a wavelength basis.
Example 3
Synthesis of Example Compound A-7
Example Compound A-7 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 3,5-diphenylphenylboronic acid.
M + of this compound, 652.2, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.72 (2H, d), 8.13 (2H, dd), 7.90 (4H, d), 7.84 (2H, dd), 7.74 (8H, d), 7.68 (2H, d), 7.51 (8H, t), 7.42 (4H, t)
The T 1 energy of Example Compound A-7 was measured as in Example 1. The T 1 energy was 447 nm on a wavelength basis.
Example 4
Synthesis of Example Compound A-12
Example Compound A-12 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(phenanthren-9-yl)-1,3,2-dioxaborolane.
M + of this compound, 548.2, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.82 (2H, d), 8.76 (2H, d), 8.60 (2H, d), 7.98 (2H, dd), 7.96-7.90 (4H, m), 7.79 (2H, s), 7.76-7.68 (6H, m), 7.65 (2H, dd), 7.58 (2H, dd)
The T 1 energy of Example Compound A-12 was measured as in Example 1. The T 1 energy was 502 nm on a wavelength basis.
Example 5
Synthesis of Example Compound A-15
Example Compound A-15 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9-dimethylfluoren-2-yl)-1,3,2-dioxaborolane.
M + of this compound, 580.2, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.68 (2H, d), 8.09 (2H, dd), 7.84 (2H, d), 7.80-7.76 (4H, m), 7.69 (2H, dd), 7.65 (2H, d), 7.48 (2H, dd), 7.40-7.33 (4H, m), 1.58 (12H, s)
The T 1 energy of Example Compound A-15 was measured as in Example 1. The T 1 energy was 487 nm on a wavelength basis.
Example 6
Synthesis of Example Compound A-16
Example Compound A-16 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9-dimethylfluoren-3-yl)-1,3,2-dioxaborolane.
M + of this compound, 580.2, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.69 (2H, d), 8.10 (2H, dd), 8.06 (2H, d), 7.85 (2H, d), 7.66 (4H, d), 7.56 (2H, d), 7.48 (2H, d), 7.42-7.34 (4H, m), 1.55 (12H, s)
The T 1 energy of Example Compound A-16 was measured as in Example 1. The T 1 energy was 450 nm on a wavelength basis.
Example 7
Synthesis of Example Compound A-22
Example Compound A-22 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4-dibenzothienylboronic acid.
M + of this compound, 560.1, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.76 (2H, d), 8.24-8.18 (6H, m), 7.88-7.84 (2H, m), 7.73 (2H, d), 7.64-7.58 (4H, m), 7.52-7.46 (4H, m)
The T 1 energy of Example Compound A-22 was measured as in Example 1. The T 1 energy was 450 nm on a wavelength basis.
Example 8
Synthesis of Example Compound A-32
Example Compound A-32 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9′-spirobi[fluoren]-3-yl)-1,3,2-dioxaborolane.
M + of this compound, 824.3, was confirmed by MALDI-TOF MS.
The structure of the compound was confirmed by 1 H-NMR.
1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.70 (2H, d), 8.18 (2H, d), 8.08 (2H, dd), 7.97 (2H, d), 7.88 (4H, d), 7.65 (2H, d), 7.46-7.38 (8H, m), 7.18-7.12 (6H, m), 6.86 (2H, d), 6.80 (4H, d), 6.77 (2H, d)
The T 1 energy of Example Compound A-32 was measured as in Example 1. The T 1 energy was 452 nm on a wavelength basis.
Examples 9 and 10
Synthesis of Example Compounds A-23 and A-31
Each Example Compound was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by a boronic acid derivative shown in Table 3.
Each Example Compound was identified by MALDI-TOF MS.
TABLE 3
Example
MALDI-T OF MS
compound
Boronic acid derivative
(M + )
Example 9
A-23
560.1
Example 10
A-31
824.3
Example 11
Synthesis of Example Compound B-1
The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2,7-Dibromoxanthone: 0.70 g (2.0 mmol)
3-Biphenylboronic acid: 0.40 g (2.0 mmol)
Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol)
Toluene: 10 mL
Ethanol: 2 mL
2M Aqueous sodium carbonate solution: 3 mL
The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the organic layer was separated, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (chloroform:heptane=1:1). As a result, 0.62 g (yield: 72%) of intermediate 1 was obtained.
The following reagents and solvents were placed in a 100 mL round-bottomed flask.
Intermediate 1: 0.62 g (1.5 mmol)
4,4,5,5-Tetramethyl-2-(triphenylen-2-yl)-1,3,2-dioxaborolane: 0.64 g (1.8 mmol)
Tetrakis(triphenylphosphine) palladium(0): 0.17 g (0.15 mmol)
Toluene: 10 mL
Ethanol: 2 mL
2M Aqueous sodium carbonate solution: 3 mL
The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the precipitated solid was filtered and washed with water, methanol, and acetone. The obtained solid was dissolved in chlorobenzene under heating and insolubles were removed by hot filtration. The solvent in the filtrate was distilled away under a reduced pressure and the precipitated solid was recrystallized in a chlorobenzene/heptane system. The resulting crystals were vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 360° C. As a result, 0.67 g (yield: 78%) of high-purity Example Compound B-1 was obtained.
M + of this compound, 574.2, was confirmed by MALDI-TOF MS.
Example 12
Synthesis of Example Compound B-4
Example Compound B-4 was obtained as in Example 11 except that 4,4,5,5-tetramethyl-2-(triphenylen-2-yl)-1,3,2-dioxaborolane used in Example 11 was replaced by 4-biphenylboronic acid.
M + of this compound, 500.2, was confirmed by MALDI-TOF MS.
Example 13
Synthesis of Example Compound C-2
The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2-Bromoxanthone: 0.55 g (2.0 mmol)
Boronic acid ester derivative 1: 1.2 g (2.4 mmol)
Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol)
Toluene: 15 mL
Ethanol: 3 mL
2M Aqueous sodium carbonate solution: 5 mL
The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the precipitated solid was filtered and washed with water, methanol, and acetone. The obtained solid was dissolved in chlorobenzene under heating and insolubles were removed by hot filtration. The solvent in the filtrate was distilled away under a reduced pressure and the precipitated solid was recrystallized in a chlorobenzene/heptane system. The resulting crystals were vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 370° C. As a result, 0.93 g (yield: 81%) of high-purity Example Compound C-2 was obtained.
M + of this compound, 574.2, was confirmed by MALDI-TOF MS.
Examples 14 to 17
Synthesis of Example Compounds C-5, C-7, C-14, and C-16
Each Example Compound was obtained as in Example 13 except that the boronic acid ester derivative 1 used in Example 13 was replaced by a boronic acid ester derivative shown in Table 4.
Each Example Compound was identified by MALDI-TOF MS.
TABLE 4
Example
MALDI-T OF MS
compound
Boronic acid derivative
(M + )
Example 14
C-5
540.2
Example 15
C-7
530.1
Example 16
C-14
540.2
Example 17
C-16
662.2
Example 18
Production of Organic Light-Emitting Device
In Example 18, an organic light-emitting device having an anode/hole transport layer/emission layer/hole blocking layer/electron transport layer/cathode structure on a substrate was produced by the following process.
Indium tin oxide (ITO) was sputter-deposited on a glass substrate to form a film 120 nm in thickness functioning as an anode. This substrate was used as a transparent conductive support substrate (ITO substrate). Organic compound layers and electrode layers below were continuously formed on the ITO substrate by vacuum vapor deposition under resistive heating in a 10 −5 Pavacuum chamber. The process was conducted so that the area of the opposing electrodes was 3 mm 2 .
Hole transport layer (40 nm) HTL-1
Emission layer (30 nm), host material 1: I-1, host material 2: none, guest material: Ir-1 (10 wt %) Hole blocking (HB) layer (10 nm) A-4 Electron transport layer (30 nm) ETL-1 Metal electrode layer 1 (0.5 nm) LiF Metal electrode layer 2 (100 nm) Al
A protective glass plate was placed over the organic light-emitting device in dry air to prevent deterioration caused by adsorption of moisture and sealed with an acrylic resin adhesive. Thus, an organic light-emitting device was produced.
The current-voltage characteristic of the organic light-emitting device was measured with 2700 series ammeter produced by Keithley Instruments Inc., and the emission luminance was measured with BM7-fast produced by TOPCON CORPORATION. A voltage of 5.0 V was applied to the ITO electrode functioning as a positive electrode and an aluminum electrode functioning as a negative electrode. The emission efficiency was 55 cd/A and emission of green light with a luminance of 2000 cd/m 2 was observed. The CIE color coordinate of the device was (x, y)=(0.31, 0.63).
The lifetime (length of time the luminance decreased 20% from the initial value) of the device when a current was passed at 40 mA/cm 2 was 65 hours.
Examples 19 to 37
Devices were produced as in Example 18 except that the HB material, the host material 1, the host material 2 (15 wt %), and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. Emission of green light was observed from all devices. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the lifetime (length of time the luminance decreased 20% from the initial value) when a current is passed at 40 mA/cm 2 are presented in Table 5.
Comparative Examples 1 and 2
Devices were produced as in Example 18 except that ETL-1 was used as the HB material and the host material 1 and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. Emission of green light was observed from both devices. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the lifetime (length of time the luminance decreased 20% from the initial value) when a current is passed at 40 mA/cm 2 are presented in Table 5.
TABLE 5
HB
Host
Host
Guest
Emission
Volt-
Life-
Example
mate-
mate-
mate-
mate-
efficiency
age
time
No.
rial
rial 1
rial 2
rial
(cd/A)
(V)
(h)
19
A-4
I-1
A-4
Ir-1
63
5.1
70
20
A-5
I-8
None
Ir-23
56
5.4
95
21
A-5
I-3
A-5
Ir-3
61
5.6
115
22
A-7
I-7
None
Ir-24
55
5.3
85
23
A-7
I-8
A-7
Ir-27
58
5.8
120
24
A-12
I-1
None
Ir-1
55
5.0
70
25
A-12
I-2
A-12
Ir-1
57
5.2
80
26
A-15
I-2
None
Ir-1
55
5.4
75
27
A-15
I-1
A-15
Ir-3
60
5.6
100
28
A-16
I-1
None
Ir-1
58
5.5
95
29
A-16
I-3
A-15
Ir-4
62
5.7
80
30
A-22
I-8
A-22
Ir-27
58
5.6
105
31
ETL-1
I-9
A-4
Ir-26
55
5.3
100
32
ETL-1
I-8
A-7
Ir-23
54
5.6
95
33
ETL-1
I-7
A-32
Ir-25
54
5.2
95
34
B-1
I-9
None
Ir-2
51
4.9
115
35
ETL-1
I-7
B-4
Ir-4
54
5.5
105
36
C-7
I-9
C-7
Ir-7
57
5.1
115
37
ETL-1
I-8
C-16
Ir-6
55
5.3
85
Comparative
ETL-1
I-1
None
Ir-1
36
5.8
20
Example 1
Comparative
ETL-1
I-2
None
Ir-5
42
5.6
35
Example 2
Examples 38 to 44
Devices were produced as in Example 18 except that the HB material, the host material 1, the host material 2 (15 wt %), and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the color of emission are presented in Table 6.
TABLE 6
HB
Host
Host
Guest
Emission
Volt-
Example
mate-
mate-
mate-
mate-
efficiency
age
Emission
No.
rial
rial 1
rial 2
rial
(cd/A)
(V)
color
38
A-4
I-5
None
Ir-13
11
6.4
Blue
39
A-5
I-5
A-5
Ir-13
10
6.6
Blue
40
A-32
I-5
A-16
Ir-15
16
6.2
Blue-green
41
B-4
I-4
None
Ir-15
14
6.3
Blue-green
42
B-4
I-5
A-22
Ir-15
16
6.2
Blue-green
43
C-5
I-6
C-5
Ir-13
10
6.7
Blue
44
C-16
I-5
C-16
Ir-13
12
6.6
Blue
The results show that when the xanthone compound is used as an electron transport material or an emission layer material in a phosphorescence-emitting device, good emission efficiency and long device lifetime can be achieved.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2010-101299, filed Apr. 26, 2010 and Japanese Patent Application No. 2010-228893, filed Oct. 8, 2010, which are hereby incorporated by reference herein in their entirety.
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An organic light-emitting device that achieves highly efficient emission and low-voltage operation is provided. The organic light-emitting device contains a 9H-xanthen-9-one derivative.
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RELATED APPLICATIONS
This application claims the priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2004-271359, filed on Sep. 17, 2004, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an oil tank for an engine-driven vehicle that separates oil from blow-by gas. More particular, the present invention relates to such an oil tank in which blow-by gas is separated from the oil by centrifugal action.
2. Description of the Related Art
In oil tanks, such as that disclosed in United States Published Patent Application No. 2003/0045187, published on Mar. 6, 2003, which claimed priority to Japanese Patent Application No. 2001-233362, filed on Aug. 1, 2001, there often is a mixture of oil and so-called blow-by gases. The oil tank disclosed in the '187 publication comprises an outer cylinder that extends in a vertical direction. An upper cover and a lower cover close off the top and the bottom of the outer cylinder. An inner cylinder is positioned along the axial centerline of the outer cylinder. A plurality of annular partition plates are positioned along the inner cylinder and extend between the inner cylinder and the outer cylinder. These partition plates divide the annular space between the inner cylinder and the outer cylinder into multiple oil chambers in the vertical direction. The inner peripheral edges of the partition plates are fixed to the outer peripheral surface of the inner cylinder while the outer peripheral edges of the partition plates are spaced from the inner peripheral surface of the outer cylinder.
The inlet of the oil tank is in the upper end of the outer cylinder. The inlet is positioned such that the oil flows into the annular space between the outer cylinder and the inner cylinder. The oil inlet also is positioned such that, when seen in plan view, the oil flows in along the inner peripheral surface of the inner peripheral wall of the outer cylinder. The oil outlet of the tank is formed at the lower end of the outer cylinder such that it opens to the lower end of the annular space defined between the inner and outer cylinders.
The annular space is partitioned by the plural partition plates into plural oil chambers arranged in the vertical direction. The oil chambers are connected by the gap formed between the inner peripheral surface of the outer cylinder and the outer peripheral edges of the partition plates. The upper portion of the uppermost oil chamber of the plural oil chambers is connected to the atmosphere by a blow-by gas discharge pipe. One end of the blow-by gas discharge pipe opens to the upper end portion of the annular space and the pipe then extends through the inside cylinder such that the other end is positioned outside of the oil tank.
In an oil tank constructed in this manner, oil mixed with blow-by gas is pressure-fed into the uppermost annular oil chamber. The mixed oil flows along the inner peripheral surface of the outer cylinder and it spins around inside the oil chamber. The oil and the blow-by gas are separated with the oil going to the outer side and blow-by gas moving to a more central location due to centrifugal forces. The spinning of the oil causes these forces and the differences of the specific gravities of oil and blow-by gas causes the movement. The oil flows down into the lower oil chamber through the gap formed between the outer cylinder and the partition plates, and is discharged to the outside of the oil tank (is supplied to the engine) from an oil discharge port positioned in the lowermost portion of the oil tank. The blow-by gas is dispersed into the atmosphere through the blow-by gas discharge pipe from the uppermost oil chamber inside the oil tank.
Because the oil must flow downward through the gaps formed between the outer cylinder and each of the partition plates, and there has been a limit on increasing the flow volume of oil through the tank. For this reason, it has not been possible to use such an oil tank in an engine requiring a large supply of oil.
Sometimes the conventional oil tank cannot separate the blow-by gas from the oil in the upper oil chamber, and blow-by gas remains in the oil. The blow-by gas cannot rise counter to the oil flowing downward. For this reason, the ability of the conventional oil tank to separate gas and liquid is poor and some of the blow-by gas ends up being supplied to the engine together with the oil.
The conventional oil tank has also had the problem that oil mist floating above the liquid surface in the uppermost oil chamber also ends up being discharged into the atmosphere through the discharge pipe together with the blow-by gas.
SUMMARY OF THE INVENTION
Accordingly, there is a need for an oil tank with improved ability to separate out blow-by gas and/or to separate out oil mist.
One aspect of the present invention involves an oil tank for an engine-driven vehicle. The oil tank comprises a tank body comprising a generally cylindrical inner wall, a top end and a bottom end. The tank body inner wall is joined to the tank body top end and the tank body bottom end. An oil chamber is positioned within the tank body. The oil chamber comprises a generally cylindrical inner wall, a top end and a bottom end. The oil chamber inner wall is joined to the oil chamber top end and the oil chamber bottom end. The oil chamber inner wall is radially spaced from the tank body inner wall. A passage is formed through a lower portion of the oil chamber inner wall such that an oil chamber volume defined within the oil chamber is in fluid communication with a tank body volume defined between the oil chamber and the tank body. A tank oil inlet communicates with the oil chamber volume through an upper portion of the oil chamber wall and a tank oil outlet communicates with the tank body chamber through a lower portion of the tank body. A blow-by gas chamber comprises a blow-by gas inlet that is in fluid communication with an upper portion of tank body and a blow-by gas outlet. The blow-by gas inlet is connected to the blow-by gas outlet by a curved air path.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will now be described with reference to the drawings of a preferred embodiment, which embodiment is intended to illustrate and not to limit the invention, and in which figures:
FIG. 1 is side view of a snowmobile engine having an oil tank that is arranged and configured in accordance with certain features, aspects and advantages of the present invention;
FIG. 2 is a plan view of the engine of FIG. 1 ;
FIG. 3 is a sectioned view of the oil tank of FIG. 1 taken along the line 3 - 3 in FIG. 2 ;
FIG. 4 is a sectioned view of the oil tank of FIG. 1 taken along the line 4 - 4 in FIG. 2 ;
FIG. 5 is a sectioned view taken along the line V-V in FIG. 4 ;
FIG. 6 is a sectioned view taken along the line VI-VI in FIG. 4 ;
FIG. 7 is a sectioned view taken along the line VII-VII in FIG. 4 ; and,
FIG. 8 is a schematic view of a lubricating system of the engine of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIG. 1 , a snowmobile 1 is shown that has an engine 2 equipped with an oil tank 12 that is arranged and configured in accordance with certain features, aspects and advantages of the present invention. While the oil tank 12 will be described in the context of the snowmobile 1 , certain features, aspects and advantages of the oil tank 12 can be utilized in other vehicles, such as, for example but without limitation, four wheeled vehicles, including automobiles, two wheeled vehicles, including motorcycles and watercraft, including jet-propelled boats and personal watercraft.
With reference to FIG. 1 and with additional reference to FIG. 2 , the illustrated snowmobile 1 comprises a seat 3 upon which a user and, in some configurations, a passenger are positioned during operation. The seat is generally positioned in the center portion of the vehicle body. A steering handle 4 is positioned forward of at least a portion of the seat and is used to control the direction in which the snowmobile will travel. In some configurations, a throttle control also is mounted to the steering handle 4 .
In the illustrated configuration, the engine 2 is a 4-cycle multi-cylinder engine. The illustrated engine 2 is installed with the crankshaft (not shown) extending in a transverse direction. In addition, the engine 2 preferably is installed in a forward portion of the vehicle body and is generally centered relative to the width of the vehicle body. With continued reference to FIGS. 1 and 2 , the illustrated engine 2 is generally inclined with the axial centerline of the cylinders being slanted rearward and upward. A carburetor 6 preferably is connected to the front surface of a cylinder head 5 of the engine 2 . In the illustrated engine, the engine has one carburetor 6 for each cylinder and the carburetors 6 receive air collectively from a single air cleaner 7 . In the illustrated configuration, the air cleaner 7 is disposed in front of and above the engine 2 . Other engine configurations also can be used. For instance, some features, aspects and advantages of the present invention may be utility with two-stroke engines, engines having less than four cylinders or more than four cylinders, and engines having differing cylinder configurations and/or differing air supply configurations.
With reference now to FIG. 8 , the engine 2 includes a lubrication system 11 . The illustrated lubrication system 11 has a configuration which causes oil to circulate through the engine 2 and an oil tank 12 . In one configuration, the oil tank 12 can be disposed at the right side of the engine 2 . Other positions also are possible. The oil tank 12 is connected by a first oil pipe 14 to an oil discharge port (not shown) of a scavenge pump 13 disposed inside the engine 2 , and is connected by a second oil pipe 15 to an oil feed pump (not shown) inside the engine 2 . Other suitable configurations also can be used to supply oil to the engine 2 from the tank 12 . In addition, as used herein, oil is intended to be broadly defined as a lubricant that is circulated within an engine for reducing friction and/or cooling components of the engine.
The scavenge pump 13 supplies oil from the bottom of the engine 2 to the oil tank 12 , and the oil feed pump supplies oil from inside the oil tank 12 to lubricated portions of the engine 2 . Any suitable oil delivery system can be used. A breather box 16 can be connected to an upper portion of the oil tank 12 . In one configuration, the breather box 16 is connected to the air cleaner 7 by a blow-by gas pipe 17 . In another configuration, the breather box 16 is formed integrally with the rest of the oil tank 12 while, in one other configuration, the breather box 16 can be a separate component that is in fluid communication with the oil tank 12 .
With reference now to FIGS. 3 to 7 , the illustrated oil tank 12 has a tank body 21 . Preferably, the tank body 21 generally comprises a closed container. The tank body 21 can have any suitable configuration. An inner cylinder 24 is supported inside the tank body 21 by two partition plates (e.g., an upper partition plate 22 and a lower partition plate 23 in the illustrated arrangement). The inner cylinder 24 can have any suitable configuration keeping in mind the goal of generating a suitable swirl of oil, as described below. The breather box 16 in the illustrated configuration extends upward from the upper portion of the illustrated tank body 21 .
In the illustrated configuration, the tank body 21 is formed of a cylinder 25 with a cover plate 26 that closes off one end of the cylinder 25 and a bottom plate 27 that closes off the other end of the cylinder 25 . In one configuration, the tank body 21 is disposed at the right side of the engine 2 and a center axis of the tank body 25 is oriented in a substantially vertical direction. The cover plate 26 preferably is positioned generally directly vertically above the bottom plate 27 . More preferably, a substantially closed space 28 is defined within the tank body 21 and the closed space preferably is in fluid communication with the inside of the inner cylinder 24 and, even more preferably, the substantially closed space 28 generally envelopes the inner cylinder 24 , which is positioned within the tank body 21 in the illustrated configuration.
With reference to FIGS. 5 to 7 , the cylinder 25 that defines the illustrated tank body 21 is formed such that its transverse sectional shape is substantially circular and generally constant from its upper end to its lower end. Other suitable configurations can be used so long as the purposes of the tank body 21 are accomplished. In the illustrated oil tank 12 , the transverse sectional shape of the tank body 21 is substantially constant from its upper end to its lower end. Thus, the speed at which the oil level drops becomes uniform when the oil inside the tank body 21 is supplied to the engine 2 and the oil level drops. For this reason, the oil can be prevented from undulating unnecessarily when it flows inside the tank body 21 . Moreover, because the illustrated oil tank 12 has a generally uniform transverse sectional shape, the plate-like members (e.g., the cover plate 26 , the bottom plate 27 , the upper partition plate 22 and the lower partition plate 23 ) can be formed from a single common blank.
In the illustrated configuration, the cover plate 26 is formed in a disk shape. The cover plate 26 can be welded to the cylinder 25 such that the outer peripheral portion of the cover plate 26 is sealed with the cylinder 25 . In one preferred configuration, the joint between the cover plate 26 and the cylinder 25 is liquid-tight.
With reference again to FIGS. 3 and 4 , a convex portion 26 a can be formed in the cover plate 26 near the radial center of the cover plate 26 . The convex portion 26 a protrudes upward. In some configurations, the convex portion 26 a can be formed of a member that is secured to an upper surface of the cover plate 26 . Regardless of how the convex portion 26 a is formed, the convex portion 26 a should protrude upward from the surrounding portion of the cover plate 26 . In the illustrated arrangement, the convex portion 26 a is formed in a circular shape when seen in plan view at a position that is slightly eccentric or off-center relative to the axial center of the cylinder 25 . Other positions also can be used. In the illustrated embodiment, the direction in which the convex portion 26 a is eccentric with respect to the cylinder 25 is toward the rear of the vehicle body (the upper side in FIG. 5 ).
With reference now to FIGS. 4 and 5 , a blow-by gas inlet 29 is formed through the cover plate 26 . In the illustrated arrangement, the inlet 29 comprises a hole that is positioned toward the right side of the vehicle body (the left side in the drawings). Other placements also can be used. In the illustrated oil tank 12 , the blow-by gas inlet 29 is at the vehicle body right side. For this reason, when the vehicle body is tilted sideways such that the engine 2 is positioned below the oil tank 12 , the blow-by gas inlet 29 is positioned above the oil level indicated by the two-dot chain line L 2 in FIG. 5 . Thus, the oil inside the tank body 21 does not pass through the blow-by gas inlet 29 and flow into the first blow-by gas chamber 66 . As a result, when the vehicle body is tilted such that the engine 2 is positioned below the oil tank 12 , the likelihood of oil passing through the blow-by gas pipe 17 and flowing out into the air cleaner 7 can be greatly reduced or eliminated.
With reference now to FIGS. 3 and 5 , a threaded insert 31 for supporting an oil level sensor 30 is secured to the cover plate 26 . The insert 31 can have any suitable configuration and preferably provides a female threaded surface. In the illustrated arrangement, the insert 31 is positioned on the vehicle body front side of the cover plate 26 (i.e., the right side in FIG. 3 and the lower side in FIG. 5 ). The oil level sensor 30 is used to detect the level of oil contained within the tank body 21 . In the illustrated oil tank 12 , the oil level sensor 30 is housed effectively using the space formed at the side of the inner cylinder 24 . Thus, the size of the tank body 21 does not increase when it is equipped with the oil level sensor 30 .
The bottom plate 27 of the tank body 21 is coupled with the cylinder 25 in any suitable manner. In one configuration, the bottom plate 27 and the cylinder 25 are welded together and, in a preferred configuration, the bottom plate 27 and the cylinder 25 are joined in a fluid-tight manner.
An oil discharge port 32 extends through the bottom plate 27 . The oil discharge port 32 preferably comprises a hole through the bottom plate 27 . In some configurations, the bottom plate 27 can define a sloping surface with the discharge port 32 being positioned in a lowermost location. The oil discharge port 32 allows oil to drain from the closed space 28 formed inside the tank body 21 . In the illustrated oil tank 12 , the inner cylinder 24 and the oil discharge port 32 are disposed at positions that are offset toward the vehicle body's rear side with respect to the tank body 21 , which causes them to be off-center. Thus, oil can be supplied to the engine 2 from the lowest location when the snowmobile 1 equipped with the illustrated oil tank 12 travels up a slope. For this reason, the oil can be reliably supplied to the lubricated parts of the engine 2 when the load of the engine 2 increases due to the slope.
A pipe coupling 34 connects a pipe member 33 to the oil discharge port 32 . The pipe coupling 34 can have any suitable configuration and can be welded to the undersurface of the bottom plate 27 in one configuration. The pipe member 33 connects with the end of the second oil pipe 15 . Any suitable coupling can be used to join the pipe member 33 and the second oil pipe 15 .
In the illustrated embodiment, an O-ring 35 is positioned where the pipe member 33 and the pipe coupling 34 are connected. The O-ring preferably reduces the likelihood of oil leakage in the region of the pipe coupling 34 . A strainer or filter 36 can be positioned within the closed space 28 . In some configurations, the filter 36 can be disposed in the pipe connection member 34 .
With continued reference to FIGS. 3 and 4 , the inner cylinder 24 is configured by a cylinder 41 that extends generally parallel to the cylinder 25 of the tank body 21 . In one configuration, the cylinder 41 is generally circular in configuration. Other suitable shapes also can be used. The inner cylinder 24 also comprises a plate member 42 that is welded to the upper end portion of the cylinder 41 such that it closes off the upper end portion of the cylinder 41 . In one configuration, the plate member 42 can be generally annular in configuration. Other suitable shapes also can be used. The lower end of the cylinder 41 can be secured to the lower partition plate 23 . In one configuration, the lower end of the cylinder 41 is welded to the lower partition plate 23 . Preferably, the cylinder 41 and the partition plate 23 are secured in a fluid-tight manner. In the illustrated oil tank 12 , a member functioning exclusively as the bottom wall of the inner cylinder 24 becomes unnecessary because the bottom wall of the inner cylinder 24 is configured by the lower partition plate 23 .
A tube body 43 can be welded to the plate member 42 . In one configuration, the tube body 43 is welded to the center of the plate member 42 . In the illustrated configuration, the tube body 43 is positioned on the axial centerline of the cylinder 41 and the tube body 43 preferably is attached to the plate member 42 such that its lower portion faces the inside of the cylinder 41 and is positioned within the cylinder 41 .
In the illustrated embodiment, as shown in FIG. 6 and FIG. 7 , the inner cylinder 24 is positioned such that it is offset or off-center toward one side in the radial direction with respect to the tank body 21 when seen in plan view. The direction in which the illustrated inner cylinder 24 is offset with respect to the tank body 21 is toward the rear of the vehicle body (the upper side in FIG. 6 and FIG. 7 ). Other positions also are possible. In the illustrated oil tank 12 , however, the inner cylinder 24 is disposed at an eccentric or off-center position with respect to the tank body 21 . Thus, the inner cylinder 24 can be more securely fixed to the tank body 21 by the upper partition plate 22 and the lower partition plate 23 at a location where the gap between the inner cylinder 24 and the tank body 21 is relatively narrow.
As shown in FIG. 6 , at the upper portion of the cylinder 41 and at the side of the tube body 43 , a through hole 44 is formed and a pipe member 45 is inserted into the through hole 44 . In one configuration, the pipe member 45 is welded in position. The pipe member 45 can be connected to the first oil pipe 14 in any suitable manner and the pipe member 45 defines an oil inlet for the oil tank 12 .
The pipe member 45 can have a tapering end such that it defines a slight nozzle to increase the velocity of the oil flow. In some arrangements, the end of the pipe member 45 does not taper. In addition, the illustrated pipe member 45 penetrates the cylinder 25 of the tank body 21 and extends into the inner cylinder 24 . Advantageously, the illustrated pipe member 45 extends into the inner cylinder 24 generally in a tangential direction (e.g., as shown in FIG. 6 ). In other words, an extension of an axial centerline of the pipe member 45 preferably does not intersect the center of the inner cylinder 24 . In addition, in the illustrated arrangement, the pipe member 45 is positioned generally between the cylinder 41 and the tube body 43 . The tube body 43 preferably extends downward beyond the lowermost portion of the pipe member 45 .
Thus, the oil tank 12 is configured such that the oil flies through the air when it flows into the inner cylinder 24 from the pipe member 45 . Thus, the oil tank 12 can directly disperse, into the air chamber inside the inner cylinder 24 , the blow-by gas included in the vicinity of the oil surface. Oil flowing at a predetermined flow rate into the inner cylinder 24 from the pipe member 45 flows along the inner peripheral surface of the cylinder 41 due to inertia. Preferably, the oil flows inside an oil chamber 46 , which is formed inside the inner cylinder 24 , such that it is generally circular in plan view and such that the oil becomes a spiral flow along the inner peripheral surface of the cylinder 41 .
With reference to FIG. 3 , FIG. 4 and FIG. 7 , communication holes 47 that extend from the inside of the cylinder 41 to the inside of the closed space 28 preferably are formed in the peripheral wall that defines the lower portion of the cylinder 41 . The communication holes 47 can be formed in any number of locations. In the illustrated arrangement, the communication holes 47 are formed at three places in the circumferential direction of the cylinder 41 in a lower region of the cylinder 41 . In the illustrated oil tank 12 , the communication holes 47 are formed in the lower portion of the inner cylinder 24 . Thus, the blow-by gas has largely separated from the oil before it passes through the communication holes 47 and flows into the second space 53 . For this reason, it becomes difficult for bubbles to form when the oil flows into the second space 53 .
In the illustrated arrangement, the upper partition plate 22 , which supports the upper portion of the inner cylinder 24 , is formed in an annular shape. The inner cylinder 24 extends through the upper partition plate 22 . The upper partition plate is joined the inside of the cylinder 25 of the tank body 21 in any suitable manner. In one configuration, the upper partition plate 22 is welded to the cylinder 25 . The upper portion of the inner cylinder 24 is suitably secured to the upper partition plate 22 . In the illustrated configuration, the inner cylinder 24 is welded to the upper partition plate 22 . Thus, the inner cylinder 24 is supported in the tank body 21 via the upper partition plate 22 .
As shown in FIG. 6 , through holes 48 , 49 and 50 extend through the upper partition plate 22 . These holes 48 , 49 , 50 are disposed at three places in sites (sites at the vehicle body front side) in the upper partition plate 22 opposite of the offset inner cylinder 24 . The through hole 49 preferably has a larger diameter than the other two holes 48 , 50 and the oil level sensor 30 preferably is inserted through the enlarged hole 49 .
The lower partition plate 23 supporting the lower portion of the inner cylinder 24 is joined with the inside of the cylinder 25 of the tank body 21 and, in some configurations, is welded to the cylinder 25 . As shown in FIG. 7 , plural through holes 51 are disposed at sites in the lower partition plate 23 on the outer side of the inner cylinder 24 . Thus, in the illustrated oil tank 12 , the oil can be prevented from undulating inside the closed space 28 using the upper partition plate 22 and the lower partition plate 23 , which are members for retaining the inner cylinder 24 inside the tank body 21 , are baffles. For this reason, the number of parts can be reduced in comparison to the case where the oil tank is equipped with a stay for exclusively retaining the inner cylinder 24 and a baffle member exclusively used for preventing the oil from undulating.
Because the inner cylinder 24 is supported in the tank body 21 by the upper partition plate 22 and the lower partition plate 23 , the closed space 28 inside the tank body 21 is partitioned into a first space 52 positioned above the upper partition plate 22 , a second space 53 positioned between the partition plates 22 and 23 , and a third space 54 positioned below the lower partition plate 23 .
The illustrated tank body 21 is configured such that during ordinary use, the oil level is positioned generally at the height indicated by the two-dot chain line L 1 in FIG. 3 and in FIG. 4 . Namely, the first space 52 is filled substantially exclusively with blow-by gas, the second space 53 is filled with oil in its lower portion and with blow-by gas in its upper portion, and the third space 54 is filled substantially exclusively with oil.
As shown in FIGS. 3 to 5 , the breather box 16 is generally defined by a housing 61 , which protrudes upward from the cover plate 26 of the tank body 21 , and a cylinder 62 , which is disposed inside the housing 61 . In the illustrated oil tank 12 , the bottom of the breather box 16 is defined by the cover plate 26 of the tank body 21 . Thus, a part dedicated to being the bottom of the breather box 16 becomes unnecessary and the number of components can be reduced as can the weight of the oil tank 12 .
In the illustrated embodiment, the housing 61 has the shape of a bottomed cylinder that opens downward. Other configurations also are possible. As shown in FIG. 5 , the illustrated housing 61 is also formed such that it is elongated in the left-right direction when seen in plan view. The housing 61 according to this embodiment is formed such that it protrudes toward the vehicle body right side (the left side in FIG. 4 and FIG. 5 ) with respect to the inner cylinder 24 when seen in plan view. According to this embodiment, a space is formed in the area above the tank body 21 to the front and left of the housing 61 . The threaded insert 31 is disposed in this space. Other configurations are possible.
The end portion of the housing 61 at the vehicle body right side (the end portion at the left side in FIG. 5 ) is formed such that covers, from above, the blow-by gas inlet 29 that extends through the cover plate 26 . A pipe member 63 extends through and, in some configurations, can be welded to an upper wall 61 a of the housing 61 at a site that generally intersects the extension line of the axial centerline of the inner cylinder 24 . Other placements can also be used. The pipe member 63 can be connected to the blow-by gas pipe 17 in any suitable manner. The lower end of the pipe member 63 is positioned in the vicinity of the center of the housing 61 in the vertical direction. Again, other configurations are possible.
The position of the pipe member 63 in the left-right direction is also positioned at the vehicle body right side (the left side in FIG. 5 ) from the two-dot chain line L 2 shown in FIG. 5 . The two-dot chain line L 2 represents the height of the oil level when the oil tank 12 is tilted to a worst case degree. Namely, as shown in FIG. 5 , the opening in the lower end of the pipe member 63 will be positioned above the oil level L 2 in FIG. 5 when the oil tank 12 reaches a worst-case scenario of tilting. For this reason, even when the vehicle body is tilted sideways such that the engine 2 is positioned below the oil tank 12 , the oil does not flow out toward the air cleaner 7 from the blow-by gas outlet. In particular, when the vehicle body is tilted sideways during maintenance, it becomes unnecessary to discharge the oil from the oil tank 12 so that maintenance can be easily conducted.
Upper communication holes 64 extend through the cylinder 62 such that the inside and the outside of the cylinder 62 are placed in communication. In the illustrated arrangement, the holes 64 are disposed in the peripheral wall at the upper portion of the cylinder 62 of the breather box 16 . The cylinder 62 can be welded to, and/or supported on, the upper wall 61 a of the housing 61 . As shown in FIG. 3 and FIG. 5 , the upper communication holes 64 can be formed in the end portion at the vehicle body front side and in the end portion at the vehicle body rear side of the cylinder 62 . In a preferred configuration, the upper communication holes 64 are formed at positions at about the same height and generally higher than the lower end of the pipe member 63 .
With reference to FIG. 3 and FIG. 4 , the lower end portion of the cylinder 62 preferably receives the convex portion 26 a of the cover plate 26 . Thus, the cylinder 62 preferably is positioned on the same axial line as the inner cylinder 24 . As shown in FIG. 4 , a lower communication hole 65 that communicates the inside and the outside of the cylinder 62 can be disposed in the lower end portion of the cylinder 62 . Any lubricant that happens to make its way into the cylinder will drop from the air as it is drawn into the pipe member 63 and will spill out of the communication hole 65 into a first blow-by gas chamber 66 .
The first blow-by gas chamber 66 , which is formed between the housing 61 and the cylinder 62 , and a second blow-by gas chamber 67 , which is formed inside the cylinder 62 , are formed inside the breather box 16 according to this embodiment. In this embodiment, what is called a curved air path in the present invention is configured by the first and second blow-by gas chambers 66 and 67 , the blow-by gas inlet 29 , the upper communication holes 64 , and the opening 68 in the lower end of the pipe member 63 . A blow-by gas outlet of the breather box 16 is defined by the opening 68 in the lower end of the pipe member 63 .
In the oil tank 12 configured in this manner, the scavenge pump 13 is driven together with the engine 2 , whereby the oil flows at a predetermined flow speed into the inner cylinder 24 from the pipe member 45 disposed in the upper portion of the inner cylinder 24 . The oil flows into the inner cylinder 24 from a position higher than the oil level L 1 . Thus, the oil momentarily flies through the air before striking the inner peripheral surface of the inner cylinder 24 , and then flows along this inner peripheral surface. The oil flows in a spiral flow pattern inside the inner cylinder 24 . Thus, the oil spins around the inside of the inner cylinder 24 whereby the blow-by gas entrained in the oil is separated from the oil by centrifugal separation.
The oil flows downward while spiraling inside the inner cylinder 24 , and passes through the communication holes 47 formed in the lower end portion of the inner cylinder 24 , whereby it flows out into the second space 53 from the inside of the inner cylinder 24 . At this time, the oil enters the communication holes 47 due to centrifugal force because the oil flows along the peripheral wall of the inner cylinder 24 . When the oil enters the second space 53 from the inside of the inner cylinder 24 , its flow speed drops and the direction in which it flows changes downward. Together with this, the blow-by gas that remains in the oil without having been separated inside the inner cylinder 24 rises and separates from the oil as a result of the change occurring in the flow of the oil inside the second space 53 . Thereafter, the oil passes through the through holes 51 in the lower partition plate 23 , flows into the third space 54 positioned therebelow, and is supplied from here to the engine 2 by the second oil pipe 15 including the pipe member 33 . The illustrated oil tank 12 supplies the oil to the engine from the bottom portion of the tank body 21 , into which the oil flows after the blow-by gas has been separated therefrom. Thus, just oil that is not mixed with blow-by gas, or oil mixed with a miniscule amount of blow-by gas, can be supplied to the engine 2 .
The illustrated inner cylinder 24 of the oil tank 12 advantageously does not have any other members disposed in the axial center portion. For this reason, the blow-by gas collecting at the center portion due to the principle of centrifugal separation is not obstructed by another member when it moves upward. Thus, the blow-by gas can be efficiently separated. Intake air negative pressure acts inside the oil tank 12 including the inside of the breather box 16 while the engine 2 is running. Thus, the blow-by gas separated from the oil inside the inner cylinder 24 passes through the tube body 43 inside the tank body 21 and enters the first space 52 .
The blow-by gas separated from the oil inside the second space 53 passes through the through holes 48 to 50 in the upper partition plate 22 and enters the first space 52 . The blow-by gas inside the first space 52 passes through the blow-by gas inlet 29 formed in the cover plate 26 and enters the first blow-by gas chamber 66 inside the breather box 16 .
The blow-by gas flowing into the first blow-by gas chamber 66 flows upward as indicated by the arrow in FIG. 4 and FIG. 5 while separating the inside of the first blow-by gas chamber 66 into a vehicle body front side and a vehicle body rear side, passes through the upper communication holes 64 formed in the cylinder 62 , and flows into the second blow-by gas chamber 67 inside the cylinder 62 . Because the blow-by gas moves in this manner while curving in the horizontal direction and the vertical direction inside the first blow-by gas chamber 66 , oil mist included in the blow-by gas adheres to the housing 61 and the cylinder 62 and is separated from the blow-by gas.
The blow-by gas flowing into the second blow-by gas chamber 67 similarly moves while curving in the horizontal direction and the vertical direction and is sucked into the pipe member 63 , because the upper communication holes 64 are positioned above the opening in the lower end of the pipe member 63 . For this reason, oil mist can be separated from the blow-by gas even in the second blow-by gas chamber 67 . The oil separated from the blow-by gas inside the second blow-by gas chamber 67 passes through the lower communication hole 65 formed in the lower end portion of the cylinder 41 and flows into the first blow-by gas chamber 66 . This oil, and the oil separated from the blow-by gas inside the first blow-by gas chamber 66 , passes through the blow-by gas inlet 29 opening to the bottom of the first blow-by gas chamber 66 and flows into the tank body 21 .
The oil tank 12 is configured to accommodate a high rate of oil flow because the oil is forcibly discharged from the inner cylinder 24 into the second space 53 by centrifugal force. Also, because the oil tank 12 can separate the blow-by gas from the oil in at least two places (e.g., inside of the inner cylinder 24 and inside of the closed space 28 ) gas/liquid separation is sufficiently conducted, and oil mist included in the blow-by gas can be more effectively separated and removed by the first and second blow-by gas chambers 66 and 67 .
Although the present invention has been described in terms of a certain embodiment, other embodiments apparent to those of ordinary skill in the art also are within the scope of this invention. Thus, various changes and modifications may be made without departing from the spirit and scope of the invention. For instance, various components may be repositioned as desired. Moreover, not all of the features, aspects and advantages are necessarily required to practice the present invention. Accordingly, the scope of the present invention is intended to be defined only by the claims that follow.
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An oil tank uses centrifugal movement of oil to separate blow-by gases. The oil tank has a tank body with an internal oil chamber. The oil chamber is spaced from the walls of the oil tank. The oil is delivered to the oil chamber and the oil swirls along the inner wall of the oil chamber in a helical pattern thereby allowing separation between the oil and the blow-by gases. The oil settles in the bottom of the oil chamber, which is in fluid communication with the region defined between the tank body and the oil chamber. The oil chamber is placed in an off-center location relative to the bottom of the tank body.
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BACKGROUND OF THE INVENTION
This invention relates generally to rock drills and more particularly to pneumatically operated percussive drills of the type adapted to be inserted into the drillhole being drilled. Such a drill is commonly known as a "down-the-hole" drill (DHD).
Many applications for down-the-hole drills require that liquids such as water, and other matter, be injected into the drill air supply to provide improved hole cleaning and stabilization. Typically, the volume of liquids injected can range from about 2.0 gallons per minute to about 15.0 gallons per minute. When water is injected into the air flow for a DHD, an appreciable loss in penetration rate results for a given pressure. One approach to avoiding this penetration rate loss is to separate the water, and other matter, from the percussive fluid in the drill string at or near the drill itself, before the percussive fluid actuates the drill piston. This separated water and other matter can then be exhausted into the drillhole to effect debris removal.
One such device for accomplishing this separation is disclosed in a pending U.S. patent application, Ser. No. 07/766,866, filed Nov. 29, 1991, entitled "A DEVICE FOR REMOVING DEBRIS FROM A DRILLHOLE" of which I am a co-inventor. This device positions a separator outside the DHD proper, adjacent the backhead of the drill. It would be useful if there were such separator device that is adapted to fit within existing drill backheads, so that the separator can be simply added to the drill backheads, as an add-on unit or as part of the complete drill, for newly manufactured units.
The foregoing illustrates limitations known to exist in present down-the-hole drilling technology. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing an improved device for removing drillhole debris that can be added to an existing drill backhead Such device separates a mixture of pneumatic fluid and other matter, flowing in a percussive, fluid-actuated, down-the-hole drill, into a first, pneumatic fluid component for actuating said drill, and into a second, heavier, exhaust component for removing drillhole debris, The device includes mounting means for mounting the device within a bore of a backhead of a drill; separator means for forming, in combination with the backhead, a separator for separating the mixture into first and second components; first passageway means on the device for fluidly transmitting the first component to fluid passageways on the drill, for actuating the drill; and second passageway means on the device for fluidly transmitting the second component, apart from the first component, to fluid exhaust passageways on the drill, for removing drillhole debris.
In a second aspect of the present invention, this is accomplished by providing a down-the-hole drill having the separator already incorporated into the backhead of the drill.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a split view of a longitudinal section of the top part of the invention, showing a check valve in the open position to the left of the centerline, and in a closed position to the right of the centerline, the section being taken along the line A--A of FIG. 2.
FIG. 1A is a continuation of the bottom part of the invention along the same section as in FIG. 1.
FIG. 2 is a section through FIG. 1, along lines B--B of FIG. 1.
FIG. 3 is a section through FIG. 1, along lines C--C of FIG. 1.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown the down-the-hole-drill 1 having a backhead 3, with an axial bore 5 extending therethrough. Backhead 3 has a top end 7 adapted to threadably connect to a drill string (not shown) through which flows a mixture of percussive pneumatic fluid (usually air) and other matter, such as water, oil or solid particles (such as rust) from the drill string. Bore 5 adjacent the top end 7 of backhead 3 has a first diameter 9, and adjacent bottom end 11 of backhead 3 bore 5 has a second, larger diameter 13, as is conventional. Bottom end 11 of backhead 3 is threadably connected to drill casing 15. Percussive drill bit 17 is mounted within chuck 19 (FIG. 1A), which is threadably connected to the bottom end 21 of casing 15, as is conventional.
The separator of this invention, shown generally as 25, is positioned in the larger diameter portion 13 of bore 5, of backhead 3, as described hereinafter.
A fluid distributor 27 is disposed within casing 15 towards bottom end 11 of backhead 3. The distributor 27 slides into place when backhead 3 is unscrewed and the separator 25 is removed. Distributor 27 is held in place by shoulder 29 positioned against the upper end 31 of cylinder 33 in casing 15, as is conventional.
An axial bore 35 is provided in the distributor 27 to provide means for transmitting fluid and separated other matter through the remainder of the impact apparatus, as described hereinafter.
Piston 37 reciprocates within casing 15 and impacts against the top end 34 of drill bit 17, as is well known. Extending through casing 15 are a first plurality of passageways, shown generally as 41, for fluidly transmitting fluid to actuate the piston 37. As is well known, these passageways are, in part, formed by undercuts and apertures in the casing 15 and cylinder 33, as is conventional.
Also extending through casing 15 is a second plurality of passageways (called exhaust fluid passageways herein), shown generally as 43, for fluidly transmitting exhaust fluid through the drill 1, for drillhole debris removal, As is well known, first and second passageways 41, 43 are separate from each other, and transmit fluid separately without mixing the actuating fluid and the exhaust fluid, at least until after the piston 37 is actuated. Exhaust fluid passageways 43 include an axial bore 35 through distributor 27, piston 37, and drill bit 17, to an exhaust port 45 on drill bit 17, as is conventional.
Separator 25, shown generally as 25, is known as a cyclonic separator that utilizes cyclonic fluid flow and reversal of fluid direction to achieve the separation desired. Separator 25 is mounted within bore 5 of backhead 3 by means of flange 51 that is clamped between bottom end 11 of backhead 3 and top end of a drill portion 53 therebelow. Flange 51 extends radially from centerline 55 of bore 5 to contact inner surface 57 of casing 15. Flange 51 rests upon spring bias means 59 that is mounted on top of shoulder 61 of distributor 27. Separator 25 can be removed by unscrewing backhead 3 from casing 15. It should be understood that separator 25 can be inserted into an existing drill assembly or installed as part of a new drill manufacture.
Separator 25 includes an inducer means 63 extending radially from centerline 55 to contact an internal surface of bore 5, which internal surface is a shoulder portion 65 connecting the smaller and larger diameter bores 9 and 13. In combination with bore 5, inducer 63 defines an inlet chamber 67, for receiving fluid mixture flowing from the drill string (not shown).
Positioned within inlet chamber 67 is a conventional check valve 71, for the purpose of closing bore 5, when fluid flow stops, so as to prevent backflow of water and debris from the drillhole into the drill. Check valve 71 is slidably positioned in an axial bore 73 in inducer 63, with a spring bias 75 acting against the bottom of bore 73 to move valve 71 into contact with shoulder 65, when flow ceases.
Inducer 63 includes a plurality of radially extending apertures 81 extending in a radial direction with respect to centerline 55. As shown in FIG. 2, apertures 81 are preferred to be tangentially disposed with respect to centerline 55, so as to cause a tangential flow of fluid passing through apertures 81. Apertures 81 can also be radially disposed with respect to centerline 55.
Connected to a bottom surface of inducer 63 is a hollow focus tube 100, that extends downwardly, and concentrically along centerline 55 to sealingly connect to top a surface of flange 51. Hollow focus tube 100 has an external surface that forms, in combination with inner surface 102 of backhead 3, formed by bore 5 at diameter 13, an annular separator chamber 104. Focus tube 100 also has an internal surface that forms an internal gallery 106 extending concentrically downward along centerline 55. A plurality of apertures 108 in focus tube 100 fluidly connect separator chamber 104 and gallery 106. A single aperture 108 will also work.
A hollow shield tube 120 is connected to a bottom surface of inducer 63, and extends downwardly and concentrically along centerline 55. Shield tube 120 is telescopically spaced over focus tube 100 a sufficient distance to cover apertures 108. Thus, shield tube 120 divides separator chamber into a first, annular, entry chamber 122, for receiving downward flow of fluid from inducer 63, and a second, annular, exit chamber 124, for receiving upward flow of fluid, as hereinafter described. Shield tube 120 prevents entry of downward flowing fluid into apertures 108, and only permits upward flowing fluid to enter apertures 108, after the fluid has had most of the heavy matter removed therefrom, as described hereinafter.
Sealingly connected to a bottom surface of flange 51 is a hollow orifice tube 130 that extends downwardly and concentrically along centerline 55, to sealingly engage bore 35 through distributor 27. Elastic seals 132 are positioned at the top and bottoms end of orifice tube 130. Orifice tube 130 has a restricted opening 134 at its bottom end, to limit fluid flow, somewhat. This restricted opening assures that most of the fluid flowing through the drill will serve to actuate the piston 37.
Connected to a lower portion of focus tube 100 is an annular baffle 140 extending radially toward inner surface 102 of backhead 3 formed by bore 5. Baffle 140 does not extend far enough to contact inner surface 102 but is spaced therefrom. Baffle 140, in combination with inner surface 102 and flange 51 forms a collection chamber 144 below baffle 140, for collecting separated matter as described hereinafter. The spacing of baffle 140 from inner surface 102 forms the entry into collection chamber 144.
A first plurality of apertures, 200 extends through flange 51 for fluidly connecting internal gallery 106 to distributor 27 by means of drill chamber 202, formed by flange 51 and distributor 27.
A second plurality of apertures 210 extend through flange 51 for fluidly connecting collection chamber 144 to orifice tube 130.
As shown in FIG. 3, a plurality of apertures 200 are spaced around centerline 55, but a single aperture will work. Also, a plurality of apertures 210 are shown space around centerline 55, but a single aperture will work.
In operation, the mixture of percussive fluid and other matter flows axially downwardly into inlet chamber 67 and against inducer 63, where it is deflected to a tangential and radially outward direction into annular separator chamber 104, to impact tangentially against inner surface 102 of backhead 3. Thereafter, the percussive fluid mixture flows downwardly and circularly, in a vortex fashion, through first annular entry chamber 122, causing separation of at least some of the heavier other matter from the percussive fluid mixture. Such separated matter flows downward along inner surface 102 of backhead to collection chamber 144. At the lower end of annular separator chamber 104, the percussive fluid mixture strikes baffle 140, reverses its flow to an upward direction, causing separation of more of the other heavier matter from percussive fluid mixture, and collection thereof in collection chamber 144.
The percussive fluid is now substantially divided into a first pneumatic fluid component, for actuating piston 37, and a second, primarily liquid and solid, exhaust component for removing drillhole debris. The first component flows upwardly along the outer surface of focus tube 100 through second annular exit chamber 124, and into collection gallery 106 of focus tube 100. Thereafter, it flows through drill chamber 202, distributor 27 and passageways 41 to actuate piston 37, as is conventional.
The second, separated component of the mixture flows through apertures 210 in flange 51 to orifice tube 130 an thereafter to exhaust passageways 43 and exhaust port 45 of drill bit 17, for debris removal, as is conventional.
In order to reduce wear on the interior of the drill 1 by the separated, second exhaust component, an elongated hollow tube 300 can be removably inserted into axial bore 35 to extend through the piston 37, to an optional distance, preferably to about the top end 39 of drill bit 17. Upper end 302 of tube 300 is flared, so as to fit into the mouth of bore 35 in distributor 29 immediately below the bottom end of orifice tube 130.
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A device for use within a backhead of a down-the-hole percussive drill, for removing debris from a drillhole, includes a separator for separating water and other matter from the percussive fluid prior to the percussive fluid actuating the piston of the drill. The water and other matter are exhausted out the drill bit, to remove the debris. The device includes a one-way flow valve to prevent backflow of debris and water into the drillhead during periods when the percussive fluid flow ceases. The device can be added to existing drill backheads, or included as part of newly manufactured units.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The invention relates to a cap for assembly onto a damper tube of a vibration damper, having an outer peripheral region which is cylindrical at least in sections, and at least one resilient spring tongue, wherein disposed on the spring tongue is at least one positive-locking element for producing a positive-locking connection between the cap and a protective element of the vibration damper.
[0002] German Patent Document DE 101 22 796 B4 discloses such a cap. The vibration damper described in this document includes a container tube in which a piston rod is guided in an axially movable manner, said piston rod being at least partially covered by a protective tube having at least one resilient fold. A stop buffer is disposed concentrically with respect to the piston rod, the stop buffer comes to lie against an end cap in an end region of a retracting movement of the piston rod. The end cap lies against the container tube in a completely assembled vibration damper. The stop buffer, the protective tube and the end cap form a preassembled structural unit independent of the vibration damper. The end cap is pressed against the container tube by the stop buffer when the piston rod undergoes a deflection movement into the container tube. For the purposes of connecting to the protective tube, the end cap comprises an edge that is circumferential at least in sections and is connected in a positive-locking manner to the protective tube. The end cap is designed to be radially resilient in the region of its edge. The container tube has a length section having a reduction in diameter in the direction of the end cap to be assembled.
[0003] A disadvantage in this known vibration damper is that the stop buffer, the protective tube and the end cap are to form a preassembled structural unit independent of the vibration damper. These components must thus be assembled to form a preassembled structural unit in a dedicated, separate working step, which requires a suitable tool in order to be able to achieve a uniform resilient deformation of the resilient segments of the end cap in order to be able to latch the protective tube with the end cap. In order to produce the positive-locking connection, a particular tool is thus required, which has to be separately obtained or produced. The assembly process is thus more complex and the production costs for the vibration damper are increased.
[0004] Exemplary embodiments of the present invention are directed to a vibration damper of the type mentioned in the introduction that can be assembled in a cost-effective manner by means of a simple assembly process.
[0005] In accordance with the invention, the at least one spring tongue comprises a region, which in the non-assembled state or in the delivery state of the cap, is set back radially inwards with respect to the outer peripheral region, wherein the set-back region comprises a spreading element by means of which the spring tongue is radially spread outwards when the cap is being assembled. By virtue of the region of the spring tongue that is radially set back with respect to the outer peripheral region, the positive-locking element is also radially set back to a position in which it cannot enter into a positive-locking connection with the protective element. Only when the cap is assembled on the damper tube is the spreading element actuated, which means that the spring tongue is spread radially outwards to such an extent that the positive-locking element moves into a position in which it enters a positive-locking connection with the protective element. Thus, the present invention does not require a particular tool for producing the positive-locking connection. The spreading element is actuated by the process of assembling the cap onto the damper tube, which is required in any case.
[0006] In accordance with a preferred embodiment of the invention, the cap is assembled by simply being slid onto the damper tube. The damper tube itself actuates the spreading element. The spreading element can be formed advantageously as an inclined surface or rounded section that is formed on the spring tongue of the cap. The inclined surface is preferably inclined radially inwards. Such an inclined surface or rounded section acts as a passive spreading element that co-operates with the damper tube when the cap is being assembled, i.e., no tool is required to spread the spring tongue radially outwards. The damper tube can have a constant diameter, in which case the spring tongues of the cap are adapted to the damper tube diameter. Alternatively, the damper tube can have a diameter enlargement, which means that only the larger diameter co-operates with the spreading element. This latter embodiment is described in more detail hereinafter during the description of a specific exemplified embodiment. The basic assembly process is the same for both of the aforementioned variations, i.e., regardless of whether the damper tube has a constant diameter or a diameter enlargement.
[0007] In accordance with exemplary embodiments of the present invention, the cap comprises several spring tongues that are disposed distributed over the circumference of the cap. In a particularly preferred manner, three spring tongues are provided distributed at regular intervals over the circumference of the cap. This ensures a reliable positive-locking connection between the cap and the protective element.
[0008] In accordance with a structurally simple embodiment of the invention, the positive-locking element is formed as an integral component of the spring tongue. For instance, the positive-locking element can be formed as a latching lug attached to or integrally formed on the spring tongue. The positive-locking element engages into a corresponding recess in the protective element in the assembled state of the cap so that that these two components are connected together in a positive-locking manner.
[0009] In an advantageous manner, the cap comprises a stop surface for positioning the protective element by means of which the protective element can be positioned relative to the positive-locking element in a position suitable for forming the positive-locking connection. The protective element lies against the stop surface in the assembled position. The stop surface is disposed on the cap such that a receptacle, provided on the protective element, for the positive-locking element is positioned relative thereto such that the positive-locking element penetrates radially outwards into the receptacle by virtue of the spreading action of the spring tongue produced when the cap is assembled. In this manner, the protective element is readily aligned into the correct position for forming the positive-locking connection. In accordance with a preferred embodiment of the invention, the stop surface is formed as a circular ring-shaped surface in order to reliably and effectively position the protective element relative to the cap.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0010] The invention will be explained in more detail hereinafter with reference to a drawing illustrating an exemplified embodiment. The drawings show in detail:
[0011] FIG. 1 a vibration damper having a cap in accordance with the invention in a partially sectional side view,
[0012] FIGS. 2 a , 2 b a partially sectional side view of the cap in accordance with the invention in two different assembly states,
[0013] FIG. 3 the assembly process when assembling the cap in accordance with the invention onto a vibration damper.
DETAILED DESCRIPTION
[0014] FIG. 1 shows a vibration damper having a cap in accordance with the invention, which is assembled onto one end of the damper tube 1 of the vibration damper. A piston rod 10 exits from the damper tube 1 . The piston rod 10 is guided so as to be movable in an oscillating and reciprocating fashion in a sealing and guiding assembly which is not shown in FIG. 1 and is disposed on the piston rod exit-side end of the damper tube 1 . With its end remote from the damper tube 1 , the piston rod 10 is fixedly connected to a damper bearing assembly 20 . The damper bearing assembly 20 will hereinafter be abbreviated to “damper bearing 20 ”. The damper bearing 20 is fixedly connected to a vehicle body of a motor vehicle which is not shown.
[0015] The damper tube 1 supports a spring plate 30 on which a spring end of a vehicle bearing spring 31 is supported. The other end of the vehicle bearing spring 31 is supported on the damper bearing 20 .
[0016] The piston rod 10 is protected against surface damage and ingress of dirt by a protective element 3 surrounding it. The protective element 3 is formed as bellows in the illustrated exemplified embodiment. A spring element 40 is disposed in the interior of the protective element 3 . The spring element 40 is supported with its end remote form the damper tube 1 on the damper bearing 20 . The other end of the spring element 40 faces the damper tube 1 or the cap assembled on the damper tube 1 . When a particular degree of deflection of the piston rod 10 is reached, i.e., when the telescopic vibration damper has been telescoped to a particular extent, the spring element 40 strikes the cap. The cap in accordance with the invention is thus also referred to by persons skilled in the art by the functional term “stop cap”.
[0017] The present invention relates to a particular configuration of the cap by means of which the vibration damper illustrated in FIG. 1 can be assembled in a cost-effective manner by means of a simple assembly process. In this respect, the stop cap is formed in a particular manner in order to produce in a simple manner the inventive positive-locking connection between the cap and the protective element 3 . The particular configuration of the cap is explained in more detail hereinafter with reference to FIGS. 2 a , 2 b.
[0018] In the non-enlarged illustration in FIGS. 2 a and 2 b , the cap formed in accordance with the invention, the protective element 3 and the spring element 40 without the vibration damper, the vehicle bearing spring 31 and the damper bearing 20 are illustrated. In both of the left-hand parts of the images in FIGS. 2 a and 2 b , a section enlargement of the cap in accordance with the invention and of the protective element 3 and a partial section of the damper tube 1 (which is not illustrated in the non-enlarged parts of the images) are illustrated. FIG. 2 a illustrates the non-assembled state of the cap in accordance with the invention. The situation illustrated in FIG. 2 a is the situation in which the cap and the protective element 3 are located immediately prior to assembly on the damper tube 1 (also see in this respect hereinafter with respect to FIG. 3 ).
[0019] FIG. 2 b illustrates the cap in accordance with the invention and the protective element 3 in the state assembled onto the damper tube 1 . In this state, the cap in accordance with the invention together with the protective element 3 is assembled on the damper tube 1 and there is a positive-locking connection between the protective element 3 and the cap.
[0020] In the illustration in FIG. 2 a , the spring tongue 5 of the cap is set back radially inwards with respect to the cylindrical outer peripheral region 4 in its region leading towards the positive-locking element 2 . It can be clearly seen that the positive-locking element 2 is not engaged with a corresponding recess A in the protective element 3 . Thus, a positive-locking connection between the cap and the protective element 3 is not formed. The protective element 3 could readily be removed upwards from the cap since the two components are not connected together in terms of a subassembly.
[0021] In order to form a positive-locking connection between the cap and the protective element 3 , the positive-locking element 2 has to engage into the receptacle A of the protective element. In order to achieve this, the positive-locking element 2 is disposed on a spring tongue 5 . The spring tongue 5 is pressed radially outwards when the cap is slid onto the damper tube 1 , which means that the positive-locking element 2 engages into the recess A of the protective element 3 in a positive-locking manner. This state is illustrated in FIG. 2 b . In order to effect the described spreading of the spring tongue 5 radially outwards, the region of the spring tongue 5 set back with respect to the cylindrical outer peripheral region 4 comprises a spreading element 6 . The spreading element 6 is formed as a simple inclined surface in the illustrated exemplified embodiment. This inclined surface can slide on the outer surface of the damper tube 1 when the cap is pressed onto the damper tube end. The damper tube 1 comprises a diameter enlargement from a diameter D 2 to a diameter D 1 (cf. FIG. 3 ), which means that when pressing the cap onto the damper tube 1 , the inclined surface forming the spreading element 6 is pressed radially outwards by the increasing diameter of the damper tube 1 . The spring tongue 5 spreads outwards which means that the positive-locking element 2 engages into the recess A of the protective element 3 in a positive-locking manner. The positive-locking engagement of the positive-locking element 2 into the recess A of the protective element 3 is illustrated in FIG. 2 b.
[0022] The section enlargement illustrated in FIG. 2 a illustrates a preassembly state or even a delivery state of the cap in which the spring tongues 5 and the positive-locking elements 2 are bent radially inwards. The positive-locking elements 2 are set out radially outwards—owing to the diameter enlargement of the damper tube 1 —only when the cap is slid onto the damper tube 1 .
[0023] FIG. 3 illustrates the simple assembly of the cap in accordance with the invention on the damper tube 1 . Beneath the number 1 , a protective element 3 is illustrated in which a spring element 40 has been incorporated. Beneath the number 2 , the damper tube 1 having a loosely placed cap in accordance with the invention is illustrated. The cap is disposed on a section of the damper tube having a reduced diameter. The radially inwardly bent spring tongues 5 can be clearly seen in FIG. 3 beneath the number 2 . The cap in accordance with the invention further comprises a stop surface 8 on which the protective element 3 can be supported for the correct positioning of the protective element 3 relative to the cap in accordance with the invention.
[0024] In the embodiment illustrated in FIG. 3 , the damper tube 1 comprises three sections having different diameters as seen in the axial direction. The cap in accordance with the invention with its spring tongues is dimensioned such that when pressing the cap onto the damper tube, the largest diameter D 1 effects the spreading of the spring tongues and thus the positive-locking locking connection between the protective element 3 and the cap. On the reduced-diameter section having the diameter D 2 , the cap in accordance with the invention can be loosely placed, which means that the spring tongues are not spread radially outwards or are so only slightly. In this state, the protective element 3 can be placed onto the cap as described hereinafter and the recesses A are positioned relative to the positive-locking elements 2 such that a positive-locking connection is produced when the spring tongues are spread radially outwards. The end section of the damper tube 1 has the smallest diameter D 3 . The cap in accordance with the invention has radially inwardly protruding ribs in its end region. The clearance between these ribs is dimensioned to be adapted to the smallest diameter D 3 such that after the cap has been pressed on, a frictionally-engaged connection between the cap and the damper tube is provided. In this manner, the pressed-on cap is fixedly seated in the axial direction on the damper tube.
[0025] Beneath the number 3 in FIG. 3 , the protective element 3 loosely placed onto the cap in accordance with the invention having the spring element 4 connected thereto is illustrated. In this state, the cap is loosely placed onto the damper tube 1 and the protective element 3 is loosely placed onto the cap. The spring element 3 is supported on the stop surface 8 of the cap. As a result, the receptacles A in the protective element 3 are positioned precisely in the provided position for forming the positive-locking connection relative to the positive-locking elements 2 of the cap.
[0026] Beneath the number 4 in FIG. 3 , the actual assembly step, i.e., pressing the cap in accordance with the invention onto the damper tube 1 forming the positive-locking connection between the protective element 3 and the cap is illustrated. In this respect, the protective element 3 , i.e., the bellows, is compressed by a force F from the outside which means that the spring element 40 lies against the cap in accordance with the invention. The cap is then pressed onto the damper tube 1 by the force F acting on the spring element 40 . Since a so-called “setting stroke” already occurs in terms of the conventional assembly of motor vehicle spring struts with bellows, this setting stroke can be used to also perform the above-mentioned assembly step in an identical manner. In this respect, no additional assembly step is required.
[0027] When pressing the cap onto the damper tube 1 , the spring tongues 5 are spread radially outwards owing to the diameter enlargement of the damper tube 1 . The positive-locking elements 2 penetrate into the receptacles A of the protective element 3 , which means that a positive-locking connection between the cap and the protective element 3 is formed. The force required for pressing the cap onto the damper tube 1 in this manner is represented by an arrow and the letter F in FIG. 3 beneath the number 4 .
[0028] If the force required for pressing the cap onto the damper tube 1 is removed and the protective element 3 formed as bellows is relieved, then the bellows spring back to the position illustrated beneath the number 5 in FIG. 3 . The spring element 40 is then removed from the cap and is positioned by the protective element 3 at a provided spaced disposition with respect to the cap. The cap is fixedly seated on the end of the damper tube 1 and is connected to the protective element 3 in a positive-locking manner.
[0029] In accordance with the present invention, no particular tools are required for the assembly of the cap and the positive-locking element connected thereto in a positive-locking manner. The cap in accordance with the invention already contains all of the features required for the correct positioning of the protective element 3 relative to the positive-locking elements 2 of the cap, since the correct positioning of the protective element 3 relative to the cap is achieved in a simple manner by the stop surfaces 8 formed on the cap itself. Furthermore, in the case of the invention, the setting stroke performed within the scope of the conventional procedure when assembling motor vehicle spring struts with bellows is also adeptly used for assembling the arrangement of the protective element 3 , spring element 40 and cap. An additional assembly step is not required.
[0030] The invention provides a simple and cost-effective solution for producing a vibration damper having a protective element 3 protecting the piston rod and a spring element 40 used as a stop buffer.
[0031] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
LIST OF REFERENCE NUMERALS
[0000]
1 Damper tube
2 Positive-locking element
3 Protective element
4 Outer peripheral region
5 Spring tongue
6 Spreading element
7 Surface
8 Stop surface
10 Piston rod
20 Damper bearing
30 Spring plate
31 Vehicle bearing spring
40 Spring element
A Recess
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A cap for mounting on a damper tube of a vibration damper, having an outer shell region that is cylindrical at least in sections and at least one elastic spring tongue. At least one positively locking element is arranged on the spring tongue in order to produce a positively locking connection between the cap and a protective element of the vibration damper. The at least one spring tongue has a region which, in the non-mounted state of the cap, is set back inwardly in the radial direction with respect to the outer shell region. The set- back region has a spreading element, by way of which the spring tongue is spread outwardly in the radial direction during the mounting of the cap.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to flight control systems (Flight Control Systems) present in aircraft.
2. Discussion of the Background
These flight control systems are at the interface between the flying means (joystick, rudder bar, etc.) and the various mobile flight surfaces of the aircraft (such as the vertical, horizontal rudders, the ailerons, the stabilizers, etc.).
Modern airliners possess “fly by wire”-type flight control systems in which mechanical actions on the flying means are converted into signals transmitted to actuators controlling the movement of the flight surfaces, these commands being transmitted to the actuators by advanced computers.
These commands are calculated according to several types of laws. One of these laws, called normal law, is an assisted-flying law that reprocesses the flying instructions provided by the flying means in order to optimize the flying conditions (comfort of the passengers, stabilization of the airplane, protection of the flight domain, etc). Another law, known as direct law, is a law that only retranscribes the instructions for movement of the airplane transmitted by the electrical flight controls without reprocessing of these signals intended to improve flying performances.
There already is known, as illustrated on FIG. 1 , a flight control system 1 comprising a control module 2 having two sets of computers 4 and 5 so as to determine the control commands to be transmitted to actuators 3 .
Set 4 comprises two computers 4 - 1 and 4 - 2 capable of calculating the control of actuators 3 established according to the normal and direct control laws (these computers are called primary computers) and a computer 4 - 3 only capable of calculating this control established according to the direct law (this computer is called secondary computer).
Set 5 comprises a primary computer 5 - 1 and two secondary computers 5 - 2 and 5 - 3 .
All these computers are installed in an avionic bay and communicate with the actuators via direct point-to-point analog links.
The actuators are connected to one or two computers, with in the case of two computers a “master/hold” architecture; the master computer ascertains the validity of the control signal transmitted to the actuator which ensures the integrity of the device. When the master computer breaks down, the computer “on hold” takes over, which ensures that a computer is always available.
In order to ascertain the validity of its command, each computer has a dual calculation unit structure (it concerns dual-path computers also called “duplex” computers), not illustrated on FIG. 1 .
The first unit is a control (COM) unit which implements the processing necessary for carrying out the functions of the computer, namely determining a control signal to an actuator.
The second unit is a surveillance or monitoring (MON) unit which for its part performs the same types of operations, the values obtained by each unit then being compared and, if there is a discrepancy that exceeds the authorized tolerance threshold, the computer is automatically disabled. It then becomes inoperative and is declared out of order so that another computer can substitute for it in order to implement the functions abandoned by this out-of-order computer.
In this way each computer is designed to detect its own breakdowns and to inhibit the corresponding outputs, while indicating its condition.
The hardware of the primary and secondary computers is different so as to minimize the risks of simultaneous failure of the set of computers (hardware dissimilarity).
Moreover, the hardware of the two paths (COM and MON) of each computer is identical, but for reasons of security the software of these two paths is different so as to ensure a software dissimilarity.
SUMMARY OF THE INVENTION
The invention seeks to provide a flight control system that has a modified architecture in comparison with that of the prior art described above, at once less costly in hardware and software resources while meeting the same requirements for security and availability as the system of the prior art.
To this end, it proposes a flight control system for an aircraft comprising:
at least one actuator for a mobile flight surface of the said aircraft;
a flight control module in communication with the said actuator, the said module comprising a first and a second computer, each computer being adapted for calculating a control command established according to at least one predetermined law for control of the said flight surface; characterized in that the said first computer, known as validating computer, comprises logical means adapted for comparing its control command with that of the said second computer, known as master computer, and for transmitting the result of the said comparison to the said actuator, the said actuator comprising logical means adapted for deciding, on the basis of this result, to execute or not to execute the command of the master computer.
Unlike the COM/MON architecture of the prior art, here the validating computer does not decide on its own whether the command of the master is to be transmitted to the actuator, the command of the master is systematically transmitted to the actuator and it is the actuator itself which, by virtue of the logical means that it comprises, decides, according to the result sent back by the validating computer or computers of the master computer, to execute or not to execute the command of the master computer.
Since a decision step is moved to the actuator, that makes it possible to produce simpler and less costly computers while providing a greater flexibility for the layout of the system.
In this way it is possible, in particular, to associate a master computer with several validating computers or else to associate an actuator with several master/validating computer pairs in order to ascertain the reliability of the transmitted command with an increased security.
This flexibility makes it possible in particular to use single-path computers (computers known as “simplex,” that is to say devoid of redundant microprocessors) while preserving the same level of security.
According to optional characteristics, the said master computer also comprises the said logic means for comparison.
This makes it possible to make each computer multi-purpose, the functions between master and validating being able to be exchanged at any time according to failures of the computers, which contributes to making the system more flexible and to reducing the total number of computers required.
According to other optional characteristics, the said actuator is in communication with a group of master computers, each master computer being associated with at least one validating computer of a group of validating computers, the said logic means of the said actuator being adapted for selecting the one to be executed from among the commands originating from the said master computers.
The actuator is associated with several master computers in order to maximize the chances that a command originating from a master will be considered as valid and therefore can be reliable.
According to other optional characteristics, the said logic means of the said actuator have a priority architecture.
The master computers connected to the actuator thus are organized in order of priority in such a way that it is the first valid command according to this priority logic that is executed.
According to still other optional characteristics, each validating computer is adapted for calculating the control command according to a program different from that of the master computer with which it is associated.
For the same control law, the software dissimilarity for the calculation of a command between master and validating computers provides an additional security.
According to still other optional characteristics, each computer is adapted for detecting when the computer with which it is associated is calculating the control command according to the same program and if such is the case, for being reconfigured to calculate this control command according to a different program.
In this way the software reconfiguration makes it possible to maximize the use of each computer which contributes to minimizing the total number of computers while preserving, for the same control law, a software dissimilarity between master and validating computers.
According to still other optional characteristics:
the said actuator comprises a control unit and a unit for monitoring the said control unit;
each unit is connected to at least one master computer and to the associated validating computer; and/or
one of the units is only connected to a master computer and the other is only connected to the associated validating computer, the said control and monitoring units also being connected to one another.
The connecting of the control and monitoring units of the actuators with the computers thus can be accomplished directly or indirectly (through the other unit).
In a second aspect, the invention also applies to an aircraft equipped with a system such as explained above.
BRIEF DESCRIPTION OF THE DRAWINGS
The explanation of the invention now will be continued with the detailed description of an exemplary embodiment, provided below in an illustrative but not limitative capacity, with reference to the attached drawings, on which:
FIG. 1 is a schematic representation of a flight control system according to the prior art described above;
FIG. 2 is a schematic view of a flight control system according to the invention;
FIG. 3 is a view detailing the communication network allowing the transfer of information from the sets of computers that comprise the system according to the invention to the actuators of this system; and
FIG. 4 is a view similar to FIG. 3 but for a variant of the communication network.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The flight control system according to the invention 11 illustrated on FIG. 2 has a control module 12 to transmit commands to a plurality of actuators 13 .
Control module 12 comprises six “simplex” computers (they have only one path and a single calculation processor) distributed in two sets 14 and 15 of three computers, each set being connected to each actuator 13 .
The set of computers 14 (respectively 15 ) communicates with actuators 13 through a digital data exchange means 16 (respectively 17 ) the structure of which will be explained in detail below with the aid of FIGS. 3 and 4 .
The set of computers 14 (respectively 15 ) comprises two primary computers 14 - 1 and 14 - 2 (respectively 15 - 1 and 15 - 2 ) making it possible to calculate the control commands according to the normal law and according to the direct law as well as a secondary computer 14 - 3 (respectively 15 - 3 ) for calculating the control commands on the basis of the direct law alone.
The primary and secondary computers are of different hardware design in order to meet security requirements (hardware dissimilarity).
The 14 - 1 and 14 - 2 (respectively 15 - 1 and 15 - 2 ) primary computers function with two program variants A and B for calculation according to the normal and direct laws which are different from one another, while computer 14 - 3 (respectively 15 - 3 ) functions for calculation according to the direct law with a program variant C different from variants A and B.
In this way the calculation according to the normal law is obtained by two different programs (A and B) while the calculation according to the direct law also is obtained by two different programs (B and C or A and C or A and B). Software dissimilarity therefore is amply ensured for the determination of the control signals, which ensures a high level of security.
As will be seen below, each computer can be reconfigured on the spot according to failures.
These sets of computers are located in the avionic bay (the avionic bay is the space in which most of the electronic equipment items of an airplane are grouped together, in general situated beneath the useful space of the airplane) and are supplied by two separate electrical systems.
Each actuator 13 comprises two paths 18 and 19 (COM path and MON path) connected to two sets of computers 14 and 15 in such a way that each actuator communicates through its paths 18 and 19 with all the computers.
Path 18 (COM control unit) performs the functions of selection of the command to be executed and path 19 (MON monitoring unit) for its part carries out the same types of operations so that at the output the values obtained by each unit are compared and, in the event of disagreement, the actuator is disabled.
In the architecture of the control system according to the invention, called priority architecture, all the computers generate control commands for the mobile flight surfaces with each computer that plays the role of master computer for one group of actuators and the role of validating computer for the other actuators.
Each master computer is associated with one or more validating computers and each actuator is associated with one or more masters.
In the case in which the actuator has several masters, the latter are classified according to a priority logic explained below in order to define the master at any moment.
Each computer transmits the flight surface commands to the actuators for which it is master and to all the other computers. Each “validating” computer compares its command with the command of the master computer for the actuators for which it is not itself master and, if the result of the comparison is positive (command of the master validated), the validating computer transmits this information to the actuators concerned. Each actuator therefore receives one or more commands as well as the corresponding validities originating from validating computers (in the illustrated example computers 14 - 2 , 14 - 3 and 15 - 1 to 15 - 3 ). The control performed by the actuator then is carried out in three steps.
According to the first step, unit 18 (respectively unit 19 ) receives commands from all the master computers controlling the actuator under consideration (in the illustrated example computers 14 - 1 to 14 - 3 and 15 - 1 and 15 - 2 are master computers for the actuator). Unit 18 (respectively 19 ) chooses the command to be applied according to a priority logic an example of which is synthesized by the table shown below:
Master
Priorities
Computer
Validating Computer
Level of laws
7
Computer 14-1
Computer 14-2 or
Normal Law
Computer 15-2
6
Computer 15-1
Computer 14-2 or
Normal Law
Computer 15-2
5
Computer 14-1
Computer 15-1, after
Normal Law
reconfiguration of this
computer with software B
4
Computer 14-2
Computer 15-2, after
Normal Law
reconfiguration of this
computer with software A
3
Computer 14-2
Computer 14-3 or
Direct Law
Computer 15-3
2
Computer 15-2
Computer 14-3 or
Direct Law
Computer 15-3
1
Computer 14-3
Computer 15-3
Direct Law
This priority logic takes into account the degradation of the laws, the normal law to be favored in relation to the degraded one (direct law), level 7 corresponding to the highest priority level.
At each priority level, software dissimilarity is preserved between the master computer and its associated validating computer.
According to a second step, unit 18 (respectively 19 ) is to validate this command on the basis of the information items from the corresponding validating computers. If the command from the selected master is not correctly validated by the validating computers, this command is ignored, and a new master computer is chosen according to the foregoing priority logic.
Finally, and according to a third step, the two units 18 and 19 transmit to all the computers the applied command, the current position of the actuator and the addresses of the current master and validating computers as well as, if need be, of the masters considered as faulty (rejected masters).
At any step, unit 19 (respectively unit 18 , is able to cut off unit 18 (respectively unit 19 ) if it detects a disagreement between the two.
When computer 15 - 1 sees that computers 14 - 2 and 15 - 2 are lost (priority 5 ), it is reconfigured in software B in order to ensure software dissimilarity for the normal law between it and computer 14 - 1 .
Likewise, when computer 15 - 2 sees that computers 14 - 1 and 15 - 1 are lost (priority 4 ), it is reconfigured according to software A in order to ensure software dissimilarity for the normal law between it and computer 14 - 2 .
An exemplary communication network between the computers of module 12 and actuators 13 now is going to be described with the aid of FIG. 3 .
This network comprises two data exchange means 16 and 17 .
Means 16 (respectively 17 ) comprises two components 16 - 1 and 16 - 2 (respectively 17 - 1 and 17 - 2 ), each component comprising a 100 Mbit/s AFDX (Avionics Full Duplex switched Ethernet) bus, situated in the avionic bay or elsewhere in the fuselage of the airplane and connected to a micro-bus (with an output of 10 Mbit/s) situated close to the actuators (these buses are not illustrated on the Figure). These buses have been developed and standardized to meet the standards of the aeronautical field.
The AFDX networks are based on the principle of the switched networks, that is to say that the actuators and the computers in charge of transmission or reception of data are organized around switches through which these data pass in transit.
These networks form a digital link between the computers and the actuators, the multiplexing of the data so obtained making it possible to have each computer easily communicate with each actuator (which was not the case with the device of the prior art where the links between the computers and the actuators were point-to-point analog links).
Each means 16 and 17 is connected to each unit 18 and 19 of each actuator 13 , so that each unit 18 and 19 is connected directly with each computer by the AFDX buses and the micro-buses.
In a variant illustrated in FIG. 4 , unit 18 of each actuator is only connected to one of the sets of computers while unit 19 is connected to the other of the sets of computers, with units 18 and 19 which are connected to one another in such a way that unit 18 can communicate with the set of computers to which it is not directly connected through unit 19 and vice versa.
As a variant, units 18 and 19 of each actuator can share the same medium in order to communicate with the computer, by using so-called application CRC (Cyclic Redundancy Check), for signing their messages.
It also is possible to use other types of buses such as ARINC (Aeronautical Radio Incorporated) buses or any other type of communication means allowing a digital multiplexing, between the computers and the actuators provided that these are compatible with the standards in the aeronautical field.
In still another variant, it is not the normal and direct laws that are implemented in the computers, but any other type of law such as, for example, a law that, unlike the direct law, would be only partially degraded in relation to the normal law (following the loss of sensor signals from the airplane, for example).
Finally, it will be recalled that the number of computers can be varied according to needs and is not restricted to the number described in the examples illustrated in FIGS. 2 to 4 .
Numerous other variants are possible according to circumstances, and in this connection it is recalled that the invention is not limited to the examples described and shown.
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A flight control system includes at least one actuator for a mobile flight surface of an aircraft, and a flight control module in communication with the actuator. The module includes a first and a second computer. Each computer calculates a control command established according to at least one predetermined law for control of the flight surface. The first computer, known as validating computer, comprises logic means adapted for comparing its control command with that of the second computer, known as master computer, and for transmitting the result of the comparison to the actuator. The actuator comprises logic means adapted for deciding, on the basis of the result, to execute or not to execute the command of the master computer. An aircraft comprising such a system is also disclosed.
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This is a division, of prior application Ser. No. 09/161,840, filed Sep. 28, 1998 which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates generally to movable barrier operators for operating movable barriers or doors. More particularly, it relates to garage door operators having improved safety and energy efficiency features.
Garage door operators have become more sophisticated over the years providing users with increased convenience and security. However, users continue to desire further improvements and new features such as increased energy efficiency, ease of installation, automatic configuration, and aesthetic features, such as quiet, smooth operation.
In some markets energy costs are significant. Thus energy efficiency options such as lower horsepower motors and user control over the worklight functions are important to garage door operator owners. For example, most garage door operators have a worklight which turns on when the operator is commanded to move the door and shuts off a fixed period of time after the door stops. In the United States, an illumination period of 4½ minutes is considered adequate. In markets outside the United States, 4½ minutes is considered too long. Some garage door operators have special safety features, for example, which enable the worklight whenever the obstacle detection beam is broken by an intruder passing through an open garage door. Some users may wish to disable the worklight in this situation. There is a need for a garage door operator which can be automatically configured for predefined energy saving features, such as worklight shut-off time.
Some movable barrier operators include a flasher module which causes a small light to flash or blink whenever the barrier is commanded to move. The flasher module provides some warning when the barrier is moving. There is a need for an improved flasher unit which provides even greater warning to the user when the barrier is commanded to move.
Another feature desired in many markets is a smooth, quiet motor and transmission. Most garage door operators have AC motors because they are less expensive than DC motors. However, AC motors are generally noisier than DC motors.
Most garage door operators employ only one or two speeds of travel. Single speed operation, i.e., the motor immediately ramps up to full operating speed, can create a jarring start to the door. Then during closing, when the door approaches the floor at full operating speed, whether a DC or AC motor is used, the door closes abruptly with a high amount of tension on it from the inertia of the system. This jarring is hard on the transmission and the door and is annoying to the user.
If two operating speeds are used, the motor would be started at a slow speed, usually 20 percent of full operating speed, then after a fixed period of time, the motor speed would increase to full operating speed. Similarly, when the door reaches a fixed point above/below the close/open limit, the operator would decrease the motor speed to 20 percent of the maximum operating speed. While this two speed operation may eliminate some of the hard starts and stops, the speed changes can be noisy and do not occur smoothly, causing stress on the transmission. There is a need for a garage door operator which opens the door smoothly and quietly, with no abruptly apparent sign of speed change during operation.
Garage doors come in many types and sizes and thus different travel speeds are required for them. For example, a one-piece door will be movable through a shorter total travel distance and needs to travel slower for safety reasons than a segmented door with a longer total travel distance. To accommodate the two door types, many garage door operators include two sprockets for driving the transmission. At installation, the installer must determine what type of door is to be driven, then select the appropriate sprocket to attach to the transmission. This takes additional time and if the installer is the user, may require several attempts before matching the correct sprocket for the door. There is a need for a garage door operator which automatically configures travel speed depending on size and weight of the door.
National safety standards dictate that a garage door operator perform a safety reversal (auto-reverse) when an object is detected only one inch above the DOWN limit or floor. To satisfy these safety requirements, most garage door operators include an obstacle detection system, located near the bottom of the door travel. This prevents the door from closing on objects or persons that may be in the door path. Such obstacle detection systems often include an infrared source and detector located on opposite sides of the door frame. The obstacle detector sends a signal when the infrared beam between the source and detector is broken, indicating an obstacle is detected. In response to the obstacle signal, the operator causes an automatic safety reversal. The door stops and begins traveling up, away from the obstacle.
There are two different “forces” used in the operation of the garage door operator. The first “force” is usually preset or setable at two force levels: the UP force level setting used to determine the speed at which the door travels in the UP direction and the DOWN force level setting used to determine the speed at which the door travels in the DOWN direction. The second “force” is the force level determined by the decrease in motor speed due to an external force applied to the door, i.e., from an obstacle or the floor. This external force level is also preset or setable and is any set-point type force against which the feedback force signal is compared. When the system determines the set point force has been met, an auto-reverse or stop is commanded.
To overcome differences in door installations, i.e. stickiness and resistance to movement and other varying frictional-type forces, some garage door operators permit the maximum force (the second force) used to drive the speed of travel to be varied manually. This, however, affects the system's auto-reverse operation based on force. The auto-reverse system based on force initiates an auto-reverse if the force on the door exceeds the maximum force setting (the second force) by some predetermined amount. If the user increases the force setting to drive the door through a “sticky” section of travel, the user may inadvertently affect the force to a much greater value than is safe for the unit to operate during normal use. For example, if the DOWN force setting is set so high that it is only a small incremental value less than the force setting which initiates an auto-reverse due to force, this causes the door to engage objects at a higher speed before reaching the auto-reverse force setting. While the obstacle detection system will cause the door to auto-reverse, the speed and force at which the door hits the obstacle may cause harm to the obstacle and/or the door.
Barrier movement operators should perform a safety reversal off an obstruction which is only marginally higher than the floor, yet still close the door safely against the floor. In operator systems where the door moves at a high speed, the relatively large momentum of the moving parts, including the door, accomplishes complete closure. In systems with a soft closure, where the door speed decreases from full maximum to a small percentage of full maximum when closing, there may be insufficient momentum in the door or system to accomplish a full closure. For example, even if the door is positioned at the floor, there is sometimes sufficient play in the trolley of the operator to allow the door to move if the user were to try to open it. In particular, in systems employing a DC motor, when the DC motor is shut off, it becomes a dynamic brake. If the door isn't quite at the floor when the DOWN travel limit is reached and the DC motor is shut off, the door and associated moving parts may not have sufficient momentum to overcome the braking force of the DC motor. There is a need for a garage door operator which closes the door completely, eliminating play in the door after closure.
Many garage door operator installations are made to existing garage doors. The amount of force needed to drive the door varies depending on type of door and the quality of the door frame and installation. As a result, some doors are “stickier” than others, requiring greater force to move them through the entire length of travel. If the door is started and stopped using the full operating speed, stickiness is not usually a problem. However, if the garage door operator is capable of operation at two speeds, stickiness becomes a larger problem at the lower speed. In some installations, a force sufficient to run at 20 percent of normal speed is too small to start some doors moving. There is a need for a garage door operator which automatically controls force output and thus start and stop speeds.
SUMMARY OF THE INVENTION
A movable barrier operator having an electric motor for driving a garage door, a gate or other barrier is operated from a source of AC current. The movable barrier operator includes circuitry for automatically detecting the incoming AC line voltage and frequency of the alternating current. By automatically detecting the incoming AC line voltage and determining the frequency, the operator can automatically configure itself to certain user preferences. This occurs without either the user or the installer having to adjust or program the operator. The movable barrier operator includes a worklight for illuminating its immediate surroundings such as the interior of a garage. The barrier operator senses the power line frequency (typically 50 Hz or 60 Hz) to automatically set an appropriate shut-off time for a worklight. Because the power line frequency in Europe is 50 Hz and in the U.S. is 60 Hz, sensing the power line frequency enables the operator to configure itself for either a European or a U.S. market with no user or installer modifications. For U.S. users, the worklight shut-off time is set to preferably 4½ minutes; for European users, the worklight shut-off time is set to preferably 2½ minutes. Thus, a single barrier movement operator can be sold in two different markets with automatic setup, saving installation time.
The movable barrier operator of the present invention automatically detects if an optional flasher module is present. If the module is present, when the door is commanded to move, the operator causes the flasher module to operate. With the flasher module present, the operator also delays operation of the motor for a brief period, say one or two seconds. This delay period with the flasher module blinking before door movement provides an added safety feature to users which warns them of impending door travel (e.g. if activated by an unseen transmitter).
The movable barrier operator of the present invention drives the barrier, which may be a door or a gate, at a variable speed. After motor start, the electric motor reaches a preferred initial speed of 20 percent of the full operating speed. The motor speed then increases slowly in a linearly continuous fashion from 20 percent to 100 percent of full operating speed. This provides a smooth, soft start without jarring the transmission or the door or gate. The motor moves the barrier at maximum speed for the largest portion of its travel, after which the operator slowly decreases speed from 100 percent to 20 percent as the barrier approaches the limit of travel, providing a soft, smooth and quiet stop. A slow, smooth start and stop provides a safer barrier movement operator for the user because there is less momentum to apply an impulse force in the event of an obstruction. In a fast system, relatively high momentum of the door changes to zero at the obstruction before the system can actually detect the obstruction. This leads to the application of a high impulse force. With the system of the invention, a slower stop speed means the system has less momentum to overcome, and therefore a softer, more forgiving force reversal. A slow, smooth start and stop also provide a more aesthetically pleasing effect to the user, and when coupled with a quieter DC motor, a barrier movement operator which operates very quietly.
The operator includes two relays and a pair of field effect transistors (FETs') for controlling the motor. The relays are used to control direction of travel. The FET's, with phase controlled pulse width modulation, control start up and speed. Speed is responsive to the duration of the pulses applied to the FETs. A longer pulse causes the FETs to be on longer causing the barrier speed to increase. Shorter pulses result in a slower speed. This provides a very fine ramp control and more gentle starts and stops.
The movable barrier operator provides for the automatic measurement and calculation of the total distance the door is to travel. The total door travel distance is the distance between the UP and the DOWN limits (which depend on the type of doors. The automatic measurement of door travel distance is a measure of the length of the door. Since shorter doors must travel at slower speeds than normal doors (for safety reasons), this enables the operator to automatically adjust the motor speed so the speed of door travel is the same regardless of door size. The total door travel distance in turn determines the maximum speed at which the operator will travel. By determining the total distance traveled, travel speeds can be automatically changed without having to modify the hardware.
The movable barrier operator provides full door or gate closure, i.e. a firm closure of the door to the floor so that the door is not movable in place after it stops. The operator includes a digital controller or processor, specifically a microcontroller which has an internal microprocessor, an internal RAM and an internal ROM and an external EEPROM. The microcontroller executes instructions stored in its internal ROM and provides motor direction control signals to the relays and speed control signals to the FETs. The operator is first operated in a learn mode to store a DOWN limit position for the door. The DOWN limit position of the door is used as an approximation of the location of the floor (or as a minimum reversal point, below which no auto-reverse will occur). When the door reaches the DOWN limit position, the microcontroller causes the electric motor to drive the door past the DOWN limit a small distance, say for one or two inches. This causes the door to close solidly on the floor.
The operator embodying the present invention provides variable door or gate output speed, i.e., the user can vary the minimum speed at which the motor starts and stops the door. This enables the user to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces. The minimum barrier speeds in the UP and DOWN directions are determined by the user-configured force settings, which are adjusted using UP and DOWN force potentiometers. The force potentiometers set the lengths of the pulses to the FETs, which translate to variable speeds. The user gains a greater force output and a higher minimum starting speed to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces speed, without affecting the maximum speed of travel for the door. The user can configure the door to start at a speed greater than a default value, say 20 percent. This greater start up and slow down speed is transferred to the linearly variable speed function in that instead of traveling at 20 percent speed, increasing to 100 percent speed, then decreasing to 20 percent speed, the door may, for instance, travel at 40 percent speed to 100 percent speed and back down to 40 percent speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a garage having mounted within it a garage door operator embodying the present invention;
FIG. 2 is an exploded perspective view of a head unit of the garage door operator shown in FIG. 1;
FIG. 3 is an exploded perspective view of a portion of a transmission unit of the garage door operator shown in FIG. 1;
FIG. 4 is a block diagram of a controller and motor mounted within the head unit of the garage door operator shown in FIG. 1;
FIGS. 5A-5D are a schematic diagram of the controller shown in block format in FIG. 4;
FIGS. 6A-6B are a flow chart of an overall routine that executes in a microprocessor of the controller shown in FIGS. 5A-5D;
FIGS. 7A-7H are a flow chart of the main routine executed in the microprocessor;
FIG. 8 is a flow chart of a set variable light shut-off timer routine executed by the microprocessor;
FIGS. 9A-9C are a flow chart of a hardware timer interrupt routine executed in the microprocessor;
FIGS. 10A-10C are a flow chart of a 1 millisecond timer routine executed in the microprocessor;
FIGS. 11A-11C are a flow chart of a 125 millisecond timer routine executed in the microprocessor;
FIGS. 12A-12E are a flow chart of a 4 millisecond timer routine executed in the microprocessor;
FIGS. 13A-13B are a flow chart of an RPM interrupt routine executed in the microprocessor;
FIG. 14 is a flow chart of a motor state machine routine executed in the microprocessor;
FIG. 15 is a flow chart of a stop in midtravel routine executed in the microprocessor;
FIG. 16 is a flow chart of a DOWN position routine executed in the microprocessor;
FIGS. 17A-17C are a flow chart of an UP direction routine executed in the microprocessor;
FIG. 18 is a flow chart of an auto-reverse routine executed in the microprocessor;
FIG. 19 is a flow chart of an UP position routine executed in the microprocessor;
FIGS. 20A-20D are a flow chart of the DOWN direction routine executed in the microprocessor;
FIG. 21 is an exploded perspective view of a pass point detector and motor of the operator shown in FIG. 2;
FIG. 22A is a plan view of the pass point detector shown in FIG. 21; and
FIG. 22B is a partial plan view of the pass point detector shown in FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and especially to FIG. 1, a movable barrier or garage door operator system is generally shown therein and referred to by numeral 8 . The system 8 includes a movable barrier operator or garage door operator 10 having a head unit 12 mounted within a garage 14 . More specifically, the head unit 12 is mounted to a ceiling 15 of the garage 14 . The operator 10 includes a transmission 18 extending from the head unit 12 with a releasable trolley 20 attached. The releasable trolley 20 releasably connects an arm 22 extending to a single panel garage door 24 positioned for movement along a pair of door rails 26 and 28 .
The system 8 includes a hand-held RF transmitter unit 30 adapted to send signals to an antenna 32 (see FIG. 4) positioned on the head unit 12 and coupled to a receiver within the head unit 12 as will appear hereinafter. A switch module 39 is mounted on the head unit 12 . Switch module 39 includes switches for each of the commands available from a remote transmitter or from an optional wall-mounted switch (not shown). Switch module 39 enables an installer to conveniently request the various learn modes during installation of the head unit 12 . The switch module 39 includes a learn switch, a light switch, a lock switch and a command switch, which are described below. Switch module 39 may also include terminals for wiring a pedestrian door state sensor comprising a pair of contacts 13 and 15 for a pedestrian door 11 , as well as wiring for an optional wall switch (not shown).
The garage door 24 includes the pedestrian door 11 . Contact 13 is mounted to door 24 for contact with contact 15 mounted to pedestrian door 11 . Both contacts 13 and 15 are connected via a wire 17 to head unit 12 . As will be described further below, when the pedestrian door 11 is closed, electrical contact is made between the contacts 13 and 15 closing a pedestrian door circuit in the receiver in head unit 12 and signalling that the pedestriam door state is closed. This circuit must be closed before the receiver will permit other portions of the operator to move the door 24 . If circuit is open, indicating that the pedestrian door state is open, the system will not permit door 24 to move.
The head unit 12 includes a housing comprising four sections: a bottom section 102 , a front section 106 , a back section 108 and a top section 110 , which are held together by screws 112 as shown in FIG. 2 . Cover 104 fits into front section 106 and provides a cover for a worklight. External AC power is supplied to the operator 10 through a power cord 122 . The AC power is applied to a step-down transformer 120 . An electric motor 118 is selectively energized by rectified AC power and drives a sprocket 125 in sprocket assembly 124 . The sprocket 125 drives chain 144 (see FIG. 3 ). A printed circuit board 114 includes a controller 200 and other electronics for operating the head unit 12 . A cable 116 provides input and output connections on signal paths between the printed circuit board 114 and switch module 39 . The transmission 18 , as shown in FIG. 3, includes a rail 142 which holds chain 144 within a rail and chain housing 140 and holds the chain in tension to transfer mechanical energy from the motor to the door.
A block diagram of the controller and motor connections is shown in FIG. 4 . Controller 200 includes an RF receiver 80 , a microprocessor 300 and an EEPROM 302 . RF receiver 80 of controller 200 receives a command to move the door and actuate the motor either from remote transmitter 30 , which transmits an RF signal which is received by antenna 32 , or from a user command switch 250 . User command switch 250 can be a switch on switch panel 39 , mounted on the head unit, or a switch from an optional wall switch. Upon receipt of a door movement command signal from either antenna 32 or user switch 250 , the controller 200 sends a power enable signal via line 240 to AC hot connection 206 which provides AC line current to transformer 212 and power to work light 210 . Rectified AC is provided from rectifier 214 via line 236 to relays 232 and 234 . Depending on the commanded direction of travel, controller 200 provides a signal to either relay 232 or relay 234 . Relays 232 and 234 are used to control the direction of rotation of motor 118 by controlling the direction of current flow through the windings. One relay is used for clockwise rotation; the other is used for counterclockwise rotation.
Upon receipt of the door movement command signal, controller 200 sends a signal via line 230 to power-control FET 252 . Motor speed is determined by the duration or length of the pulses in the signal to a gate electrode of FET 252 . The shorter the pulses, the slower the speed. This completes the circuit between relay 232 and FET 252 providing power to motor 118 via line 254 . If the door had been commanded to move in the opposite direction, relay, 234 would have been enabled, completing the circuit with FET 252 and providing power to motor 118 via line 238 .
With power provided, the motor 118 drives the output shaft 216 which provides drive power to transmission sprocket 125 . Gear reduction housing 260 includes an internal pass point system which sends a pass point signal via line 220 to controller 200 whenever the pass point is reached. The pass point signal is provided to controller 200 via current limiting resistor 226 to protect controller 200 from electrostatic discharge (ESD). An RPM interrupt signal is provided via line 224 , via current limiting resistor 228 , to controller 200 . Lead 222 provides a plus five volts supply for the Hall effect sensors in the RPM module. Commanded force is input by two force potentiometers 202 , 204 . Force potentiometer 202 is used to set the commanded force for UP travel; force potentiometer 204 is used to set the commanded force for DOWN travel. Force potentiometers 202 and 204 provide commanded inputs to controller 200 which are used to adjust the length of-the pulsed signal provided to FET 252 .
The pass point for this system is provided internally in the motor 118 . Referring to FIG. 21, the pass point module 40 is attached to gear reduction housing 260 of motor 118 . Pass point module 40 includes upper plate 42 which covers the three internal gears and switch within lower housing 50 . Lower housing 50 includes recess 62 having two pins 61 which position switch assembly 52 in recess 62 . Housing 50 also includes three cutouts which are sized to support and provide for rotation of the three geared elements. Outer gear 44 fits rotatably within cutout 64 . Outer gear includes a smooth outer surface for rotating within housing 50 and inner gear teeth for rotating middle gear 46 . Middle gear 46 fits rotatably within inner cutout 66 . Middle gear 46 includes a smooth outer surface and a raised portion with gear teeth for being driven by the gear teeth of outer ring gear 44 . Inner gear 48 fits within middle gear 46 and is driven by an extension of shaft 216 (FIG. 4 ). Rotation of the motor 118 causes shaft 216 to rotate and drive inner gear 48 .
Outer gear 44 includes a notch 74 in the outer periphery. Middle gear includes a notch 76 in the outer periphery. Referring to FIG. 22A, rotation of inner gear 48 rotates middle gear 46 in the same direction. Rotation of middle gear 46 rotates outer gear 44 in the same direction. Gears 46 and 44 are sized such that pass point indications comprising switch release cutouts 74 and 76 line up only once during the entire travel distance of the door. As seen in FIG. 22A, when switch release cutouts 74 and 76 line up, switch 72 is open generating a pass point presence signal. The location where switch release cutouts 74 and 76 line up is the pass point. At all other times, at least one of the two gears holds switch 72 closed generating a signal indicating that the pass point has not been reached.
The receiver portion 80 of controller 200 is shown in FIG. 5 A. RF signals may be received by the controller 200 at the antenna 32 and fed to the receiver 80 . The receiver 80 includes variable inductor L 1 and a pair of capacitors C 2 and C 3 that provide impedance matching between the antenna 32 and other portions of the receiver. An NPN transistor Q 4 is connected in common-base configuration as a buffer amplifier. Bias to the buffer amplifier transistor Q 4 is provided by resistors R 2 , R 3 . The buffered PR output signal is supplied to a second NPN transistor Q 5 . The radio frequency signal is coupled to a bandpass amplifier 280 to an average detector 282 which feeds a comparator 284 . Referring to FIGS. 5C and 5B, the analog output signal A, B is applied to noise reduction capacitors C 19 , C 20 and C 21 then provided to pins P 32 and P 33 of the microcontroller 300 . Microcontroller 300 mans be a Z86733 microprocessor.
As can be seen in FIG. 5D, an external transformer 212 receives AC power from a source such as a utility and steps down the AC voltage to the power supply 90 circuit of controller 200 . Transformer 212 provides AC current to full-wave bridge circuit 214 , which produces a 28 volt full wave rectified signal across capacitor C 35 . The AC power may have a frequency of 50 Hz or 60 Hz. An external transformer is especially important when motor 118 is a DC motor. The 28 volt rectified signal is used to drive a wall control switch, an obstacle detector circuit, a door-in-door switch and to power FETs Q 11 and Q 12 (FIG. 5C) used to start the motor. Zener diode D 18 protects against overvoltage due to the pulsed current, in particular, from the FETs rapidly switching off inductive load of the motor. The potential of the full-wave rectified signal is further reduced to provide 5 volts at capacitor C 38 , which is used to power the microprocessor 300 , the receiver circuit 80 and other logic functions.
The 28 volt rectified power supply signal indicated by reference numeral T in FIG. 5C is voltage divided down by resistors R 61 and R 62 , then applied to an input pin P 24 of microprocessor 300 (FIG. 5 B). This signal is used to provide the phase of the power line current to microprocessor 300 . Microprocessor 300 constantly checks for the phase of the line voltage in order to determine if the frequency of the line voltage is 50 Hz or 60 Hz. This information is used to establish the worklight time-out period and to select the look-up table stored in the ROM in the microcontroller for converting pulse width to door speed.
When the door is commanded to move, either through a signal from a remote transmitter received through antenna 32 and processed by receiver 80 , or through an optional wall switch, the microprocessor 300 commands the work light to turn on. Microprocessor 300 (FIG. 5B) sends a worklight enable signal from pin P 07 . In FIG. 5C, the worklight enable signal is applied to the base of transistor Q 3 , which drives relay K 3 . AC power from a signal U provides power for operating the worklight 210 .
Microprocessor 300 reads from and writes data to an EEPROM 302 via its pins P 25 , P 26 and P 27 . EEPROM 302 may be a 93C46. Microprocessor 300 provides a light enable signal at pin P 21 which is used to enable a learn mode indicator yellow LED D 15 . LED D 15 is enabled or lit when the receiver is in the learn mode. Pin P 26 provides double duty. When the user selects switch S 1 , a learn enable signal is provided to both microprocessor 300 and EEPROM 302 . Switch S 1 is mounted on the head unit 12 and is part of switch module 39 , which is used by the installer to operate the system.
An optional flasher module provides an additional level of safety for users and is controlled by microprocessor 300 at pin P 22 . The optional flasher module is connected between terminals 308 and 310 . In the optional flasher module, after receipt of a door command, the microprocessor 300 sends a signal from P 22 which causes the flasher light to blink for 2 seconds. The door does not move during that 2 second period, giving the user notice that the door has been commanded to move and will start to move in 2 seconds. After expiration of the 2 second period, the door moves and the flasher light module blinks during the entire period of door movement. If the operator does not have a flasher module installed in the head unit, when the door is commanded to move, there is no time delay before the door begins to move.
Microprocessor 300 provides the signals which start motor 118 , control its direction of rotation (and thus the direction of movement of the door) and the speed of rotation (speed of door travel). FETs Q 11 and Q 12 are used to start motor 118 . Microprocessor 300 applies a pulsed output signal to the gates of FETs Q 11 and Q 12 . The lengths of the pulses determine the time the FETs conduct and thus the around of time current is applied to start and run the motor 118 . The longer the pulse, the longer current is applied, the greater the speed of rotation the motor 118 will develop. Diode D 11 is coupled between the 28 volt power supply and is used to clean up flyback voltage to the input bridge D 4 when theFETs are conducting. Similarly, Zener diode D 19 (see FIG. 5D) is used to protect against overvoltage when the FETs are conducting.
Control of the direction of rotation of motor 118 (and thus direction of travel of the door) is accomplished with two relays, K 1 and K 2 (FIG. 5 C). Relay K 1 supplies current to cause the motor to rotate clockwise in an opening direction (door moves UP); relay K 2 supplies current to cause the motor to rotate counterclockwise in a closing direction (door moves DOWN). When the door is commanded to move UP, the microprocessor 300 sends an enable signal from pin P 05 to the base of transistor Q 1 , which drives relay K 1 . When the door is commanded to move DOWN, the microprocessor 300 sends an enable signal from pin P 06 to the base of transistor Q 2 , which drives relay K 2 .
Door-in-door contacts 13 and 15 are connected to terminals 304 and 306 . Terminals 304 and 306 are connected to relays K 1 and K 2 . If the signal between contacts 13 and 15 is broken, the signal across terminals 304 and 306 is open, preventing relays K 1 and K 2 from energizing. The motor 118 will not rotate and the door 24 will not move until the user closes pedestrian door 1 l, making contact between contacts 13 and 15 .
In FIG. 5B, the pass point signal 220 from the pass point module 40 (see FIG. 21) of motor 118 is applied to pin P 23 of microprocessor 300 . The RPM signal 224 from the RPM sensor module in motor 118 is applied to pin P 31 of microprocessor 300 . Application of the pass point signal and the RPM signal is described with reference to the flow charts.
An optional wall control, which duplicates the switches on remote transmitter 30 , may be connected to controller 200 at terminals 312 and 314 . When the user presses the door command switch 39 , a dead short is made to ground, which the microprocessor 300 detects by the failure to detect voltage. Capacitor C 22 is provided for RF noise reduction. The dead short to ground is sensed at pins P 02 and P 03 , for redundancy.
Switches S 1 and S 2 are part of switch module 39 mounted on head unit 12 and used by the installer for operating the system. As stated above, S 1 is the learn switch. S 2 is the door command switch. When S 2 is pressed, microprocessor 300 detects the dead short at pins P 02 and P 03 .
Input from an obstacle detector (not shown) is provided at terminal 316 . This signal is voltage divided down and provided to microprocessor 300 at pins P 20 and P 30 , for redundancy. Except when the door is moving and less than an inch above the floor, when the obstacle detector senses an object in the doorway, the microprocessor executes the auto-reverse routine causing the door to stop and/or reverse depending on the state of the door movement.
Force and speed of door travel are determined by two potentiometers. Potentiometer R 33 adjusts the force and speed of UP travel; potentiometer R 34 adjusts the force and speed of DOWN travel. Potentiometers R 33 and R 34 ,act as analog voltage dividers. The analog signal from R 33 , R 34 is further divided down by voltage divider R 35 /R 37 , R 36 /R 38 before it is applied to the input of comparators 320 and 322 . Reference pulses from pins P 34 and P 35 of microprocessor 300 are compared with the force input from potentiometers R 33 and R 34 in comparators 320 and 322 . The output of comparators 320 and 322 is applied to pins P 01 and P 00 .
To perform the A/D conversion, the microprocessor 300 samples the output of the comparators 320 and 322 at pins P 00 and P 01 to determine which voltage is higher: the voltage from the potentiometer R 33 or R 34 (IN) or the voltage from the reference pin P 34 or P 35 (REF). If the potentiometer voltage is higher than the reference, then the microprocessor outputs a pulse. If not, the output voltage is held low. The RC filter (R 39 , C 29 /R 40 , C 30 ) converts the pulses into a DC voltage equivalent to the duty cycle of the pulses. By outputting the pulses in the manner described above, the microprocessor creates a voltage at REF which dithers around the voltage at IN. The microprocessor then calculates the duty cycle of the pulse output which directly correlates to the voltage seen at IN.
When power is applied to the head unit 12 including controller 200 , microprocessor 300 executes a series of routines. With power applied, microprocessor 300 executes the main routines shown in FIGS. 6A and 6B. The main loop 400 includes three basic functions, which are looped continuously until power is removed. In block 402 the microprocessor 300 handles all non-radio EEPROM communications and disables radio access to the EEPROM 302 when communicating. This ensures that during normal operation, i.e., when the garage door operator is not being programmed, the remote transmitter does not have access to the EEPROM, where transmitter codes are stored. Radio transmissions are processed upon receipt of a radio interrupt (see below).
In block 404 , microprocessor 300 maintains all low priority tasks, such as calculating new force levels and minimum speed. Preferably, a set of redundant RAM registers is provided. In the event of an unforeseen event (e.g., an ESD event) which corrupts regular RAM, the main RAM registers and the redundant RAM registers will not match. Thus, when the values in RAM do not match, the routine knows the regular RAM has been corrupted. (See block 504 below.) In block 406 , microprocessor 300 tests redundant RAM registers. Several interrupt routines can take priority over blocks 402 , 404 and 406 .
The infrared obstacle detector generates an asynchronous IR interrupt signal which is a series of pulses. The absence of the obstacle detector pulses indicates an obstruction in the beam. After processing the IR interrupt, microprocessor 300 sets the status of the obstacle detector as unobstructed at block 416 .
Receipt of a transmission from remote transmitter 30 generates an asynchronous radio interrupt at block 410 . At block 418 , if in the door command mode, microprocessor 300 parses incoming radio signals and sets a flag if the signal matches a stored code. If in the learn mode, microprocessor 300 stores the new transmitter codes in the EEPROM.
An asynchronous interrupt is generated if a remote communications unit is connected to an optional RS-232 communications port located on the head unit. Upon receipt of the hardware interrupt, microprocessor 300 executes a serial data communications routine for transferring and storing data from the remote hardware.
Hardware timer 0 interrupt is shown in block 422 . In block 424 , microprocessor 300 reads the incoming AC line signal from pin P 24 and handles the motor phase control output. The incoming line signal is used to determine if the line voltage is 50 Hz for the foreign market or 60 Hz for the domestic market. With each interrupt, microprocessor 300 , at block 426 , task switches among three tasks. In block 428 , microprocessor 300 updates software timers. In block 430 , microprocessor 300 debounces wall control switch signals. In block 432 , microprocessor 300 controls the motor state, including motor direction relay outputs and motor safety systems.
When the motor 118 is running, it generates an asynchronous RPM interrupt at block 434 . When microprocessor 300 receives the asynchronous RPM interrupt at pin P 31 , it calculates the motor RPM period at block 436 , then updates the position of the door at block 438 .
Further details of main loop 400 are shown in FIGS. 7A through 7H. The first step executed in main loop 400 is block 450 , where the microprocessor checks to see if the pass point has been passed since the last update. If it has, the routine branches to block 452 , where the microprocessor 300 updates the position of the door relative to the pass point in EEPROM 302 or non-volatile memory. The routine then continues at block 454 . An optional safety feature of the garage door operator system enables the worklight, when the door is open and stopped and the infrared beam in the obstacle detector is broken.
At block 454 , the microprocessor checks if the enable/disable of the worklight for this feature has been changed. Some users want the added safety feature; others prefer to save the electricity used. If new input has been provided, the routine branches to block 456 and sets the status of the obstacle detector-controlled worklight in non-volatile memory in accordance with the new input. Then the routine continues to block 458 where the routine checks to determine if the worklight has been turned on without the timer. A separate switch is provided on both the remote transmitter 30 and the head unit at module 39 to enable the user to switch on the worklight without operating the door command switch. If no, the routine skips to block 470 .
If yes, the routine checks at block 460 to see if the one-shot flag has been set for an obstacle detector beam break. If no, the routine skips to block 470 . If yes, the routine checks if the obstacle detector controlled worklight is enabled at block 462 . If not, the routine skips to block 470 . If it is, the routine checks if the door is stopped in the fully open position at block 464 . If no, the routine skips to block 470 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8) to enable the appropriate turn off time (4.5 minutes for 60 Hz systems or 2.5 minutes for 50 Hz systems). At block 468 , the routine turns on the worklight.
At block 470 , the microprocessor 300 clears the one-shot flag for the infrared beam break. This resets the obstacle detector, so that a later beam break can generate an interrupt. At block 472 , if the user has installed a temporary password usable for a fixed period of time, the microprocessor 300 updates the non-volatile timer for the radio temporary password. At block 474 , the microprocessor 300 refreshes the RAM registers for radio mode from non-volatile memory (EEPROM 302 ). At block 476 , the microprocessor 300 refreshes I/O port directions, i.e., whether each of the ports is to be input or output. At block 478 , the microprocessor 300 updates the status of the radio lockout flag, if necessary. The radio lockout flag prevents the microprocessor from responding to a signal from a remote transmitter. A radio interrupt (described below) will disable the radio lockout flag and enable the remote transmitter to communicate with the receiver.
At block 480 , the microprocessor 300 checks if the door is about to travel. If not, the routine skips to block 502 . If the door is about to travel, the microprocessor 300 checks if the limits are being trained at block 482 . If they are, the routine skips to block 490 . If not, the routine asks at block 484 if travel is UP or DOWN. If DOWN, the routine refreshes the DOWN limit from non-volatile memory (EEPROM 302 ) at block 486 . If UP, the routine refreshes the UP limit from non-volatile memory (EEPROM 302 ) at block 488 . The routine updates the current operating state and position relative to the pass point in non-volatile memory at block 490 . This is a redundant read for stability of the system.
At block 492 , the routine checks for completion of a limit training cycle. If training is complete, the routine branches to block 494 where the new limit settings and position relative to the pass point are written to non-volatile memory.
The routine then updates the counter for the number of operating cycles at block 496 . This information can be downloaded at a later time and used to determine when certain parts need to be replaced. At block 498 the routine checks if the number of cycles is a multiple of 256. Limiting the storage of this information to multiples of 256 limits the number of times the system has to write to that register. If yes it updates the history of force settings at block 500 . If not, the routine continues to block 502 .
At block 502 the routine updates the learn switch debouncer. At block 504 the routine performs a continuity check by comparing the backup (redundant) RAM registers with the main registers. If they do not match, the routine branches to block 506 . If the registers do not match, the RAM memory has been corrupted and the system is not safe to operate, so a reset is commanded. At this point, the system powers up as if power had been removed and reapplied and the first step is a self test of the system (all installation settings are unchanged).
If the answer to block 504 is yes, the routine continues to block 508 where the routine services any incoming serial messages from the optional wall control (serial messages might be user input start or stop commands). The routine then loads the UP force timing from the ROM look-up table, using the user setting as an index at block 510 . Force potentiometers R 33 and P 34 are set by the user. The analog values set by the user are converted to digital values. The digital values are used as an index to the look-up table stored in memory. The value indexed from the look-up table is then used as the minimum motor speed measurement. When the motor runs, the routine compares the selected value from the look-up table with the digital timing from the RPM routine to ensure the force is acceptable.
Instead of calculating the force each time the force potentiometers are set, a look-up table is provided for each potentiometer. The range of values based on the range of user inputs is stored in ROM and used to save microprocessor processing time. The system includes two force limits: one for the UP force and one for the DOWN force. Two force limits provide a safer system. A heavy door may require more UP force to lift, but need a lower DOWN force setting (and therefore a slower closing speed) to provide a soft closure. A light door will need less UP force to open the door and possibly a greater DOWN force to provide a full closure.
Next the force timing is divided by power level of the motor for the door to scale the maximum force timeout at block 512 . This step scales the force reversal point based on the maximum force for the door. The maximum force for the door is determined based on the size of the door, i.e. the distance the door travels. Single piece doors travel a greater distance than segmented doors. Short doors require less force to move than normal doors. The maximum force for a short door is scaled down to 60 percent of the maximum force available for a normal door. So, at block 512 , if the force setting is set by the user, for example at 40 percent, and the door is a normal door (i.e., a segmented door or multi-paneled door), the force is scaled to 40 percent of 100 percent. If the door is a short door (i.e., a single panel door), the force is scaled to 40 percent of 60 percent, or 24 percent.
At block 514 , the routine loads the DOWN force timing from the ROM look-up table, using the user setting as an index. At block 516 , the routine divides the force timing by the power level of the motor for the door to scale the force to the speed.
At block 518 the routine checks if the door is traveling DOWN. If yes, the routine disables use of the MinSpeed Register at block 524 and loads the MinSpeed Register with the DOWN force setting, i.e., the value read from the DOWN force potentiometer at block 526 . If not, the routine disables use of the MinSpeed Register at block 520 ant loads the MinSpeed Register with the UP force setting from the force potentiometer at block 522 .
The routine continues at block 528 where the routine subtracts 24 from the MinSpeed value. The MinSpeed value ranges from 0 to 63. The system uses 64 levels of force. If the result is negative at block 530 , the routine clears the MinSpeed Register at block 532 to effectively truncate the lower 38 percent of the force settings. If no, the routine divides the minimum speed by 4 to scale 8 speeds to 32 force settings at block 534 . At block 536 , the routine adds 4 into the minimum speed to correct the offset, and clips the result to a maximum of 12. At block 538 the routine enables use of the MinSpeed Register.
At block 540 the routine checks if the period of the rectified AC line signal (input to microprocessor 300 at pin P 24 ) is less than 9 milliseconds (indicating the line frequency is 60 Hz). If it is, the routine skips to block 548 . If not, the routine checks if the light shut-off timer is active at block 542 . If not, the routine skips to block 548 . If yes, the routine checks if the light time value is greater than 2.5 minutes at block 544 . If no, the routine skips to block 548 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8 ), to correct the light timing setting, at block 546 .
At block 548 the routine checks if the radio signal has been clear for 100 milliseconds or more. If not, the routine skips to block 552 . If yes, the routine clears the radio at block 550 . At block 552 , the routine resets the watchdog timer. At block 554 , the routine loops to the beginning of the main loop.
The SetVarLight subroutine, FIG. 8, is called whenever the door is commanded to move and the worklight is to be turned on. When the SetVarLight subroutine, block 558 is called, the subroutine checks if the period of the rectified power line signal (pin P 24 of microprocessor 300 ) is greater than or equal to 9 milliseconds. If yes, the line frequency is 50 Hz, and the timer is set to 2.5 minutes at block 564 . If no, the line frequency is 60 Hz and the timer is set to 4.5 minutes at block 562 . After setting, the subroutine returns to the call point at block 566 .
The hardware timer interrupt subroutine operated by microprocessor 300 , shown at block 422 , runs every 0.256 milliseconds. Referring to FIGS. 9A-9C, when the subroutine is first called, it sets the radio interrupt status as indicated by the software flags at block 580 . At block 582 , the subroutine updates the software timer extension. The next series of steps monitor the AC power line frequency (pin P 24 of microprocessor 300 ). At step 584 , the subroutine checks if the rectified power line input is high (checks for a leading edge). If yes, the subroutine skips to block 594 , where it increments the power line high time counter, then continues to block 596 . If no, the subroutine checks if the high time counter is below 2 milliseconds at block 586 . If yes, the subroutine skips to block 594 . If no, the subroutine sets the measured power line time in RAM at block 588 .
The subroutine then resets the power line high time counter at block 590 and resets the phase timer register in block 592 .
At block 596 , the subroutine checks if the motor power level is set at 100 percent. If yes, the subroutine turns on the motor phase control output at block 606 . If no, the subroutine checks if the motor power level is set at 0 percent at block 598 . If yes, the subroutine turns off the motor phase control output at block 604 . If no, the phase timer register is decremented at block 600 and the result is checked for sign at block 602 . If positive the subroutine branches to block 606 ; if negative the subroutine branches to block 604 .
The subroutine continues at block 608 where the incoming RPM signal (at pin P 31 of microprocessor 300 ) is digitally filtered. Then the time prescaling task switcher (which loops through 8 tasks identified at blocks 620 , 630 , 640 , 650 ) is incremented at block 610 . The task switcher varies from 0 to 7. At block 612 , the subroutine branches to the proper task depending on the value of the task switcher.
If the task switcher is at value 2 (this occurs every 4 milliseconds), the execute motor state machine subroutine is called at block 620 . If the task is value 0 or 4 (this occurs every 2 milliseconds), the wall control switches are debounced at block 630 . If the task value is 6 this occurs every 4 milliseconds), the execute 4 ms timer subroutine is called at block 640 . If the task is value 1, 3, 5 or 7, the 1 millisecond timer subroutine is called at block 650 . Upon completion of the called subroutine, the 0.256 millisecond timer subroutine returns at block 614 .
Details of the 1 ms timer subroutine (block 650 ) are shown in FIGS. 10A-10C. When this subroutine is called, the first step is to update the A/D converters on the UP and DOWN force setting potentiometers (P 34 and P 35 of microprocessor 300 ) at block 652 . At block 654 , the subroutine checks if the A/D conversion (comparison at comparators 320 and 322 ) is complete. If yes, the measured potentiometer values are stored at block 656 . Then the stored values (which vary from 0 to 127) are divided by 2 to obtain the 64 level force setting at block 658 . If no, the subroutine decrements the infrared obstacle detector timeout timer at block 660 . In block 662 , the subroutine checks if the timer has reached zero. If no, the subroutine skips to block 672 . If yes, the subroutine resets the infrared obstacle detector timeout timer at block 664 . The flag setting for the obstacle detector signal is checked at block 666 . If no, the one-shot break flag is set at block 668 . If yes, the flag is set indicating the obstacle detector signal is absent at block 670 .
At block 672 , the subroutine increments the radio time out register. Then the infrared obstacle detector reversal timer is decremented at block 674 . The pass point input is debounced at block 676 . The 125 millisecond prescaler is incremented at block 678 . Then the prescaler is checked to see if it has reached 63 milliseconds at block 680 . If yes, the fault blinking LED is updated at block 682 . If no, the prescaler is checked if it has reached 125 ms at block 684 . If yes, the 125 ms timer subroutine is executed at block 686 . If no, the routine returns at block 688 .
Turning to FIGS. 11A-C, the 125 millisecond timer subroutine (block 690 ) is used to manage the power level of the motor 118 . At block 692 , the subroutine updates the RS-232 mode timer and exits the RS-232 mode timer if necessary. The same pair of wires is used for both wall control switches and RS-232 communication. If RS-232 communication is received while in the wall control mode, the RS-232 mode is entered. If four seconds passes since the last RS-232 word was received, then the RS-232 timer times out and reverts to the wall control mode. At block 694 the subroutine checks if the motor is set to be stopped. If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent. If no, the subroutine checks if the pre-travel safety light is flashing at block 696 (if the optional flasher module has been installed, a light will flash for 2 seconds before the motor is permitted to travel and then flash at a predetermined interval during motor travel). If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent.
If no, the subroutine checks if the microprocessor 300 is in the last phase of a limit training mode at block 698 . If yes, the subroutine skips to block 710 . If no, the subroutine sets the motor ramp-up complete flag in step 702 and checks if the microprocessor 300 is in another part of the limit training mode at block 700 . If no, the subroutine skips to block 710 . If yes, the subroutine checks if the minimum speed (as determined by the force settings) is greater than 40 percent at block 704 . If no, the power level is set to 40 percent at block 708 . If yes, the power level is set equal to the minimum speed stored in MinSpeed Register at block 706 .
At block 710 the subroutine checks if the flag is set to slow down. If yes, the subroutine checks if the motor is running above or below minimum speed at block 714 . If above minimum speed, the power level of the motor is decremented one step increment (one step increment is preferably 5% of maximum motor speed) at block 722 . If below the minimum speed, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) to minimum speed at block 720 .
If the flag is not set to slow down at block 710 , the subroutine checks if the motor is running at maximum allowable speed at block 712 . If no, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) at block 720 . If yes, the flag is set for motor ramp-up speed complete.
The subroutine continues at block 724 where it checks if the period of the rectified AC power line (pin P 24 of microprocessor 300 ) is greater than or equal to 9 ms. If no, the subroutine fetches the motor's phase control information (indexed from the power level) from the 60 Hz look-up table stored in ROM at block 728 . If yes, the subroutine fetches the motor's phase control information (indexed from the power level) from the 50 Hz look-up table stored in ROM at block 726 .
The subroutine tests for a user enable/disable of the infrared obstacle detector-controlled worklight feature at block 730 . Then the user radio learning timers, ZZWIN (at the wall keypad if installed) and AUXLEARNSW (radio on air and worklight command) are updated at block 732 . The software watchdog timer is updated at block 734 and the fault blinking LED is updated at block 736 . The subroutine returns at block 738 .
The 4 millisecond timer subroutine is used to check on various systems which do not require updating as often as more critical systems. Referring to FIGS. 12A and 12B, the subroutine is called at block 640 . At block 750 , the RPM safety timers are updated. These timers are used to determine if the door has engaged the floor. The RPM safety timer is a one second delay before the operator begins to look for a falling door, i.e., one second after stopping. There are two different forces used in the garage door operator. The first type force are the forces determined by the UP and DOWN force potentiometers. These force levels determine the speed at which the door travels in the UP and DOWN directions. The second type of force is determined by the decrease in motor speed due to an external force being applied to the door (an obstacle or the floor). This programmed or pre-selected external force is the maximum force that the system will accept before an auto-reverse or stop is commanded.
At block 752 the 0.5 second RPM timer is checked to see if it has expired. If yes, the 0.5 second timer is reset at block 754 . At block 756 safety checks are performed on the RPM seen during the last 0.5 seconds to prevent the door from falling. The 0.5 second timer is chosen so the maximum force achieved at the trolley will reach 50 kilograms in 0.5 seconds if the motor is operating at 100 percent of power.
At block 758 , the subroutine updates the 1 second timer for the optional light flasher module. In this embodiment, the preferred flash period is 1 second. At block 760 the radio dead time and dropout timers are updated. At block 762 the learn switch is debounced. At block 764 the status of the worklight is updated in accordance with the various light timers. At block 766 the optional wall control blink timer is updated. The optional wall control includes a light which blinks when the door is being commanded to auto-reverse in response to an infrared obstacle detector signal break. At block 768 the subroutine returns.
Further details of the asynchronous RPM signal interrupt, block 434 , are shown in FIGS. 13A and 13B. This signal, which is provided to microprocessor 300 at pin P 31 , is used to control the motor speed and the position detector. Door position is determined by a value relative to the pass point. The pass point is set at 0. Positions above the pass point are negative; positions below the pass point are positive. When the door travels to the UP limit, the position detector (or counter) determines the position based on the number of RPM pulses to the UP limit number. When the door travels DOWN to the DOWN limit, the position detector counts the number of RPM pulses to the DOWN limit number. The UP and DOWN limit numbers are stored in a register.
At block 782 the RPM interrupt subroutine calculates the period of the incoming RPM signal. If the door is traveling UP, the subroutine calculates the difference between two successive pulses. If the door is traveling DOWN, the subroutine calculates the difference between two successive pulses. At block 784 , the subroutine divides the period by 8 to fit into a binary word. At block 786 the subroutine checks if the motor speed is ramping up. This is the max force mode. RPM timeout will vary from 10 to 500 milliseconds. Note that these times are recommended for a DC motor. If an AC motor is used, the maximum time would be scaled down to typically 24 milliseconds. A 24 millisecond period is slower than the breakdown RPM of the motor and therefore beyond the maximum possible force of most preferred motors. If yes, the RPM timeout is set at 500 milliseconds (0.5 seconds) at block 790 . If no, the subroutine sets the RPM timeout as the rounded-up value of the force setting in block 788 .
At block 792 the subroutine checks for the direction of travel. This is found in the state machine register. If the door is traveling DOWN, the position counter is incremented at block 796 and the pass point debouncer is sampled at block 800 . At block 804 , the subroutine checks for the falling edge of the pass point signal. If the falling edge is present, the subroutine returns at block 814 . If there is a pass point falling edge, the subroutine checks for the lowest pass point (in cases where more than one pass point is used). If this is not the lowest pass point, the subroutine returns at block 814 . If it is the only pass point or the lowest pass point, the position counter is zeroed at block 812 and the subroutine returns at block 814 .
If the door is traveling UP, the subroutine decrements the position counter at block 794 and samples the pass point debouncer at block 798 . Then it checks for the rising edge of the pass point signal at block 802 . If there is no pass point signal rising edge, the subroutine returns at block 814 . If there is, it checks for the lowest pass point at block 806 . If no the subroutine returns at block 814 . If yes, the subroutine zeroes the position counter at block 810 and returns at block 814 .
The motor state machine subroutine, block 620 , is shown in FIG. 14 . It keeps track of the state of the motor. At block 820 , the subroutine updates the false obstacle detector signal output, which is used in systems that do not require an infrared obstacle detector. At block 822 , the subroutine checks if the software watchdog timer has reached too high a value. If yes, a system reset is commanded at block 824 . If no, at block 826 , it checks the state of the motor stored in the motor state register located in EEPROM 302 and executes the appropriate subroutine.
If the door is traveling UP, the UP direction subroutine at block 832 is executed. If the door is traveling DOWN, the DOWN direction subroutine is executed at block 828 . If the door is stopped in the middle of the travel path, the stop in midtravel subroutine is executed at block 838 . If the door is fully closed, the DOWN position subroutine is executed at block 830 . If the door is fully open, the UP position subroutine is executed at block 834 . If the door is reversing, the auto-reverse subroutine as executed at block 836 .
When the door is stopped in midtravel, the subroutine at block 838 is called, as shown in FIG. 15 . In block 840 the subroutine updates the relay safety system (ensuring that relays K 1 and K 2 are open). The subroutine checks in block 842 for a received wall command or radio command. If there is no received command, the subroutine updates the worklight status and returns at block 850 . If yes, the motor power is set to 20 percent at block 844 and the motor state is set to traveling DOWN at block 846 . The worklight status is updated and the subroutine returns at block 850 . If the door is stopped in midtravel and a door command is received, the door is set to close. The next time the system calls the motor state machine subroutine, the motor state machine will call the DOWN direction subroutine. The door must close to the DOWN limit before it can be opened to the full UP limit.
If the state machine indicates the door is in the DOWN position (i.e. the DOWN limit position), the DOWN position subroutine, block 830 , at FIG. 16 is called. When the door is in the DOWN position, the subroutine checks if a wall control or radio command has been received at block 852 . If no, the subroutine updates the light and returns at block 858 . If yes, the motor power is set to 20 percent at block 854 and the motor state register is set to show the state is traveling UP at block 856 . The subroutine then updates the light and returns at block 858 .
The UP direction subroutine, block 832 , is shown in FIGS. 17A-17C. At block 860 the subroutine waits until the main loop refreshes the UP limit from EEPROM 302 . Then it checks if 40 milliseconds have passed since closing of the light relay K 3 at block 862 . If not, the subroutine returns at block 864 . If yes, the subroutine checks for flashing the warning light prior to travel at block 866 (only if the optional flasher module is installed). If the light is flashing, the status of the blinking light is updated and the subroutine returns at block 868 . If not, or the flashing is terminated, the motor UP relay is turned on at block 870 . Then the subroutine waits until 1 second has passed after the motor was turned on at block 872 . If no, the subroutine skips to block 888 . If yes, the subroutine checks for the RPM signal timeout at block 874 . If no, the subroutine checks if the motor speed is ramping up at block 876 by checking the value of the RAMPFLAG register in RAM (i.e., UP, DOWN, FULLSPEED, STOP). If yes, the subroutine skips to block 888 . If no, the subroutine checks if the measured RPM is longer than the allowable RPM period at block 878 . If no, the subroutine continues at block 888 .
If the RPM signal has timed out at block 874 or the measured time period is longer than allowable at block 878 , the subroutine branches to block 880 . At block 880 , the reason is set as force obstruction. At block 882 , if the training limits are being set, the training status is updated. At block 884 the motor power is set to zero and the state is set as stopped in midtravel. At block 886 the subroutine returns.
At block 888 the subroutine checks if the door's exact position is known. If it is not, the door's distance from the UP limit is updated in block 890 by subtracting the UP limit stored in RAM from the position of the door also stored in RAM. Then the subroutine checks at block 892 if the door is beyond its UP limit. If yes, the subroutine sets the reason as reaching the limit in block 894 . Then the subroutine checks if the limits are being trained. If yes, the limit training machine is updated at block 898 . If no, the motor's power is set as zero and the motor state is set at the UP position in block 900 . Then the subroutine returns at block 902 .
If the door is not beyond its UP limit, the subroutine checks if the door is being manually positioned in the training cycle at block 904 . If not, the door position within the slowdown distance of the limit is checked at block 906 . If yes, the motor slow down flag is set at block 910 . If the door is being positioned manually at block 904 or the door is not within the slow down distance, the subroutine skips to block 912 . At block 912 the subroutine checks if a wall control or radio command has been received. If yes, the motor power is set at zero and the state is set at stopped in midtravel at block 916 . If no, the system checks if the motor has been running for over 27 seconds at block 914 . If no, the subroutine returns at block 918 . If yes, the motor power is set at zero and the motor state is set at stopped in midtravel at block 916 . Then the subroutine returns at block 918 .
Referring to FIG. 18, the auto-reverse subroutine block 836 is described. (Force reversal is stopping the motor for 0.5 seconds, then traveling UP.) At block 920 the subroutine updates the 0.5 second reversal timer (the force reversal timer described above). Then the subroutine checks at block 922 for expiration of the force-reversal timer. If yes, the motor power is set to 20 percent at block 914 and the motor state is set to traveling UP at block 926 and the subroutine returns at block 932 . If the timer has not expired, the subroutine checks for receipt of a wall command or radio command at block 928 . If yes, the motor power is set to zero and the state is set at stopped in midtravel at block 930 , then the subroutine returns at block 932 . If no, the subroutine returns at block 932 .
The UP position routine, block 834 , is shown in FIG. 19 . Door travel limits training is started with the door in the UP position. At block 934 , the subroutine updates the relay safety system. Then the subroutine checks for receipt of a wall command or radio command at block 936 indicating an intervening user command. If yes, the motor power is set to 20 percent at block 938 and the state is set at traveling DOWN in block 940 . Then the light is updated and the subroutine returns at block 950 . If no wall command has been received, the subroutine checks for training the limits at block 942 . If no, the light is updated and the subroutine returns at block 950 . If yes, the limit training state machine is updated at block 944 . Then the subroutine checks if it is time to travel DOWN at block 946 . If no, the subroutine updates the light and returns at block 950 . If it is time to travel DOWN, the state is set at traveling DOWN at block 948 and the system returns at block 950 .
The DOWN direction subroutine, block 828 , is shown in FIGS. 20A-20D. At block 952 , the subroutine waits until the main loop routine refreshes the DOWN limit from EEPROM 302 . For safety purposes, only the main loop or the remote transmitter (radio) can access data stored in or written to the EEPROM 302 . Because EEPROM communication is handled within software, it is necessary to ensure that two software routines do not try to communicate with the EEPROM at the same time (and have a data collision). Therefore, EEPROM communication is allowed only in the Main Loop and in the Radio routine, with the Main loop having a busy flag to prevent the radio from communicating with the EEPROM at the same time. At block 954 , the subroutine checks if 40 milliseconds has passed since closing of the light relay K 3 . If no, the subroutine returns at block 956 . If yes, the subroutine checks if the warning light is flashing (for 2 seconds if the optional flasher module is installed) prior to travel at block 958 . If yes, the subroutine updates the status of the flashing light and returns at block 960 . If no, or the flashing is completed, the subroutine turns on the DOWN motor relay K 2 at block 962 . At block 964 the subroutine checks if one second has passed since the motor was first turned on. The system ignores the force on the motor for the first one second. This allows the motor time to overcome the inertia of the door (and exceed the programmed force settings) without having to adjust the programmed force settings for ramp up, normal travel and slow down. Force is effectively set to maximum during ramp up to overcome sticky doors.
If the one second time has not passed, the subroutine skips to block 984 . If the one second time limit has passed, the subroutine checks for the RPM signal time out at block 966 . If no, the subroutine checks if the motor speed is currently being ramped up at block 968 (this is a maximum force condition). If yes, the routine skips to block 984 . If no, the subroutine checks if the measured RPM period is longer than the allowable RPM period. If no, the subroutine continues at block 984 .
If either the RPM signal has timed-out (block 966 ) or the RPM period is longer than allowable (block 970 ), this is an indication of an obstruction or the door has reached the DOWN limit position, and the subroutine skips to block 972 . At block 972 , the subroutine checks if the door is positioned beyond the DOWN limit setting. If it is, the subroutine skips to block 990 where it checks if the motor has been powered for at least one second. This one second power period after the DOWN limit has been reached provides for the door to close fully against the floor. This is especially important when DC motors are used. The one second period overcomes the internal braking effect of the DC motor on shut-off. Auto-reverse is disabled after the position detector reaches the DOWN limit. If the door is not positioned beyond the DOWN limit setting, the subroutine sets the reason as force obstruction at block 974 , updates the training status if the operator is training limits at block 976 , and sets the motor power at 0 at block 978 . The motor state is set as auto-reverse at block 980 , and the subroutine returns at block 982 .
If the subroutine determines that the door position is beyond the DOWN limit setting and if the motor has been running for one second, at block 990 , the subroutine sets the reason as reaching the limit at block 994 . The subroutine then checks if the limits are being trained at block 998 . If yes, the limit training machine is updated at block 1002 . If no, the motor's power is set to zero and the motor state is set at the DOWN position in block 1006 . In block 1008 the subroutine returns.
If the motor has not been running for at least one second at block 990 , the subroutine sets the reason as early limit at block 1026 . Then the subroutine sets the motor power at zero and the motor state as auto-reverse at block 1028 and returns at block 1030 .
Returning to block 984 , the subroutine checks if the door's position is currently unknown. If yes, the subroutine skips to block 1004 . If no, the subroutine updates the door's distance from the DOWN limit using internal RAM in microprocessor 300 in block 986 . Then the subroutine checks at block 988 if the door is three inches beyond the DOWN limit. If yes, the subroutine skips to block 990 . If no, the subroutine checks if the door is being positioned manually in the training cycle at block 992 . If yes, the subroutine skips to block 1004 . If no, the subroutine checks if the door is within the slow DOWN distance of the limit at block 996 . If no, the subroutine skips to block 1004 . If yes, the subroutine sets the motor slow down flag at block 1000 .
At block 1004 , the subroutine checks if a wall control command or radio command has been received. If yes, the subroutine sets the motor power at zero and the state as auto-reverse at block 1012 . If no, the subroutine checks if the motor has been running for over 27 seconds at block 1010 . If yes, the subroutine sets the motor power at zero and the state at auto-reverse at block 1012 . If no, the subroutine checks if the obstacle detector signal has been missing for 12 milliseconds or more at block 1014 indicating the presence of the obstacle or the failure of the detector. If no, the subroutine returns at block 1018 . If yes, the subroutine checks if the wall control or radio signal is being held to override the infrared obstacle detector at block 1016 . If yes, the subroutine returns at block 1018 . If no, the subroutine sets the reason as infrared obstacle detector obstruction at block 1020 . The subroutine then sets the motor power at zero and the state as auto-reverse at block 1022 and returns at block 1024 . (The auto-reverse routine stops the motor for 0.5 seconds then causes the door to travel up.)
The appendix attached hereto includes a source listing of a series of routines used to operate a movable barrier operator in accordance with the present invention.
While there has been illustrated and described a particular embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which followed in the true spirit and scope of the present invention.
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A movable barrier operator having improved safety and energy efficiency features automatically detects line voltage frequency and uses that information to set a worklight shut-off time. The operator automatically detects the type of door (single panel or segmented) and uses that information to set a maximum speed of door travel. The operator moves the door with a linearly variable speed from start of travel to stop for smooth and quiet performance. The operator provides for full door closure by driving the door into the floor when the DOWN limit is reached and no auto-reverse condition has been detected. The operator provides for user selection of a minimum stop speed for easy starting and stopping of sticky or binding doors.
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PROVISIONAL PATENT APPLICATION FILING
[0001] Entitled to the benefit of Provisional Patent Application Ser. No. 60/599,222 filed Jul. 29, 2004, “(−)-Hydroxycitric Acid For Protection Against Soft Tissue And Arterial Calcification.”
BACKGROUND OF THE INVENTION
[0002] 1. Field Of The Invention
[0003] This invention relates to pharmaceutical compositions containing (−)-hydroxycitric acid, its salts and related compounds useful for reducing and regulating calcification of the blood vessels and other soft tissues. Such regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, and the calcification of surgical stints, such as those containing elastin.
[0004] 2. Description Of Prior Art
[0005] (−)-Hydroxycitric acid (abbreviated herein as HCA), a naturally-occurring substance found chiefly in fruits of the species of Garcinia, and several synthetic derivatives of citric acid have been investigated extensively in regard to their ability to inhibit the production of fatty acids from carbohydrates, to suppress appetite, and to inhibit weight gain. (Sullivan A C, Triscari J. Metabolic regulation as a control for lipid disorders. I. Influence of (−)-hydroxycitrate on experimentally induced obesity in the rodent American Journal of Clinical Nutrition 1977;30:767-775.) Weight loss benefits were first ascribed to HCA, its salts and its lactone in U.S. Pat. No. 3,764,692 granted to John M. Lowenstein in 1973. The claimed mechanisms of action for HCA, most of which were originally put forth by researchers at the pharmaceutical firm of Hoffmann-La Roche, have been summarized in at least two United States Patents. In U.S. Pat. No. 5,626,849 these mechanisms are given as follows: “(−) HCA reduces the conversion of carbohydrate calories into fats. It does this by inhibiting the actions of ATP-citrate lyase, the enzyme that converts citrate into fatty acids and cholesterol in the primary pathway of fat synthesis in the body. The actions of (−) HCA increase the production and storage of glycogen (which is found in the liver, small intestine and muscles of mammals) while reducing both appetite and weight gain. (−) Hydroxycitric acid also causes calories to be burned in an energy cycle similar to thermogenesis . . . (−) HCA also increases the clearance of LDL cholesterol . . . ” U.S. Pat. No. 5,783,603 further argues that HCA serves to disinhibit the metabolic breakdown and oxidation of stored fat for fuel via its effects upon the compound malonyl CoA and that gluconeogenesis takes place as a result of this action. The position that HCA acts to unleash fatty acid oxidation by negating the effects of malonyl CoA with gluconeogenesis as a consequence (McCarty M F. Promotion of hepatic lipid oxidation and gluconeogenesis as a strategy for appetite control. Medical Hypotheses 1994;42:215-225) is maintained in U.S. Pat. No. 5,914,326.
[0006] Most of the primary research on HCA was carried out by Hoffman-La Roche nearly three decades ago. The conclusion of the Roche researchers was that “no significant differences in plasma levels of glucose, insulin, or free fatty acids were detected in (−)-hydroxycitrate-treated rats relative to controls. These data suggest that peripheral metabolism, defined in the present context as metabolite flux, may be involved in appetite regulation . . . ” (Sullivan, Ann C. and Joseph Triscari. Possible interrelationship between metabolite flux and appetite. In D. Novin, W. Wyriwicka and G. Bray, eds., Hunger: Basic Mechanisms and Clinical Implications (New York: Raven Press,1976) 115-125.)
[0007] HCA is highly researched as of 2005, with 157 citations appearing on PubMed under “hydroxycitrate” and 101 appearing under “hydroxycitric acid.” Quite surprisingly, HCA has been discovered by the inventor to regulate calcification of the soft tissues. Such regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, and the calcification of surgical stints, such as those containing elastin. No existing literature teaches such a role despite more than three decades of active research on the compound. The inventor's claims regarding HCA clearly are novel.
[0008] Unlike most serum lipid markers, which unless they are oxidized primarily are putative indicators of cardiovascular disease risk rather than causal agents, now that proper measurement techniques have been developed, it has been shown that vascular calcification is a highly significant factor in the initiation, progression and physiologic actions of arterial plaques. Indeed, the preponderance of available evidence indicates that uncalcified plaques are relatively benign. In addition, inhibition of calcification effectively inhibits the plaque formation process without any alteration in serum cholesterol levels, something demonstrated conclusively thirty years ago. (Chan C T, Wells H, Kramsch D M. Suppression of calcific fibrous-fatty plaque formation in rabbits by agents not affecting elevated serum cholesterol levels. The effect of thiophene compounds. Circ Res. 1978 July;43(1): 115-25.) These results are reproducible with other compounds that are calcium inhibitors. (Sugano M, Nakashima Y, Tasaki H, Takasugi M, Kuroiwa A, Koide O. Effects of diltiazem on suppression and regression of experimental atherosclerosis. Br J Exp Pathol. 1988 August;69(4):515-23.) The challenge, of course, is to find calcium agonists that act only locally in the vascular system without negatively influencing bone mineralization or other health parameters.
[0009] Calcification, in any event, is highly correlated with carotid and arotic wall changes. For instance, the results of the Rotterdam Coronary Calcification Study, a recent population-based study in subjects age 55 years and over. Participants of the study underwent an electron beam CT scan. Coronary calcification was quantified according to the Agatston calcium score. Measures of extracoronary atherosclerosis included common carotid intima media thickness (IMT), carotid plaques, ankle-arm index (AAI) and aortic calcification. The first 2,013 participants were used for the present analyses. Age-adjusted geometric mean calcium scores were computed for categories of extracoronary measures using analyses of variance. Graded associations with coronary calcification were found for the carotid and aortic measures. Associations were strongest for carotid plaques and aortic calcification; coronary calcification increased from the lowest category (no plaques) to the highest category 9-fold and 11-fold in men and 10-fold and 20-fold in women, respectively. A nonlinear association was found for AAI with an increase in coronary calcification only at lower levels of AAI. (Oei H H, Vliegenthart R, Hak A E, Iglesias del Sol A, Hofman A, Oudkerk M, Witteman J C. The association between coronary calcification assessed by electron beam computed tomography and measures of extracoronary atherosclerosis: the Rotterdam Coronary Calcification Study. J Am Coll Cardiol. 2002 June 5;39(11):1745-51.) Moreover, calcification, which is an active component of direct damage to the cardiovascular system, is much more sensitive than are the so-called risk factors. Almost 30% of the men and 15% of the women without risk factors examined in the Rotterdam Study had extensive coronary calcification. (Oei H H, Vliegenthart R, Hofman A, Oudkerk M, Witteman J C. Risk factors for coronary calcification in older subjects. The Rotterdam Coronary Calcification Study. Eur Heart J. 2004 January;25(1):48-55.) Calcification is highly predictive of myocardial infarctions. (Vliegenthart R, Oudkerk M, Song B, van der Kulp D A, Hofman A, Witteman J C. Coronary calcification detected by electron-beam computed tomography and myocardial infarction. The Rotterdam Coronary Calcification Study. Eur Heart J. 2002 October;23(20):1596-1603.) Calcification, similarly, is predictive of stroke. (Vliegenthart R, Hollander M, Breteler M M, van der Kuip D A, Hofman A, Oudkerk M, Witteman J C. Stroke is associated with coronary calcification as detected by electron-beam CT: the Rotterdam Coronary Calcification Study. Stroke. 2002 February;33(2):462-5.) Similarities in the pathogenesis of arterial and articular cartilage calcification have come to light in recent years. These include the roles of aging, of chronic low-grade inflammation and so forth and so on. (Rutsch F, Terkeltaub R Deficiencies of physiologic calcification inhibitors and low-grade inflammation in arterial calcification: lessons for cartilage calcification. Joint Bone Spine. 2005 March;72(2):110-8.) As another example, matrix metalloproteinase-9 (MMP-9), accepted as a primary actor in vascular calcification, has been demonstrated to be active in arthritis and joint diseases. (Itoh T, Matsuda H, Tanioka M, Kuwabara K, Itohara S, Suzuki R. The role of matrix metalloproteinase-2 and matrix metalloproteinase-9 in antibody-induced arthritis. J Immunol. 2002 September 1;169(5):2643-7.) Kidney disease/end stage renal failure is similarly plagued by tissue calcification, which usually is attributed to altered serum calcium and phosphate balances, yet can be given an alternative analysis not prejudicial to the phosphate balance hypothesis. It can be shown that factors, such as angiotensin-converting enzyme, that influence the progression of renal failure also play a direct role in vascular calcification. (Chiurchiu C, Remuzzi G, Ruggenenti P. Angiotensin-converting enzyme inhibition and renal protection in nondiabetic patients: the data of the meta-analyses. J Am Soc Nephrol. 2005 March;16 Suppl 1:S58-63.) Both direct and indirect mechanisms are in common between vascular and a number of other forms of soft tissue calcification. Moreover, there is a linkage between calcification and other untoward changes in vascular tissues. Experimentally, it has been demonstrated that administration of bisphosphonates decreases not only mineral deposition, but also the accumulation of cholesterol, elastin and collagen in these tissues.
[0010] A known influence in vascular calcification is elevated insulin and blood glucose. Hyperglycemia alters metalloproteinase activity and thus acts on a major factor in vascular calcification, perhaps via oxidative stress. (Uemura S, Matsushita H, Li W, Glassford A J, Asagami T, Lee K H, Harrison D G, Tsao P S. Diabetes mellitus enhances vascular matrix metalloproteinase activity: role of oxidative stress. Circ Res. 2001 June 22;88(12):1291-8.) However, as the well-known failures of supplementation with vitamins C and E have demonstrated, merely ingesting antioxidants does not seem to alter the actions of localized and system oxidative stress sufficiently to give significant cardiovascular protection. Similarly, as demonstrated by the actually increased rates of morbidity and mortality found with a number of diabetes drugs, mere regulation of blood sugar levels is not enough. Although there is universal agreement that tight regulation of blood sugar levels should be beneficial, the sulfonylurea class of drugs in terms of end points has proved to be a failure-in various trials, the death rate went up in comparison with blood sugar regulation via diet and exercise alone.
[0011] In contrast, diabetes drugs that influence ligands for peroxisome proliferator-activated receptor-γ (PPAR-γ) have beneficial effects on the arterial wall in atherosclerosis, perhaps via an anti-inflammatory mechanism. (Gaillard V, Casellas D, Seguin-Devaux C, Schohn H, Dauca M, Atkinson J, Lartaud I. Pioglitazone Improves Aortic Wall Elasticity in a Rat Model of Elastocalcinotic Arteriosclerosis. Hypertension. 2005 June 20; [Epub ahead of print]) It must be stressed that anti-inflammatory does not necessarily mean anti-oxidant. Moreover, other factors are at work. Pioglitazone has been shown to act independently of simple glycemic control and to positively influence direct regulators of vascular calicification, such as vascular endothelial growth factor, matrix metalloproteinase (MMP-9) and monocyte chemoattractant protein (MCP-1). (Pfutzner A, Marx N, Lubben G, Langenfeld M, Walcher D, Konrad T, Forst T. Improvement of cardiovascular risk markers by pioglitazone is independent from glycemic control: results from the pioneer study. J Am Coll Cardiol. 2005 June 21 ;45(12): 1925-31.) Aside from the actions of hyperinsulinemia and hyperglycemia, conveniently placed under such headings as the Insulin Resistance Syndrome/the Metabolic Syndrome/Syndrome X and covered by our issued U.S. Pat. No. 6,207,714, several other mechanisms have been proposed. It is generally accepted that direct testing of these mechanisms in vivo has remained difficult up to the time of this writing in 2005. Nevertheless, it is well established that a number of physiologic substances actively induce, inhibit and/or participate in soft tissue calcification. Among these are:
angiotension I-converting enzyme (ACE) glucocorticoids inflammation/localized oxidative stress leptin matrix metalloproteinase (MMP-9) monocyte chemoattractant protein (MCP-1) peroxisome proliferator-activated receptor-≢ (PPAR-γ) resistin tumor necrosis factor-alpha (TNF-α)
[0021] It is the current inventor who has demonstrated the relationship of most of the above factors to the actions of HCA and who holds the relevant issued and pending patents governing angiotension-converting enzyme, gluccocorticoids, inflammation, leptin, PPAR-γ, resistin and TNF-α.
[0022] No direct data as of yet is available on HCA and MMP-9 or MCP-1. However, it can be shown that both of these are influenced by other compounds/mechanisms discovered by the inventor. In the case of MMP-9, inflammation is a direct activator and local inhibition of vascular tissue inflammation also reduces MMP-9 activity. (Egi K, Conrad N E, Kwan J, Schulze C, Schulz R, Wildhirt S M. Inhibition of inducible nitric oxide synthase and superoxide production reduces matrix metalloproteinase-9 activity and restores coronary vasomotor function in rat cardiac allografts. Eur J Cardiothorac Surg. 2004 August;26(2):262-9.) (Pfutzner A, Marx N, Lubben G, Langenfeld M, Walcher D, Konrad T, Forst T. Improvement of cardiovascular risk markers by pioglitazone is independent from glycemic control: results from the pioneer study. J Am Coll Cardiol. 2005 June 21;45(12):1925-31.) MCP-1 is similarly regulated by localized inflammation. (Doherty T M, Fitzpatrick L A, Shaheen A, Rajavashisth T B, Detrano R C. Genetic determinants of arterial calcification associated with atherosclerosis. Mayo Clin Proc. 2004 February;79(2):197-210.) Available evidence indicates that MMP-9 and MCP-1, therefore, can be modified by regulators of TNF-α and other inflammatory compounds and also by regulators of PPAR-γ. U.S. patent application 20050032901, “(−)-Hydroxycitric acid for controlling inflammation” by the present inventor addresses the issue of inflammation and further data on TNF-α is found in the Examples below. Regulation of PPAR-γ is found in the inventor's U.S. Pat. No. 6,474,071, “Correcting polymorphic metabolic dysfunction with (−)-hydroxycitric acid.”
[0023] Knowledge of the role of ACE in vascular calcification is recent. Inflammatory cells release enzymes (including ACE) that generate angiotensin II. One explanation is that a local positive-feedback mechanism could be established in the vessel wall for oxidative stress, inflammation, and endothelial dysfunction. Angiotensin II also acts as a direct growth factor for vascular smooth muscle cells and can stimulate the local production of metalloproteinases and plasminogen activator inhibitor. This is to say that angiotensin-converting enzyme (ACE) activation and the de novo production of angiotensin II contribute to cardiovascular disease through direct pathological tissue effects. (Dzau V J. Theodore Cooper Lecture: Tissue angiotensin and pathobiology of vascular disease: a unifying hypothesis. Hypertension. 2001 April;37(4):1047-52.) ACE is now seen as actively involved in vascular calcification. (Doherty T M, Fitzpatrick L A, Shaheen A, Rajavashisth T B, Detrano R C. Genetic determinants of arterial calcification associated with atherosclerosis. Mayo Clin Proc. 2004 February;79(2):197-210.) The present inventor has discovered a role for HCA in regulating ACE, for which see Provisional Patent Application Ser. No. 60/599223 and now the full U.S. patent application filed Jun. 14, 2005.
[0024] Many other factors have been suggested as promoting vascular calcification, but here it is useful to focus only on four of these, to wit, glucocorticoids, leptin, peroxisome proliferator-activated receptor-γ (PPAR-γ) and resistin. A model of the means by which glucocorticoids enhance vascular calcification has been developed. (Mori K, Shioi A, Jono S, Nishizawa Y, Morii H. Dexamethasone enhances In vitro vascular calcification by promoting osteoblastic differentiation of vascular smooth muscle cells. Arterioscler Thromb Vase Biol. 1999 September; 19(9):2112-8.) Leptin, similarly, has been shown to directly enhance calcification of the vascular cells. Leptin possesses procoagulant and antifibrinolytic properties, and it promotes thrombus and atheroma formation, probably through the leptin receptors by promoting vascular inflammation, proliferation, and calcification, and by increasing oxidative stress. (Parhami F, Tintu Y, Ballard A, Fogelman A M, Demer L L. Leptin enhances the calcification of vascular cells: artery wall as a target of leptin. Circ Res. 2001 May 11;88(9):954-60.) (Kougias P, Chai H, Lin P H, Yao Q, Lumsden A B, Chen C. Effects of adipocyte-derived cytokines on endothelial functions: implication of vascular disease. J Surg Res. 2005 June 1;126(1):121-9.) That PPAR-γ suppresses early osteogenenic differentiation in the vascular wall has been established. (Vattikuti R, Towler D A. Osteogenic regulation of vascular calcification: an early perspective. Am J Physiol Endocrinol Metab. 2004 May;286(5):E686-96.) As discussed above, one regulator of PPAR-γ, pioglitazone, has been shown to inhibit arterial calcification. Finally, resistin increases the expression of the adhesion molecules, up-regulates the monocyte chemoattractant chemokine-1 (hence, MCP-1) and promotes endothelial cell activation, hence is a potent activator of vascular calcification. (Kougias P, Chai H, Lin P H, Yao Q, Lumsden A B, Chen C. Effects of adipocyte-derived cytokines on endothelial functions: implication of vascular disease. J Surg Res. 2005 June 1;126(1):121-9.) The modulation of all four of these compounds-glucocorticoids, leptin, peroxisome proliferator-activated receptors (PPAR-γ) and resistin is found in the inventor's U.S. Pat. No. 6,474,071, “Correcting polymorphic metabolic dysfunction with (−)-hydroxycitric acid.”
[0025] The period of active research and publication on HCA began in 1969. Until now, it had never been suggested that HCA regulates calcification of the soft tissues and such a claim would appear quite surprising in light of existing publications. Indeed, all of the primary research that supports such a finding has come from the present inventor. Hence, the inventor's claims regarding HCA and the regulation of calcification of vascular and other soft tissues clearly are novel. Regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, and the calcification of surgical stints, such as those containing elastin.
SUMMARY OF THE INVENTION
[0026] The inventor has discovered that supplementation with (−)-hydroxycitric acid, its salts and related compounds is useful for reducing and regulating calcification of the blood vessels and other soft tissues. Such regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, the calcification of surgical stints, such as those containing elastin. These benefits of HCA are especially pronounced with the use of the preferred salts of the acid, potassium hydroxycitrate and potassium-magnesium hydroxycitrate, and may be further potentiated by the use of a controlled-release form of the compound. The discovery that HCA has calcium-regulating effects in the soft tissues allows for the creation of novel and more efficacious approaches to preventing and ameliorating cardiovascular diseases, arthritis and a variety of other conditions. Inasmuch as one element common to advancing years is an increased level of generalized calcification of the soft tissues, the invention lends itself to reducing or delaying this aspect of aging. Furthermore, this discovery makes possible the development of adjuvant modalities that can be used to improve the results realized with other treatment compounds while at the same time reducing the side effects normally found with such drugs. HCA delivered in the form of its potassium salt is efficacious at a daily dosage (bid or tid) of between 750 mg and 10 grams, preferably at a dosage of between 3 and 6 grams for most individuals. A daily dosage above 10 grams might prove desirable under some circumstances, such as with extremely large or resistant individuals, but this level of intake is not deemed necessary under normal conditions.
OBJECTS AND ADVANTAGES
[0027] It is an objective of the present invention to provide a method for preventing, treating or ameliorating conditions that involve calcium deposition in vascular and other soft tissues. These include cardiovascular diseases in general, aortic and other forms of vascular calcification, osteoarthritis, rheumatoid arthritis and calcification of surgical stints. Very few compounds are known that have any reliable effect in these areas and these compounds typically are associated with a variety of side effects. For instance, other PPAR- Y modifiers cause weight gain and statin drugs, which are weak as inhibitors of calcification, are noted for such numerous and unpleasant side effects that approximately seventy-five percent of patients discontinue use within two years. Knowledge of the present invention has the further advantage of allowing the use of forms of (−)-hydroxycitric acid, including especially through controlled release formulations, as adjuvants to cardiovascular drugs and other drugs. In the well established problem of drugs such as warfarin actually promoting vascular calcification, HCA can be employed to ameliorate this side effect.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The free acid form and various salts of (−)-hydroxycitric acid (calcium, magnesium, potassium, sodium and mixtures of these) have been available commercially for several years. Any of these materials can be used to fulfill the invention revealed here, but with varying degrees of success. These materials are generally useful in this descending order of efficacy: potassium salt, sodium salt, free acid, magnesium salt, and calcium salt. Exact dosing will depend upon the form of HCA used, the weight of the individual involved, and the other components of the diet. Controlled release can also be expected to improve results by aiding in maintaining a sustained exposure to the drug as required for therapy. The previously patented hydroxycitric acid derivatives (mostly amides and esters of hydroxycititric acid, the patents for which are now expired, to wit, U.S. Pat. Nos. 3,993,668; 3,919,254; and 3,767,678) likely are roughly equivalent to the HCA sodium salt in efficacy.
EXAMPLE 1
Clinical Evidence for Blood Glucose/Insulin Regulation
[0029] A multi-week pilot open clinical weight loss trial with extremely obese patients was planned to gauge the effects of a pouch delivery form of a potassium salt of (−)-hydroxycitrate under the normal circumstances faced in clinical practice with this patient population. Fourteen patients were enrolled, three of whom were diabetics on medications and several others who were suspected of suffering from insulin resistance. The patients ingested 3-4 grams of HCA per day in two divided doses. Aside from being informed that they must eat a carbohydrate-containing meal within one hour of taking the HCA and that they should avoid eating late in the day, they were not instructed to follow any special diet or exercise plan outside their normal habits and no caloric restriction was imposed. This particular form of potassium (−)-hydroxycitrate delivery typically was mixed into water or juice and consumed at mid-morning and mid-afternoon. The delivery was a water-soluble immediate release form. It was a pre-commercial preparation and nearly all of the patients complained regarding the inconvenience and poor taste of the product, albeit there were no other issues of tolerability. A number of patients continued on the program for 6 weeks. However, comparative data was good for only 3 weeks because two of the diagnosed diabetics experienced hypoglycemic reactions. Several other patients experienced good appetite suppression, yet also complained off episodic tiredness at the beginning of the program, a sign of low blood sugar. Two patients subsequently were placed on phentermine. One patient who followed the program for 10 weeks with excellent weight loss (32 pounds over 10 weeks) found that his tendency toward elevated blood sugar was stabilized during the program. This patient returned to his prior experiences of infrequent hypoglycemia roughly one week after he had left the program, something which suggests a carryover effect from the compound. The average weight loss over the 3 week period for these patients was approximately 3 pounds per person per week. The clinical decision was made that potassium (−)-hydroxycitrate in an immediate release format can exercise a strong hypoglycemic effect in diabetics and that it appears to influence blood sugar levels in protodiabetics, as well. At therapeutically effective dosages, HCA probably should be used with diabetic populations only under a physician's care.
[0030] The results of this pilot trial cited in U.S. Pat. No. 6,207,714 and using a pre-production material subsequently have been confirmed by a number of published studies using other models. HCA used appropriately ameliorates insulin resistance and reduces elevated blood sugar levels.
EXAMPLE 2
Ace Inhibition: Evidence from Blood Pressure Modulation
[0031] A known effect of ACE inhibitors is a reduction in elevated systolic blood pressure. To test this, the following protocol was employed: Sprague-Dawley Rats (SD), approximately 8 weeks of age were obtained. Six groups of eight male SD received the same standard rat chow manufactured to specifications. The special diets derived 30% of calories from fats (one half from lard and one half from corn oil), 50% from carbohydrates, and 20% from proteins. Twenty percent of dietary calories was derived from sucrose and the preponderance of the remaining carbohydrate calories was derived from dextrin. During weekdays (M-F), each group was gavaged twice daily with a solution containing a commercial source of potassium hydroxycitrate (KHCA), a commercial source of potassium-calcium hydroxycitrate (KCaHCA), or a pre-commercial non-salt source of potassium-magnesium hydroxycitrate (KMgHCA, listed as KMgHCA L-Low, M-Intermediate or H-High depending upon the dose). Over the weekends (S-S), a similar quantity of the weekday daily dose was added to twenty grams of food, that is, an amount of food estimated to be close to the daily intake of the animals. At initiation of study and four weeks, and eight weeks later, bloods were drawn from all SD for routine blood chemistries. Body weight (BW) was measured weekly and systolic blood pressure (SBP) was measured every two weeks.
[0032] The HCA dosages in the arms varied. The dosage used in the KHCA arm was extrapolated from the recommended 1,500 mg HCA per day for humans consuming a normal diet (i.e., ≧30% calories derived from fats) advocated by a commercial seller of KHCA and claimed to have produced acceptable clinical results. The approximate equivalent for the rat model is 35.4 mg HCA per day, which we increased to 38.4 mg HCA per day for convenience in employing a 48% HCA potassium salt and to remain safely on the high side in practice. For the sake of comparison, a commercial KCaHCA salt (60% HCA) was chosen and delivered at an HCA dosage level of 48 mg per day, which slightly exceeded the lowest dosage of HCA found to be efficacious for inhibition of weight gain in rats in the early pharmaceutical trials (45.4 mg/day) using pure trisodium hydroxycitrate and a very low fat diet. The design thus utilized a realistic diet with rough equivalents of the HCA dosages claimed to be effective in both the human and rat models.
[0033] Calculations were based on the early work on HCA by Roche in which the lowest dose in rats shown to be efficacious in reducing weight gain was 0.33 mmol/kg twice a day (delivered as trisodium hydroxycitrate) on a diet consisting of 70% glucose and 1% fat [8]. (−)-Hydroxycitric acid (C 6 H 8 O 8 ) has a molecular weight of 208, therefore 1 millimole=208 mg. The rat dose thus would be calculated as 0.33 mmol/kg b.i.d., meaning 208×0.33 kg rat wt (in kg assuming an average weight of 333 grams)=22.65/1000=22.7 mg b.i.d. or 45.4 mg HCA total intake per day, which is equivalent to 76 mg daily of a 60% HCA salt. This should be put in perspective as to the likely lowest efficacious human dose under similar conditions of less than 10% calories from fat in the diet. At 0.33 mmol HCA b.i.d., the human dosage is 208 mg×0.33×70 kg=4.8 grams of HCA per dose×2=9.6 grams HCA/day=16 grams of a 60% salt. Using the normal rat-to-human multiplier for calculating the small animal effect [9], an appropriate dose for humans would be close to 9.6÷5=1.92 grams hydroxycitric acid content on an extremely low fat diet and assuming the material is supplied via a salt that is equivalent to pure trisodium hydroxycitrate in efficacy and is delivered without food effect on uptake.
[0034] The experimental KMgHCA dosings varied considerably from that of the other two salts. Subsequent to the start of the trials, it was discovered that the KMgHCA was diluted with as much as 15% potassium chloride (inactive) and that there was a mistake in the calculation of the waters of hydration. As a result, the recalculated HCA doses for the experimental compound were a low dose (KMgHCA L) of 14 mg, an intermediate dose (KMgHCA M) of 28 mg and a high dose (KMgHCA H) of 84 mg per day. The difficulty in calculating the HCA content in this case is not unique inasmuch as there is as of yet no universally accepted method for calculating the HCA content of the various salts. Again, preparations yielded the equivalent of 48 mg HCA per day from KCaHCA and 38.4 mg HCA per day from KHCA.
[0035] Systolic Blood Pressure (SBP): SBP was estimated by tail plethysmography in unanesthetized rats after a brief warming period. Readings were taken approximately one minute apart. To be accepted, SBP measurements had to be virtually stable for a minimum of three consecutive readings.
[0036] Statistical Analyses: Results are presented as mean±SEM. Many statistics were performed by one-way analysis of variance (ANOVA). SBP and BW were examined by two-way analyses of variance (one factor being dietary group and the second factor being time of examination). Where a significant effect of diet was detected by ANOVA (p<0.05), the Dunnett t test was used to establish which differences between means reached statistical significance (p<0.05). If a Student's t test was employed, this is noted.
[0037] Findings for Systolic Blood Pressure: The general trend was for all test groups to consistently show significantly lower SBP during the course of study. The only exception was low-dose of KMgHCA (KMgHCA L), which apparently was below the threshold for effect (FIG. 1). At the end of eight weeks, the doses of the KHCA and KCaHCA and the two higher doses of the KMgHCA caused significant decreases in SBP compared to control (FIG. 2). With regard to 3 different doses of KMgHCA (FIG. 6), the low dose essentially did nothing, but the intermediate and high doses caused virtually the same significant lowering of SBP at the end of 8 weeks—over 10 mm Hg.
[0038] Findings for Blood Chemistries: Blood chemistries were obtained at baseline, one month and two months. No significant differences were seen in BUN, and serum creatinine, ALT, AST, and glucose among the six groups. Accordingly, no evidence of liver and renal toxicities was apparent. Although the average insulin concentrations were lower in all KMgHCA groups and in the KHCA group (FIG. 3), the differences were not significant compared to control using ANOVA. The lack of significance may be due to the small numbers of animals examined and the large variances found, especially with control. Only the KCaHCA group did not show a trend toward lower circulating insulin. Recalculating control versus KHCA alone for insulin using the Student's t test showed significance; a similar recalculation of control versus KMgHCA H was at the margin of significance (p=0.058).
[0039] An earlier study not described here had demonstrated a decrease in SBP using a KCaHCA salt at a dose of 120 mg HCA per day. In the present study, significantly decreased SBP was produced readily in all the hydroxycitrate groups with the exception of the low dose of KMgHCA (14 mg HCA). One surprising finding was that that the intermediate dose of KMgHCA supplying only 28 mg HCA (KMgHCA M) was equal in this regard to KHCA supplying 38.4 mg HCA and KCAHCA supplying 48 mg HCA (FIG. 2). Another interesting outcome was that elevating the dose of HCA further, in this case to 84 mg in the high KMgHCA dose (KMgHCA H) did not have exert a greater impact on SBP (FIG. 4). Taken together, these findings suggest that there may be a limit to the blood pressure effect of HCA and that this limit is reached with a relatively low dose. Whether all the salts are equally effective remains to be seen. With regard to at least one of the vectors influencing blood pressure, insulin, the KCaHCA salt appears to be significantly less active than the others tested. Moreover, the fact that KCaHCA had little positive impact upon insulin regulation in this model, yet still improved SBP suggests that more than one blood pressure regulating mechanism is at work.
EXAMPLE 3
Ace Inhibition: Response to Losarten Challenge
[0040] Many factors can positively influence blood pressure, e.g., diuretics, antioxidants, regulators of sympathetic/parasympathetic tone, compounds that improve insulin sensitivity and so forth. Therefore, losartan, an angiotensin-2 receptor blocker, was utilized to discover whether the ACE system was involved in the results discussed in Example 1.
[0041] Spontaneously hypertensive rats (SHR) were placed on a diet composed of regular rat chow (60% w/w) and table sugar (40% w/w). This diet reliably elevates blood pressure in this animal model. One group received 100 mg HCA per day in the form of a new potassium-magnesium hydroxycitrate (different from that used in Example 1) via an added 5 g HCA per kg of food mix. Systolic blood pressure and body weight were tested as in Example 1 on a weekly basis.
[0042] Over three weeks, there was a trend for an increase in body weight in SHR consuming KMgHCA (p=0.084) in this model. This was viewed as likely positive in that rats gain weight steadily as long as they remain in good health and the SHR at middle age, as used here, lives a relatively short life and its health deteriorates as its blood pressure rises. SBP steadily increased in control as shown in FIG. 5, where delta SBP steadily increased in control. In contrast, the KMgHCA rats showed a decrease in SBP from baseline. A glucose tolerance test was administered in which 0.1 unit of regular insulin was injected along with glucose. At 7.5 minutes, there was a significantly lesser rise in glucose appearance in bloodstream. This finding indicates increased insulin sensitivity. (FIG. 6)
[0043] When losartan was injected, the SBP of both groups decreased. At 6 hours, the SBP were essentially the same. As shown in FIG. 7, the decreases in SBP's at 6 hours (−50±6.1 vs −21.7±7.0) were significantly different (p=0047). Thus, HCA appears to decrease angiotensin-2 in rats and to lower elevated SBP. Although insulin regulation likely is a factor in the blood pressure modulating effect of HCA, this evidence argues that inhibition of ACE is also important. Moreover, taken together with the evidence in Example 1, this second experiment helps to explain the difference in efficacy in blood pressure regulation between KCaHCA and the other HCA salts tested, to wit, although KCaHCA has little impact upon insulin metabolism, it nevertheless moderates blood pressure via ACE inhibition. Thus there is both direct and indirect evidence from experiments with several different salts of HCA indicating that the compound modulates ACE metabolism. ACE is known to be involved in vascular calcification.
EXAMPLE 4
Anti-Inflammatory: Effects Upon C-Reactive Protein and TNF-α
[0044] To test the properties of HCA in various forms under conditions similar to those found in human clinical trials, the inventor arranged for rats to be fed a diet in which 30% of the calories were obtained from fat under standard conditions, with a further approximately 20% of the calories being supplied as simple sugars. Such a dietary combination of fat and simple sugars is noted as promoting a variety of metabolic imbalances and dysfunctions. The rats were intubated twice daily with one of five HCA salts or placebo. On weekends, the HCA was added to the food at an approprate dosage. The amount of HCA in each arm of 8 animals was based on the minimum dosage which had been found effective in the form of the pure trisodium salt of HCA in tests by Hoffmann-La Roche in animals ingesting a 70% glucose diet, i.e., 0.33 mmoles/kg body weight HCA given twice per day. The HCA salts used were these: KCaHCA=a mixed potassium and calcium or double metal HCA salt commercially marketed as being entirely water soluble and of relatively high purity; KHCA=a relatively clean commercial potassium salt of HCA with a good mineral ligand attachment supplying 4467 mg potassium/100 grams of material; KMgHCA=three different dosage levels of an experimental potassium and magnesium salt with special characteristics, but suspected of being relatively unstable when exposed to stomach acid. The KCaHCA and KHCA salts were 60% HCA delivered at the rate of approximately 76 mg/day. The KMgHCA salts were delivered at the rate of 76 mg/day (r), 38 mg/day (l) and 228 mg/day (h), but due to initial miscalculations of the water of crystallization, this salt was only 45% HCA rather than 60%. The proper dosage for the KMgHCA(r) should have been 100 mg/day; the half dose (I) should have been 50 mg/day, and the triple dose (h) should have been 300 mg/day to match the commercial salts.
[0045] Tests were performed for C-reactive protein. Data was obtained for the animals at start and then at week 4 based on serum. Optical Density (OD) readings in the test kit used were 1 unit equals 50 picograms/mL. The delta changes over the 4 weeks for each arm vs control are shown.
Delta CRP Δ OD units Standard versus Base- Modu- GROUP after 4 wks Error Control line lation Control 339 113 KMgHCA(r) −145 105 0.0007 0.0006 ** KMgHCA(l) 33 70 0.0481 0.0268 ** KMgHCA(h) −11.3 41 0.0186 0.0035 ** KHCA −155 94 0.0005 <0.0001 ** KCaHCA 56 33 0.0756 0.0943 ** = significant
Four out of the five active arms showed significant improvements in the change (delta A) in CRP compared with control. In the cases of KMgHCA (r) and (h) as well as KHCA, the absolute readings for the arms also were lower at week 4 than initially, an interesting finding in that these were young animals and in rats, as in humans, inflammation tends to steadily increase over time, as was true in the control. Only the KCaHCA arm failed to yield significant results. The KCaHCA and the KMgHCA(l) arms were also the only two active arms in which absolute CRP levels increased, albeit only slightly.
[0046] In rats, blood pressure rises steadily with age, and this is what was seen in the control arm even over this short period of time. It should be noted that all active arms showed significantly lowered systolic blood pressure versus control at week 4 (data not shown). Similarly, by week 6, all the active arms had begun to diverge from control with lower body weights (data not shown), with the KHCA and the KCaHCA arms showing the greatest trend differences.
[0047] These results suggest that appetite regulation by HCA salts may not be controlled by or at least to the same extent by the same mechanisms with each particular salt as are other elements of the metabolism, such as inflammation. Even an extremely low dose of HCA as the KMgHCA salt used in this experiment had a stronger effect upon CRP levels than did the commercial KCaHCA salt used although the latter salt had a stronger effect upon weight gain. What is clear, however, is that several different HCA salts at different dosage levels positively modulated CRP in this experiment despite the short period of time allowed for results to appear.
[0048] At eight weeks, the findings were only slightly changed. With regard to CRP, readings at two months did not show statistical differences among the groups, although the means of all the test groups were lower than control. With regard to TNF-α, there was a trend toward a lowering in all groups compared to control. Using a simple t test versus control calculation in the case of TNF-α indicated significance with the low and intermediate doses of KMgHCA. Keeping in mind the small n, an increase in the number of test animals probably would have led to significance with regard to both CRP and TNF-α in all arms at eight weeks. Inflammation, especially that related to TNF-α, is known to play a role in vascular and other soft tissue calcification.
EXAMPLE 5
Leptin, Glucocorticoids, PPAR-γ and Resistin
[0049] OM rats aged 10 weeks to be fed a diet in which 30% of the calories were obtained from fat under standard conditions. The rats were intubated twice daily with one of three HCA salts or placebo. The amount of HCA in each arm of 5 animals was the minimum dosage which had been found effective in the form of the pure trisodium salt of HCA in tests by Hoffmann-La Roche in animals ingesting a 70% glucose diet, i.e., 0.33 mmoles/kg body weight HCA given twice per day. The HCA salts used were these: CaKHCA=a mixed calcium and potassium HCA salt commercially marketed as being entirely water soluble; KHCA 1=a relatively clean, but still hardly pure potassium salt of HCA with a good mineral ligand attachment supplying 44.67 grams potassium/100 grams of material; KHCA 2=an impure potassium salt of HCA with large amounts of gums attached and poor mineral ligand attachment supplying 21.69 grams potassium/100 grams of material. Data was collected with regard to serum insulin, leptin and cortisol levels.
Insulin Leptin Corticosterone Group ng/mL ng/mL ng/mL Control 2.655 9.52 269.38 Control 7.077 18.94 497.87 Control 4.280 34.34 265.71 Control 9.425 24.32 209.54 Control 3.798 8.40 116.12 KHCA 1 3.880 9.93 45.79 KHCA 1 4.399 7.31 33.10 KHCA 1 3.181 9.25 65.57 KHCA 1 3.210 24.36 55.40 KHCA 1 3.639 9.07 84.62 KHCA 2 4.427 9.13 26.02 KHCA 2 4.301 9.75 270.83 KHCA 2 3.245 8.00 45.44 KHCA 2 3.695 9.16 45.63 KHCA 2 2.053 8.26 38.04
[0050] Both of the potassium (−)-hydroxycitrate arms were superior to the calcium/potassium arm (data not shown here) in reducing insulin, leptin and corticosterone concentrations. Because of the difficulty in achieving significance with only 5 data points per arm, calculations regarding insulin and leptin combined the data from the two KHCA arms. With respect to insulin, the one-tailed P value was a significant 0.0306, and the two-tailed P value fell slightly short of significance at 0.0612. Using this combined data, there was also a significant one-tailed P value difference between the two KHCA arms and the result found with the CaKHCA. With respect to leptin, the two KHCA arms were combined, in part, because of one anomalously high data point and yielded a one-tailed P value which was a significant 0.0241 and a two-tailed P value which was significant at 0.0482. Corticosterone results were highly significant even at 5 data points per arm. KHCA 1 was easily significantly superior to control: the one-tailed P value was a highly significant 0.0048, and the two-tailed P value was a highly significant 0.0096.
[0051] Non-esterified fatty acid levels were not significantly different between control and the KHCA arms, but serum glucose and triglyceride levels exhibited a trend towards elevation. This is consistent with HCA's biophasic properties on a fatty diet and with published animal data to the effect that HCA elevates fatty acid oxidation at rest, although this effect is not significant during actual exercise. Elevated fatty acid oxidation typically slightly increases some fractions of blood fats, and also increases the rate of gluconeogenesis, hence may slightly increase blood glucose levels. However, in those individuals with markedly elevated blood glucose levels/glucose dysregulation, HCA can be used to improve glucose regulation. (U.S. Pat. No. 6,207,714) The same has been shown in animals with regard to elevated blood fats. The clear implication of these data is that HCA, if supplied in appropriate amounts, may be useful in reducing insulin levels and insulin resistance, leptin levels and leptin resistance, and elevated glucocorticoid levels. There was sustained reduction in weight gain found with KHCA 1 even after food consumption had returned to the level of control, a finding indicating an increased basal metabolic rate (BMR) and is in agreement with published studies already mentioned which give evidence of an increased BMR in HCA-treated animals.
[0052] It should be noted that an increased BMR is typical in cases in which fat consumption above the norm does not lead to weight gain. Elevated leptin blood levels have been found to correlate significantly in lean subjects with dietary fat intake and negatively with carbohydrate intake, whereas there is no correlation with total energy intake. Individuals who are lean on a chronically high fat diet (45% of calories) typically also have lower serum glucose levels. (Cooling J, Barth J, Blundell J. The high-fat phenotype: is leptin involved in the adaptive response to a high fat (high energy) diet? Int J Obes Relat Metab Disord. 1998 November;22(11): 1132-5.) This implies that some factor other than fatty acid oxidation, such as elevated insulin or glucocorticoid levels, has a role in inducing leptin resistance. Our findings suggest, based upon what is presently known of its actions, that the recently discovered signaling compound resistin likely is a common element involved in insulin resistance and leptin resistance which is affected by the chronic administration of adequate amounts of HCA. The impact of HCA upon resistin is itself mediated by way of peroxisome proliferator-activated receptor γ.
[0053] The evidence for this presently is indirect, yet a substantial case can be made. KHCA arms 1 and 2 significantly lowered insulin, leptin and glucocorticoid levels in comparison with control. This is important in that, as is true of insulin, in obese humans there is resistance to leptin and much elevated levels of leptin just as there is resistance to insulin and an elevated release of insulin. Elevated glucocorticoid levels increase leptin levels and may play a significant role in the development of leptin resistance, whereas norepinephrine and epinephrine decrease leptin production. (Fried S K, Ricci M R, Russell C D, Laferrere B. Regulation of leptin production in humans. J Nutr. 2000 December;130(12S Suppl):3127S-31S.) Long ago, it was observed that HCA incubated with white fat cells had an effect similar to that observed with epinephrine. (Fried S K, Lavau M, Pi-Sunyer F X. Role of fatty acid synthesis in the control of insulin-stimulated glucose utilization by rat adipocytes. J Lipid Res. 1981 July;22(5):753-62.)
[0054] Resistin levels are highly correlated with those of leptin. Resistin is exclusively made in adipose tissue. Moreover, its exclusive expression in adipocytes, its large increase during the late stage of adipogenesis, and its dramatic induction during fasting/refeeding and by insulin administration to streptozotocin-diabetic animals suggest that this factor may be involved in sensing the nutritional status of the animals to affect adipogenesis. Many of these properties are most similar to those observed with leptin, which is secreted only by adipocytes and is induced dramatically by fasting/refeeding and by diabetes/insulin. (Kee-Hong Kim, Kichoon Lee, Yang Soo Moon, and Hei Sook Sul. A Cysteine-rich Adipose Tissue-specific Secretory Factor Inhibits Adipocyte Differentiation. The Journal of Biological Chemistry 2001 April 6;276(14):11252-11256.) However, unlike resistin, leptin increases Krebs Cycle and uncoupling protein activity and it is an agonist for at least one peroxisome proliferator-activated receptor, that is, peroxisome proliferator-activated receptor a. (Ceddia R B, William W N Jr, Lima F B, Flandin P, Curi R, Giacobino J P. Leptin stimulates uncoupling protein-2 mRNA expression and Krebs cycle activity and inhibits lipid synthesis in isolated rat white adipocytes. Eur J Biochem. 2000 October;267(19):5952-8.)
[0055] The thiazolidinediones (TZDs), such as rosiglitazone, appear to work at least in part by down-regulating the expression of resistin while, and very likely by, up-regulating the actions of peroxisome proliferator-activated receptor-γ. As with resistin, the biological functions of PPAR-γ seem to be connected to fuel sensing. Agonists for the latter increase energy expenditure and reduce insulin resistance. Significantly, the TZDs also downregulate leptin gene expression, increase the flux through the Krebs Cycle and increase liver acetyl-CoA carboxylase, thus making cells more citrate-sensitive. As would be expected from this description, one side effect of rosiglitazone can be mild weight gain. (Thampy G K, Haas M J, Mooradian A D. Troglitazone stimulates acetyl-CoA carboxylase activity through a post-translational mechanism. Life Sci. 2000 December 29;68(6):699-708.) Rosiglitazone is thought to have no liver toxicity, but troglitazone, another TZD, certainly does.
[0056] The similarities between the actions of HCA and the TZDs is remarkable. HCA reduces insulin and leptin levels, increases the flux through the Krebs Cycle, increases liver acetyl-CoA carboxylase and, in at least one sense, makes cells more citrate-sensitive. The latter actions likely are those which activate PPAR-γ, for it has been shown elsewhere that an increase in long-chain CoA (acyl-CoA) affects the PPARs. (Belfiore F, lannello S. Insulin resistance in obesity: metabolic mechanisms and measurement methods. Mol Genet Metab. 1998 October;65(2): 121-8.) Activating PPAR-γ and reducing leptin levels, as already indicated, lowers resistin levels. (Steppan C M, Bailey S T, Bhat S, Brown E J, Banerjee R R, Wright C M, Patel H R, Ahima R S, Lazar M A. The hormone resistin links obesity to diabetes. Nature. 2001 January 18;409(6818):307-12.) Hence, in our view HCA provides the benefits and shares some of the primary mechanisms of action of the thiazolidinediones, but does not exhibit any of the toxicity found with some members of that class of drugs. When used properly, HCA not only does not promote the weight gain found with TZDs, it actually encourages weight loss. Therefore, HCA can be used to manipulate the resistin-PPAR-γ axis as well as the levels of insulin, leptin and glucocorticoids. As indicated in the text, all of these pathways have been shown to modulate vascular calcification.
EXAMPLE 6
A Standard Dosage Form
[0057] Numerous methods can be given as means of delivering HCA as required by the invention, including capsules, tablets, powders and liquid drinks. The following preparation will provide a stable and convenient dosage form.
1 Kg Ingredient Weight Percent Batch 1. Aqueous Potassium 500 gm 62.5% 0.63 Hydroxycitrate 2. Calcium Carbonate 50 gm 6.25% 0.06 3. Potassium Carbonate 50 gm 6.25% 0.06 4. Anhydrous Lactose 150 gm 18.75% 0.19 5. Cellulose Acetate Pthalate 50 gm 6.25% 0.06 Acetate Total 800 gm 100.00% 100.00
[0058] A. Blend items 1-5 in mixing bowl until smooth and even.
[0059] B. Take the liquid and spray into spray-drying oven at 300° C. until white powder forms. When powder has formed, blend with suitable bulking agent, if necessary, and compress into 800 mg tablets with hardness of 10-15 kg. This will mean that each tablet, if starting with 62% KHCA polymer powder, will have about 31% KHCA. However, if the tablets are pressed to 1600 mg, the dose will be equal to 800×62% KHCA.
[0060] C. After pressing the granulate through the screen, make sure that it flows well and compress into oblong tablets.
[0061] D. Tablets should have a weight of 1600 mg and a hardness of 14±3 kg fracture force. When tablets are completed, check for disintegration in pH 6.8, 0.05M KH2PO4. Disintegration should occur slowly over 4-5 hours.
EXAMPLE 7
An Enteric Softgel Dosage Form
[0062] Soft gelatin encapsulation is used for oral administration of drugs in liquid form. For this purpose, HCA may be provided in a liquid form by suspending it in oils, polyethylene glycol-400, other polyethylene glycols, poloxamers, glycol esters, and acetylated monoglycerides of various molecular weights adjusted such as to insure homogeneity of the capsule contents throughout the batch and to insure good flow characteristics of the liquid during encapsulation. The soft gelatin shell used to encapsulate the HCA suspension is formulated to impart enteric characteristics to the capsule to ensure that the capsule does not disintegrate until it has reached the small intestine. The basic ingredients of the shell are gelatin, one or more of the enteric materials listed above, plasticizer, and water. Care must be exercised in the case of softgels to use the less hygroscopic salts and forms of HCA or to pretreat the more hygroscopic salts to reduce this characteristic. The carrier may need to be adjusted depending on the HCA salt, ester or amide used so as to avoid binding of the ingredients to the carrier. Water should never be used as a carrier. Various amounts of one or more plasticizer are added to obtain the desired degree of plasticity and to prevent the shell from becoming too brittle.
EXAMPLE 8
[0063]
A CONTROLLED-DELIVERY DOSAGE FORM
Ingredient
mg/Tablet
Percent
1.
HCA calcium salt
500.00
mg
71.43%
2.
Microcrystalline cellulose
17.00
mg
2.42%
3.
Dicalcium phosphate
45.00
mg
6.42%
4.
Corn starch
9.00
mg
1.28%
5.
TPGS
46.00
mg
6.60%
6.
Hydrogenated vegetable oil
50.00
mg
7.14%
7.
Cellulose acetate phthalate
15.00
mg
2.14%
8.
Carbopol ® 974P Carbomer
15.00
mg
2.14%
9.
Magnesium Sterate
3.00
mg
0.43%
TOTAL
700.00
mg
100.00%
[0064] 1. Weigh and blend items 1-4 in a fluid bed dryer and blend for 4-5 minutes. Dissolve item #5 by heating to 40° C. until molten then stir with magnetic stir rod. After the powders are blended, continue steady blending while adding the TPGS as a molten liquid. Pour in all fluid until an even granulate is formed. Next melt the hydrogenated vegetable oil until molten and fluid in nature. Spray this material at the same time stirring with a magnetic stir rod. Continue blending with air at 30° C. When all the material is thoroughly coated and the granulate is hardened, spray the cellulose acetate phthalate which has been completely dissolved in ammoniated water. Continue spraying until all the granulate has been covered then allow to dry at room temperature in the fluid bed dryer with continuous blending. Remove the granulate from the bowl, when the granulate is dry, pass through an #093 screen using a D3 Fitzmill comminutor.
[0065] 2. When the granulate has been dried and reduced in size, blend in fluid bed first with Carbopol — 974P, then when completely blended, add magnesium stearate and blend for 2-3 minutes.
[0066] 3. Place the mixed granulate on a rotary press and compress the material into tablets with a weight of 700 mg and a fracture force of 10-15 kg.
CONCLUSIONS
[0067] (−)-Hydroxycitrate has a multitude of metabolic functions. The literature teaches that the compound reduces blood lipids, induces weight loss and decreases appetite in both animals and humans. However, the inventor has discovered that this compound can be employed for reducing and regulating calcification of the blood vessels and other soft tissues. Such regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, and the calcification of surgical stints, such as those containing elastin. This safe use for ameliorating problems of soft tissue calcification is an entirely unexpected and novel employment of (−)-hydroxycitric acid, its derivatives and its salt forms.
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The inventor has discovered that supplementation with (−)-hydroxycitric acid, its salts and related compounds constitutes a novel means of inhibiting, reducing and regulating calcification of the blood vessels and other soft tissues and is useful for preventing, treating and ameliorating conditions involving soft tissue calcification. Such regulation offers benefits against arterial calcification and vascular diseases, osteoarthritis, rheumatoid arthritis, the calcification of surgical stints, such as those containing elastin. These benefits of HCA are especially pronounced with the use of the preferred salts of the acid, potassium hydroxycitrate and potassium-magnesium hydroxycitrate, and may be further potentiated by the use of a controlled-release form of the compound. The discovery that HCA has calcium-regulating effects in the soft tissues allows for the creation of novel and more efficacious approaches to preventing and ameliorating cardiovascular diseases, arthritis and a variety of other conditions. Inasmuch as one element common to advancing years is an increased level of generalized calcification of the soft tissues, the invention lends itself to reducing or delaying this aspect of aging. Furthermore, this discovery makes possible the development of adjuvant modalities that can be used to improve the results realized with other treatment compounds while at the same time reducing the side effects normally found with such drugs. HCA delivered in the form of its potassium salt is efficacious at a daily dosage (bid or tid) of between 750 mg and 10 grams, preferably at a dosage of between 3 and 6 grams for most individuals. A daily dosage above 10 grams might prove desirable under some circumstances, such as with extremely large or resistant individuals, but this level of intake is not deemed necessary under normal conditions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electronic control apparatus for an internal combustion engine capable of determining failure in a control device for exhaust gas return which controls a return quantity of exhaust gas.
2. Discussion of Background
A conventional electronic control apparatus for an internal combustion engine of this kind is to be explained in FIG. 1.
In FIG. 1, numeral 1 signifies a conventional four cycle spark ignition type engine mounted on an automobile. The engine 1 sucks air for combustion through the air cleaner 2, the suction pipe 3 and the throttle valve 4. Fuel is supplied to the engine 1 by the electromagnetic valve 5 installed at the suction pipe 3 from a fuel system, not shown. At the downstream side of the throttle valve 4 of the suction pipe 3, there is a pressure sensor 6 for detecting an absolute pressure in the suction pipe 3 and converting it to an electric voltage. The throttle sensor 7 detects the opening of the throttle valve 4, and generates an electric voltage corresponding thereto. The electronic engine control device 8 receives the outputs of the pressure sensor 6, a crank angle sensor (not shown), the throttle sensor 7, a cooling water temperature sensor (not shown), and so on, and controls the drive of the electromagnetic injection valve 5, an air control valve 17 and an electromagnetic valve 9.
A part of the exhaust gas separated to the exhaust gas branch pipe 11, which is connected to the exhaust gas pipe 10, returns to the engine 1 by flowing into the downstream side of the throttle valve 4 of the suction pipe 3 via an exhaust gas return, hereafter EGR, control valve 12 which controls the return of the exhaust gas, and the EGR intake pipe 13. The EGR control valve 12 is composed of a well known structure, the constituent parts of which are negative pressure chamber 12A, valve 12B and spring 12C of the negative pressure chamber 12A. The negative pressure chamber 12A is connected to the negative pressure control pipe 14 which is connected in the neighborhood of the downstream side of the throttle valve 4 of the suction pipe 3 via the electromagnetic valve 9. The EGR quantity is controlled by a negative pressure working on the negative pressure chamber 12A through the valve 12B and the EGR intake pipe 13.
Next, the operation of the above device is explained. The electronic engine control device 8 receives the input signals from the pressure sensor 6, a crank angle sensor (not shown), and a cooling water temperature sensor (not shown), and so on, to purify the exhaust gas, especially NO x , to an optimum condition, and controls the electromagnetic valve 9 by determining the operation or the non-operation of the EGR control valve 12, so that no bad influence is put on the driving condition of the engine 1. First, this electronic engine control device 8 generates a control signal whereby the electromagnetic valve 9 is closed, when the EGR control valve 12 is operated. In this case, the negative pressure chamber 12A and the negative pressure control pipe 14 are connected whereby the valve 12B is in fully open state by the negative pressure at the downstream side of the throttle valve 4. As a result, the EGR is in operation.
The EGR control valve 12 does not operate, when a control signal is outputted whereby the electromagnetic valve 9 is open. In this case the negative pressure chamber 12A is open to the air via pipe 16, which fully closes the valve 12B. Accordingly, exhaust gas is not returned and the EGR is not in operation. The above-mentioned conventional electronic control device for an internal combustion engine has a problem because fault detection of the EGR control system is not possible in the case of failure, malfunction of the EGR control system or clogging of valves and pipes by dirts. As the result, return to the engine of the exhaust gas of a predetermined quantity and deterioration of the exhaust gas, can not be detected.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an electronic control apparatus for an internal combustion engine capable of detecting failures in the EGR control system.
According to the present invention, there is provided an electronic control apparatus for an internal combustion engine which comprises a control device for exhaust gas return having a control valve for exhaust gas return so that a part of exhaust gas returns from an exhaust gas passage to a suction gas passage, a pressure sensor for detecting pressure in a suction gas pipe, and a failure detecting means for detecting failure of said control device for exhaust gas return based on a value of pressure in said suction gas pipe when said control valve for exhaust gas return is in operation, and a second value of pressure in the exhaust gas pipe when the control valve of exhaust gas return is not in operation.
The above failure detecting means may detect the failure when the internal combustion engine is under a load below a predetermined value and running in steady state.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a block diagram showing an embodiment of the electronic control apparatus for an internal combustion engine according to the present invention;
FIG. 2 is a flow chart showing the operation of the apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, explanation will be given on the present invention.
FIG. 1 is a block diagram showing an electronic control apparatus for an internal combustion engine of the present invention. The structure and the general operation of this block diagram was already explained. Therefore, explanation will not be given to these matters.
Next, explanation will be given to the detailed operations of the electronic engine control device 8 which carries out the major operations of this embodiment, based on the flow chart of FIG. 2. The electronic engine control device 8 is composed of a well known microcomputer, an A/D interface, a ROM, a RAM and so on. The content of the flow chart of FIG. 2 is programed and memorized in the ROM. The program memorized in the ROM is operated by the microcomputer.
First, in Step 101, the control device receives the input information such as a revolution speed of engine, a suction pipe pressure, a throttle opening, a water temperature and so on, from output signals of a crank angle sensor (not shown), the pressure sensor 6, the throttle sensor 7, a cooling water temperature sensor (not shown), and so on. Next, in Step 102, a judgment is made whether the above various information is in the EGR control zone which is memorized and set beforehand in the RAM, or whether the running condition of the engine is in the zone which necessitates EGR. When the information is out of the EGR control zone, the judgment is NO in Step 102. In this case, in Step 103, the electromagnetic valve 9 is off and open which makes the EGR not introduced, and, in Step 104, a judgment is made whether the running condition of the engine falls in a failure determining zone. The failure determining zone is limited to the case of a condition of an engine when the engine runs in steady state as in running on a highway, and when an accelerator pedal is lightly pushed and the opening of the throttle valve 4 is small. The reason is because the variation of the pressure in the suction pipe 3 is considerably varied when the internal combustion engine is not in steady state, and because, when the engine is under heavy load, the pressure difference in the suction pipe 3, between the case where the EGR operates and in the case of non-operation of the EGR is difficult to be determined. In Step 104, when the running condition of the engine does not fall in the failure determining zone, the judgment is NO, and the operation goes to Step 111. When the running condition of the engine falls in the failure determining zone, the judgment is YES, the operation goes to Step 105, and the control device reads the pressure of the suction pipe 3 P OFF which is the pressure when the EGR is not in operation.
On the other hand, in Step 102, when the running condition of an engine falls in the EGR control zone, in Step 106, the electromagnetic valve 9 is on and closed whereby the introduction of the EGR is possible, and in Step 107, a judgment is made whether the running condition of the engine falls in the failure determining zone, the definition of which is the same as explained in Step 104. In Step 107, when the running condition of the engine does not fall in the failure determining zone, the judgment is NO, and the operation goes to Step 111. When the running condition of the engine falls in the failure determining zone, the judgment is YES, and the operation goes to Step 108 wherein the control device reads the pressure of the suction pipe 3 P ON which is the pressure when the EGR is in operation. In Step 109, the difference between the suction pipe pressure when the EGR is in operation and that when the EGR is not in operation, P ON -P OFF , both of which are in the failure determining zone, is calculated. When the EGR is in operation, exhaust gas is introduced into the suction pipe 3. Therefore, when the engine runs in the same condition, the pressure of the suction pipe 3 is increased compared with that when the EGR is not in operation and approaches to the atmospheric pressure. Accordingly, when the EGR is in normal operation, the following relationship is established:
P.sub.on -P.sub.OFF >ΔP
where ΔP is a failure criteria which is experimentally given, and which is below the value of P on -P OFF .
In Step 109, when the operation is judged as normal, that is, when the relationship of P on -P OFF >ΔP is established, the judgment is YES, and the operation goes to Step 111. In Step 109, when the running condition of the engine is determined to fall in the failure determining zone, that is, when the relationship of P on -P OFF >ΔP is established, the judgment is NO, and the EGR control device is regarded as in a failure state, and the operation goes to Step 110. In Step 110, a failsafe treatment of the EGR, that is, a fail-safe treatment of EGR such as a generation of warning etc., is carried out and the operation goes to Step 111. In Step 111, the other treatments such as a calculation treatment for fuel injection and the control of fuel injection and so on, are carried out.
In this embodiment, explanation is given to the operation for an example wherein the failure determining zone is set as single threshold. However, this failure determining zone can be divided into a plurality of subzones with which the values of the differences of the suction pressures correspond.
As for the fault detection of the EGR control device in this embodiment, explanation is given for the system wherein the suction air quantity of the internal combustion engine is detected by the suction pipe pressure and the fuel injection is carried out according to the detected value. However, this failure detecting system is applicable to another system wherein the suction pipe pressure sensor is added to a detection system in which the suction air quantity is detected by an air-flow sensor.
As explained above, this invention discovers the fact wherein the suction pipe pressure when the EGR control valve is in operation, is higher than that when the EGR control valve is not in operation, and approaches to the atmospheric pressure, and carries out the detection of the failure of the EGR control device by the difference between the suction pipe pressure when the EGR control valve is operated and that when the EGR control valve is not operated. Therefore, in this invention, special parts are not necessary to be added, which enables the detection of the failure at a low expense, and an accurate detection of the failure can be carried out, since the detection of failure is done in the failure determining zone when an internal combustion engine is under light load state and in steady state.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An electronic control apparatus for an internal combustion engine which comprises a control device for exhaust gas return having a control valve for exhaust gas return so that a part of exhaust gas returns from an exhaust gas passage to a suction gas passage, a pressure sensor for detecting pressure in a suction gas pipe, and a failure detecting means for detecting failure of said control device for exhaust gas return based on a value of pressure in said suction gas pipe when said control value for exhaust gas return is in operation, and a second value of pressure in the exhaust gas pipe when the control valve of exhaust gas return is not in operation.
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FIELD OF INVENTION
The present invention relates to an improved process for preparation of 2-phenyl ethanol. More specifically, the present invention relates to a process for preparing 2-phenyl ethanol by catalytic transfer hydrogenation of styrene oxide, in the presence of a supported transition metal catalyst. The catalyst system comprises of a palladium supported on silica, alumina, clay or charcoal.
BACKGROUND OF THE INVENTION
2-phenyl ethanol (PEA) has a variety of industrial applications. PEA is a colourless liquid possessing a faint but lasting odour of rose petals. Due to this property, 2-phenyl ethanol is important as a fragrance chemical and it is being used in perfumes, deodorants, etc. PEA also has bacteriostatic and antifungicidal properties and is therefore used in the preparation of antiseptic creams and deodorants. PEA is also extensively used in formulation of cosmetics such as hair shampoos and hair dyes to improve texture and quality of hair. 2-phenyl ethanol finds a number of important applications in the manufacture of chemicals such as styrene, phenyl ethyl ester, phenyl acetaldehyde, phenyl acetic acid, benzoic acid, bis-phenyl ether, etc. As it contains an aromatic ring, 2-phenyl ethanol can be nitrated, sulphonated, or chlorinated to give various substituted industrially important compounds.
Several methods for preparing this compound have been described in the literature. The conventional synthetic methods for 2-phenyl ethanol involves Grignard synthesis in which chlorobenzene is converted to phenyl magnesium chloride which reacts with ethylene oxide at 100° C. to give phenyl ethoxy magnesium chloride which is then decomposed with sulphuric acid to give 2-phenyl ethanol. The drawback of this process is the use of hazardous diethyl ether as a solvent. Also, the preparation of phenyl magnesium chloride in situ is very difficult. However, the main problem of this process is the poor quality of the 2-phenyl ethanol, which is not acceptable for perfumery applications. Biphenyl along with rearranged products as the major side products are difficult to separate from 2-phenyl ethanol even by vacuum distillation [Ernet T. Theimer in Fragrance Chemistry, page 271, Academic Press New York (1982)].
Another conventional method for the preparation of 2-phenyl ethanol involves low temperature Friedel Craft alkylation of benzene with ethylene oxide, in the presence of anhydrous AlCl 3 . This process is operated below 25° C. and thus the molar ratios of the reactants are extremely critical and hence very difficult to maintain these parameters. At a slightly higher temperature, coupling takes place forming a dibenzyl compound. In addition, this process is not an eco-friendly process due to the use of AlCl 3 as a reagent [Richard Wilson in Kirk Othmer's Encyclopedia of Chemical Technology Vol. 4, page 116, John Wiley & Sons, New York (1991)], which finally ends up in accumulation of inorganic salts posing environmental problems.
2-phenyl ethanol is also prepared by reduction of styrene oxide using different reducing agents like LiAlH 4 , LiAlH 4 /AlCl 3 , B 2 H 6 , LiInH 4 , NaBH 4 , and LiBHEt 3 . The use of these reagents leads to the formation of a mixture of primary and secondary alcohols. Reduction of styrene oxide with lithium indium hydride has been reported to give only 33% of 2-phenyl ethanol [Koji Tanaka et al., Tetrahedron letters 36(18), 3169 (1995)].
Catalytic hydrogenation of styrene oxide using both homogeneous and heterogeneous catalysts under hydrogen pressure also has been reported. U.S. Pat. No. 2,822,403 reported catalytic hydrogenation of styrene oxide in the presence of water. Use of emulsifying or dispersing agents was recommended to achieve the required yield. In this process the catalyst used was a combination of Raney nickel and other hydrogenating catalysts like cobalt, platinum and palladium. Similarly, British Patent 760768 and U.S. Pat. No. 3,579,593 describe a process for catalytic hydrogenation of a suspension of styrene oxide in water in presence of combination of Raney nickel and palladium. These processes have several disadvantages like expensive and time consuming distillation, which is required to remove the large amounts of water. Solvent extraction and salting out procedure are rendered difficult due to the presence of emulsifying agents. The greatest disadvantage of the process is the formation of large quantities of ethyl benzene, which destroys the aroma of PEA. In U.S. Pat. No. DE 3,239,611, PEA selectivity was as high as 97% by a two step hydrogenation of styrene oxide and using a combination of acetic acid and triethyl amine as a promoter system.
Catalytic hydrogenation of styrene oxide using hydrogen gas under pressure has been studied previously [U.S. Pat. No. 4,064,186, British Patent 1492257, British Patent 760768]. Recently, almost complete selectivity to PEA has been reported in catalytic hydrogenation of styrene oxide under H 2 pressure using palladium supported on carbon in presence of a promoter (NaOH) by Chaudhari et al. [U.S. Pat. No. 6,166,269]. For all these catalytic hydrogenation processes, gaseous hydrogen under pressure is used and an additive is needed to avoid formation of side products. Use of hydrogen under pressure may pose a serious risk of fire or explosion as well as the process is always accompanied with the formation of byproducts. Also, this process requires special high-pressure reactors and is quite uneconomical for laboratory preparations.
The reduction process, in which an organic molecule is used as the hydrogen donor in the presence of a catalyst, is known as catalytic transfer hydrogenation. Compounds like ammonium formate, an aqueous alkaline sodium formate is well known hydrogen donors. Dragovich et al. (J. Org. Chem., 60, 4922, 1995) have reported the use of 10% Pd on activated carbon as a catalyst in the transfer hydrogenation of styrene oxide to 2-phenyl ethanol by ammonium formate and ethanol in which complete reduction of styrene oxide was achieved but with only 58% selectivity to 2-phenyl ethanol. Also, loading of a noble metal (Pd) is.very high, giving TON (turn over number) in the range of 20–80. Iyer et al. (Synth. Comm. 25(15), 2267, 1995) have also studied the transfer hydrogenation of styrene oxide to phenyl ethanol over 5% Pd/C catalyst with methanol and ammonium formate giving TON of 213. Due to the use of methanol as solvent, formation of a by product 1-methoxy ethyl benzene is very likely.
From the above literature, it is clear that there is a scope to have catalytic transfer hydrogenation process for styrene oxide to PEA, to achieve higher selectivity to PEA with higher TON. It is well known that the performance of the heterogeneous catalyst depends on the support used. In all the above-mentioned work on transfer hydrogenation by heterogeneous catalysts, the support used is carbon. In such catalysts, the quality of carbon is very critical in achieving the best activity and selectivity. The properties of carbon depend on the source of carbon and treatment of carbon. Therefore, it is desirable to have a support other than carbon for which the preparation method is standardized leading to higher and consistent activity and selectivity.
The clay support in particular does not need any pretreatment unlike carbon. Also, in the present case, an epoxide is a very reactive species and can undergo various reactions other than hydrogenation to give various side products. Hence, the clay was chosen with certain acidic character in such a way that it would influence the regio selective opening of an epoxide ring to give highest selectivity to 2-phenyl ethanol without using any other additives.
OBJECTS OF THE INVENTION
The main object of the present invention is to provide a process for the selective preparation of 2-phenyl ethanol, which avoids the use of hazardous chemicals like ethylene oxide, aluminium chloride, gaseous hydrogen under pressure etc.
Another object of the present invention is to provide a process using supported catalysts, which could be easily separated from the reaction mixture.
Another object of the present invention is to provide a process with clay as a support for the catalyst which gives almost total selectivity for the desired product, 2-phenyl ethanol.
It is another object of the invention to provide an environmentally friendly process for the preparation of 12-phenyl ethanol.
It is another object of the invention to provide a process for the preparation of PEA which uses a catalyst support with uniform chemical composition prepared by a standard method and then used for the preparation of the hydrogenation catalyst to give high activity and selectivity to the desired product.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a process for the preparation of 2-phenyl ethanol comprising subjecting a solution of styrene oxide in an organic solvent to catalytic transfer hydrogenation under stirring conditions, over a heterogeneous transition metal catalyst and in the presence of a hydrogen donor, terminating the reaction, separating the catalyst and the 2-phenyl ethanol.
In one embodiment of the invention, the heterogeneous transition metal catalyst contains a metal from platinum group such as platinum, palladium and nickel and a support.
In another embodiment, the concentration of the metal in the catalyst is in the range of 0.02–5.0% (w/w).
In another embodiment catalyst to styrene oxide ratio is in the range of 1:100 to 1:4000.
In another embodiment, support for catalyst is selected from the group consisting of clay, charcoal, silica and alumina.
In yet another embodiments, the support for the catalyst is a saponite clay of the formula [Na + (x) {M 2+ (6) }{Si (8-x) Al (x) }O 20 (OH) 4 ] wherein M is magnesium or zinc, x is in the range of 0.2 to 2.0.
In another embodiment, the organic solvent used for preparing the solution of styrene oxide comprises an aliphatic alcohol selected from the group consisting of methanol, ethanol and isopropyl alcohol.
In another embodiment the hydrogen donor compound is selected from the group consisting of aliphatic alcohol, alkali metal and amine esters of fatty acids exemplified by sodium acetate, ammonium formate, sodium formate and potassium formate preferably ammonium formate and sodium formate.
In another embodiment of the invention, the conversion of styrene oxide is complete and the selectivity to 2-phenyl ethanol is ≧99.9% with high TON at milder reaction conditions and also avoiding the use of molecular hydrogen, hazardous material such as diethyl ether, ethylene oxide, and AlCl 3 of the conventional process.
In still another embodiment of the invention, the reaction time varies depending on the concentration of the metal in the catalyst and is in the range of 1 to 12 hours.
In another embodiment of the invention, the reaction is carried out at a temperature in the range of 30–80° C. for 1–12 hours.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a single step process for preparation of 2-phenyl ethanol [CAS 60-12-8] by catalytic transfer hydrogenation of styrene oxide [CAS 96-09-3] with a transition metal catalyst such as a palladium catalyst supported on clay in presence of a hydrogen donor and a solvent. The reaction is carried out in a temperature range of 30-80° C. under stirring conditions. After completion of the reaction, the reaction mixture is cooled to room temperature, and the catalyst is separated from the product by conventional methods like filtration. Products were analyzed using gas chromatography and also identified by gas chromatograph-mass spectroscopy (GCMS). This method is particularly useful as an alternative to the conventional methods like Grignard synthesis, Friedel-Craft alkylation and also for molecular hydrogen for preparation of 2-phenyl ethanol. This invention eliminates the handling of dangerous hydrogen gas, hazardous diethyl ether solvent, ethylene oxide and the use of AlCl 3 , which poses serious effluent problems. The invention produces 2-phenyl ethanol selectively via catalytic transfer hydrogenation of styrene oxide using clay supported palladium catalyst.
The present invention provides an improved process for the selective preparation of 2-phenyl ethanol, which avoids the use of hazardous chemicals like ethylene oxide, aluminium chloride, gaseous hydrogen under pressure etc. The catalyst used comprises a supported catalyst which is easily separable from the reaction mixture. The support for the catalyst is preferably clay and the selectivity for the desired product, 2-phenyl ethanol is almost total.
The catalyst used in the invention which comprises palladium supported on clay does not generate any problems relating to the environment, such as heavy metal, when being used to hydrogenate styrene oxide to 2-phenyl ethanol. The catalyst has a uniform chemical composition prepared by a standard method and then used for the preparation of the hydrogenation catalyst to give high activity and selectivity to the desired product.
The process of the present invention also avoids the use of hydrogen under pressure, hazardous material such as diethyl ether, ethylene oxide, and AlCl 3 , of the conventional process. The present process gives complete conversion of styrene oxide with >99.9% selectivity to 2-phenyl ethanol at milder reaction conditions. The present process achieves a very high selectivity to 2-phenyl ethanol, and it requires merely the filtration of catalyst and distillation of 2-phenyl ethanol of the perfumery grade purity. The conversion and selectivity to PEA was found to be dependent on the supports used for the preparation of the catalysts. PEA selectivity was >99.9% for only clay as a support and for other supports it varied between 40-80% while conversion also varied from 60 to 99.9% depending on support used.
The present invention comprises catalytic transfer hydrogenation of styrene oxide in an organic solvent under stirring conditions, over a supported palladium metal catalyst in presence of a hydrogen donor, preferably at a temperature range of 30–80° C. for 1–12 hours. The catalyst is separated by any conventional method and the product 2-phenyl ethanol separated by distillation.
The heterogeneous catalyst contains a metal from platinum group such as platinum, palladium and nickel and a support. The concentration of the metal in the catalyst is preferably in the range of 0.02–5.0% (w/w) and the catalyst to styrene oxide ratio can be in the range of 1:100 to 1:4000. The support for the catalyst is a saponite clay of the formula, [Na + (x) {M 2+ (6) }{Si (8-x) Al (x) }O 20 (OH) 4 ] wherein M can be either magnesium or zinc, x is preferably in the range of 0.2 to 2.0.
The organic solvents used for preparing the solution of styrene oxide are aliphatic alcohols selected from the group containing methanol, isopropyl alcohol or higher alcohols. The hydrogen donor compound are preferably selected from aliphatic alcohols, alkali metal or amine esters of fatty acids exemplified by sodium acetate, ammonium formate, sodium formate and potassium formate preferably ammonium formate and sodium formate.
In a feature of the present process a complete conversion and almost complete selectivity (≧99.9%) to 2-phenyl ethanol is obtained with high TON at milder reaction conditions and also avoids the use of molecular hydrogen, hazardous material such as diethyl ether, ethylene oxide, and AlCl 3 of the conventional process. In still another feature the reaction time may vary depending on the concentration of the metal in the catalyst and may be in the range of 1 to 12 hours.
The following examples describe specific illustrative embodiments of the present invention, and should not be construed to limit the scope of the invention in any manner.
EXAMPLE 1
This example demonstrates synthesis of saponite type clay support for the metal catalyst. For synthesis of saponite type clay, slurry of sodium silicate (17.962 gm), aluminium nitrate (3.127 gm) and sodium hydroxide (0.391 gm) was made in de-ionized water and stirred for half an hour at 90° C. After being mixed homogeneously, magnesium nitrate (15.827 gm) and urea (15.015 gm) were added. Whole mixture was stirred for 12 hrs. The mixture was cooled, filtered and washed with distilled water and kept over night in aluminium nitrate solution and then again filtered, washed with distilled water and kept for drying for 10 hrs.
EXAMPLE 2
This example demonstrates preparation of catalysts used in transfer hydrogenation of styrene oxide to 2-phenyl ethanol process. For the preparation of 0.5% Pd on clay, a solution of anhydrous palladium chloride (0.04166 gm) in HCl (1N, 10 ml) was obtained by warming for two hrs. This was added drop wise to a stirred hot (80° C.) suspension of clay (4.975 gm) in water (55 ml) and stirred for 5-6 hrs until the supernatant solution becomes colourless. Formaldehyde (4 ml) was added followed by 10% NaOH solution sufficient to make the suspension strongly alkaline and kept under stirring for 2-3 hrs. The catalyst was filtered, washed with distilled water (until the pH became neutral) and dried in an oven at 110° C.
EXAMPLE 3
This example illustrates the effect of concentration of Pd, which is supported on clay for the conversion of styrene oxide to 2-phenyl ethanol. In a typical experiment, styrene oxide 1.2015 gm (10 mmol), isopropyl alcohol 19.771 gm, ammonium formatel 891 gm (30 mmol), Pd on clay 0.200 gm catalyst were charged in a 50 ml two neck round bottom flask. The reaction mixture was stirred at 65° C. After the reaction was complete, the round bottom flak was cooled below ambient temperature and content were discharged. The reaction mixture was filtered and the resulting filtrate was analyzed by gas chromatography and confirmed by GCMS GCIR. The results are given in Table 1.
TABLE 1
Pd concn. on
Reaction
%
% Selectivity
Sr. No.
support (%)
time (hrs)
Conversion
to PEA
TON
1
0.2
8
99.7
>99.9
2608.9
2
0.5
4.00
100
>99.9
1073.3
3
1
2.25
100
>99.9
485.8
4
2
1.50
100
>99.9
265.4
EXAMPLE 4
This example illustrates the effect of temperature, for the conversion of styrene oxide to 2-phenyl ethanol. In typical experiment, styrene oxide 1.2015 gm (10 mmol), isopropyl alcohol 19.771 gm, ammonium formatel.891 gm (30 mmol), 0.5% Pd on clay catalyst 0.200 gm were charged in a 50 ml two neck round bottom flask. The reaction mixture was stirred at different temperatures. After the reaction was complete, the round bottom flak was cooled below ambient temperature and content were discharged. The reaction mixture was filtered and the resulting filtrate was analyzed by gas chromatography and confirmed by GCMS GCIR. The results are given Table 2.
TABLE 2
Reaction
temperature
Reaction
% Selectivity
Sr. No.
(° C.)
time (hrs)
% Conversion
to PEA
1
65
4
100
>99.9
2
55
8
93.75
>99.9
3
40
8
61.20
>99.9
EXAMPLE 5
This example illustrates the effect of solvent for the conversion of styrene oxide to 2-phenyl ethanol. In typical experiment, styrene oxide 1.2015 gm (10 mmol), solvent 19.771 gm, ammonium formate 1.891 gm (30 mmol), Pd on clay catalyst 0.200 gm were charged in a 50 ml two neck round bottom flask. The reaction mixture was stirred at 65° C. After the reaction was complete, the round bottom flak was cooled below ambient temperature and content were discharged. The reaction mixture was filtered and the resulting filtrate was analyzed by gas chromatography and confirmed by GCMS GCIR. The results are given in Table 3. The major side product was obtained in case of entry No. 1, 1-hydroxy 2-methoxy and in case of entry No.2, 1-hydroxy 2-ethoxy ethyl benzene.
TABLE 3
Reaction
% Selectivity
Sr. No.
Solvent
time (hrs)
% Conversion
to PEA
1
Methanol
6
100
91.8
2
Ethanol
8
51.66
65.0
3
Isopropyl
4
100
≧99.9
alcohol
EXAMPLE 6
This example illustrates the use of Pd/clay and the use of sodium formate, for the conversion of styrene oxide to 2-phenyl ethanol. In typical experiment, styrene oxide 1.201 gm (10 mmol), isopropyl alcohol 19.398 gm, sodium formate 2.040 gm (30 mmol), 0.5% Pd on clay catalyst 0.200 gm were charged in a 50 ml two neck round bottom flask. The reaction mixture was stirred at 65° C. for 8 hrs. After the reaction was complete, the round bottom flak was cooled below ambient temperature and content were discharged. The reaction mixture was filtered and the resulting filtrate was analyzed by gas chromatography and confirmed by GCMS GCIR. The GC analysis of reaction mixture showed 51.7% conversion of styrene oxide while the selectivity of 2-phenyl ethanol obtained was 50.1%. 1-hydroxy 2-isopropoxide ethyl benzene was obtained as a side product.
The Advantages of the Present Invention are
i) This process gives complete selectivity to 2-phenyl ethanol.
ii) Turn over number (TON) for this process is very high (1073).
iii) The process is very convenient to operate since; it does not involve hydrogen gas under pressure.
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The present invention provides an improved process for preparation of 2-phenyl ethanol. More specifically, the present invention relates to a process for preparing 2-phenyl ethanol by catalytic transfer hydrogenation of styrene oxide, in the presence of a supported transition metal catalyst. The catalyst system comprises of a palladium supported on silica, alumina, clay or charcoal.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority to and hereby incorporates by reference in its entirety U.S. Provisional Patent Application Ser. No. 61/811,521 entitled “Metal ornamental piece that makes a clean transition from door casing to floor, Casing Plate” filed on Apr. 12, 2013.
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates generally to interior trim work in buildings. More particularly, this invention pertains to trimming door casings, jambs and stops.
Various flooring materials have different thicknesses. For example, hardwood flooring has a thickness of about ¾″, vinyl flooring has a thickness of about ⅛″, laminate flooring has a thickness of about ½″, and tile has an overall thickness of about ½″ (i.e., raises the walking surface approximately ½″ above the top of the subfloor). When trimming hardwood, vinyl, laminate, or tile along a wall, a baseboard is laid along the wall above the walking surface of the flooring material (approximately 1″ above the subfloor), and quarter round is put down to close the gap between the bottom of the baseboard and the walking surface of the flooring material.
Carpet has an actual thickness of about ⅜″, but can fill gaps up to 1″ under baseboards and other trim work. Carpet is typically not trimmed with quarter round because the carpet covers the bottom edge of the baseboard and door trim (i.e., door casing, jamb, and/or door stop) along the edges of the room. One popular renovation is to change common areas of residential dwellings from carpet to hardwood or tile. In areas with baseboard, the addition of quarter round covers the gap between the bottom edge of the baseboard and the walking surface of the new flooring material. However, around door trim (i.e., door casing, jamb, and/or stop), a gap of about ¼″ to ½″ exists between the bottom of the door trim the walking surface (i.e., top) of the new flooring material. Caulk cannot be used to fill a gap this large, and replacing the door casing with one that extends from the top of the door opening to the walking surface of the flooring material involves removing all of the current door trim (i.e., casing, jamb, and stop if any) and hanging a new door with trim. Installing a new door and trim to achieve an extension of the door trim down to the walking surface of the flooring material is cost prohibitive. This same situation arises when there is a change order regarding the flooring material during construction or a door casing is simply cut too short during installation. Further, the situation is compounded when the gap may be uneven because the flooring material changes at the doorway. That is, new hardwood replacing carpet that previously met hardwood in the doorway typically has a wider gap than on the side of the doorway with the preexisting hardwood because the door trim was cut to fit hardwood on one side and carpet on the other when the doorway and flooring were originally installed.
BRIEF SUMMARY OF THE INVENTION
Aspects of the present invention provide a door trim floor gap cover system including a trim piece operable to cover a gap between a bottom edge of door trim and a walking surface of a flooring material under the door trim (i.e., casing, jamb, and optional door stop). The trim piece may be one piece that bends about the door trim. The trim piece may be a resilient material that deforms while being positioned and is biased toward its original shape to hold onto the door casing. The trim piece may be more than one piece wherein a first portion is positioned on the casing and jamb and the second portion is then interlocked with the first portion to complete the trim piece, covering the floor gap. Each of a pair of hooks extends behind the casing to engage a distal face of the casing, retaining the system against the door trim (casing and jamb).
In one aspect, a. door trim floor gap cover system is configured to cover a gap between a bottom of a door trim and a walking surface of a flooring material under the door trim when installed on the door trim. The system includes a center portion, a first longitudinal portion, a second longitudinal portion, a first hook, and a second hook. The center portion extends laterally and is configured to extend along an outer face of a jamb of the door trim. The first longitudinal portion extends generally longitudinally from a first end of the center portion and is configured to extend along an outer face of a first casing of the door trim. The second longitudinal portion extends generally longitudinally from a second end of the center portion and is configured to extend along an outer face of a second casing of the door trim. The first hook extends longitudinally beyond the first longitudinal portion and generally inward toward the second longitudinal portion such that the first hook engages a distal face of the first casing when the system is installed on the door trim. The second hook extends longitudinally beyond the second longitudinal portion and generally inward toward the first longitudinal portion such that the second hook engages a distal face of the second casing when the system is installed on the door trim.
In another aspect, a method of installing a door trim floor gap cover system on a door trim to cover a gap between a bottom of the door trim and a walking surface of a flooring material under the door trim includes positioning an inner face of a first interlocking section of a center portion of the system against an outer face of a jamb of the door trim such that an inner face of a first longitudinal portion of the system contacts an outer face of a first casing of the door trim, a bottom of the first interlocking section contacts the walking surface of the flooring material, and a first hook of the system engages a distal face of the first casing. The first interlocking section of the center portion has a recess or protrusion adjacent a lateral edge of the first interlocking section. The center portion extends laterally when the system is installed on the door trim. The first longitudinal portion extends generally longitudinally from a first end of the center portion when the system is installed on the door trim and is configured to extend along the outer face of the first casing of the door trim when the system is installed on the door trim. The first hook extends longitudinally beyond the first longitudinal portion and generally toward a second longitudinal portion of the system when the system is installed on the door trim. The method continues with positioning an inner face of a second interlocking section of the center portion of the system against the outer face of the jamb of the door trim such that an inner face of the second longitudinal portion of the system contacts an outer face of a second casing of the door trim, a second hook of the system engages a distal face of the second casing, and the second interlocking section is not in contact with the walking surface of the flooring material. The second interlocking section of the center portion has a recess or protrusion adjacent a lateral edge of the second interlocking section and the recess or protrusion of the second interlocking section is substantially complementary to the recess or protrusion of the first interlocking section. The second longitudinal portion extends generally longitudinally from a second end of the center portion when the system is installed on the door trim and is configured to extend along the outer face of the second casing of the door trim when the system is installed on the door trim. The second hook extends generally longitudinally beyond the first longitudinal portion and generally toward the first longitudinal portion of the system when the system is installed on the door trim. The second interlocking section is then lowered to the walking surface of the flooring material such that the recess or protrusion of the first interlocking section interlocks with the complementary recess or protrusion of the second interlocking section.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an isometric view of a system for covering a door trim floor gap.
FIG. 2 is a top plan view of the system of FIG. 1 wherein the system is separated into two pieces at an interlocking joint of the system.
FIG. 3 is a top plan view of the system of FIGS. 1 and 2 wherein the system the interlocking joint is assembled.
FIG. 4 is a cutaway isometric view of a doorway showing door trim components.
FIG. 5 is an isometric view of a door trim with a door stop cut during installation of the door trim floor gap system.
FIG. 6 is an elevated perspective view of a door trim and door trim floor gap system during installation.
FIG. 7 is an isometric view of a door trim and door trim floor gap system being caulked.
FIG. 8 is a top plan view of a malleable door trim floor gap system.
Reference will now be made in detail to optional embodiments of the invention, examples of which are illustrated in accompanying drawings. Whenever possible, the same reference numbers are used in the drawing and in the description referring to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
To facilitate the understanding of the embodiments described herein, a number of terms are defined below. The terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but rather include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as set forth in the claims.
As described herein, an upright position is considered to be the position of apparatus components while in proper operation or in a natural resting position as described herein. Vertical, horizontal, above, below, side, top, bottom and other orientation terms are described with respect to this upright position during operation or use unless otherwise specified. The term “when” is used to specify orientation for relative positions of components, not as a temporal limitation of the claims or apparatus described and claimed herein unless otherwise specified. The terms “above”, “below”, “over”, and “under” mean “having an elevation or vertical height greater or lesser than” and are not intended to imply that one object or component is directly over or under another object or component.
The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may. Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.
Referring to FIGS. 1-5 , a door trim floor gap cover system 100 is configured to cover a gap 102 (see FIG. 5 ) between a bottom 104 of a door trim 300 and a walking surface 106 of a flooring material under the door trim 300 . The door trim 300 includes a first casing 302 , a second casing 304 , and a jamb 306 . Optionally, the door trim 300 may also include a doorstop 308 . The first casing 302 has a proximal face 310 , a distal face 312 , and an outer face 314 having a profile. The jamb 306 has a first lateral end 316 , a second lateral end 318 , and an outer face 320 . The second casing 304 is a proximal face 322 , a distal face 324 , and an outer face 326 having a profile.
The system 100 includes a center portion 400 , a first longitudinal portion 402 , a second longitudinal portion 404 , a first hook 406 , and a second hook 408 . The center portion 400 extends laterally and is configured to extend along the outer face 320 of the jamb 306 . The first longitudinal portion 402 extends generally longitudinally from a first end 410 of the center portion 400 and is configured to extend along the outer face 314 of the first casing 302 . The second longitudinal portion 404 extends generally longitudinally from a second end 412 of the center portion 300 opposite the first end 410 of the center portion 400 and is configured to extend along the outer face 326 of the second casing 304 . The first hook 406 extends longitudinally beyond the first longitudinal portion 402 and generally inward toward the second longitudinal portion 404 (e.g., toward the second hook 408 ) such that the first hook 406 engages the distal face 312 of the first casing 302 when the system 100 is installed on the door trim 300 . The second hook 408 extends longitudinally beyond the second longitudinal portion 404 and generally inward toward the first longitudinal portion 402 (e.g., toward the first hook 406 ) such that the second hook 408 engages the distal face 324 of the second casing 304 when the system 100 is installed on the door trim 300 . In one embodiment, the first hook 406 and second hook 408 cooperate to at least partially hold an inner face 502 of the center portion 400 against the outer face 320 of the jamb 306 . In another embodiment, the inner face 502 of the center portion 400 is maintained at a relatively small distance (e.g., less than ⅛″) from the outer face 320 of the jamb 306 . As described herein, the latitudinal and longitudinal directions are substantially horizontal and parallel with the floor walking surface 106 when the system 100 is installed on the door trim 300 . The vertical direction is perpendicular to the latitudinal and longitudinal directions. In one embodiment, the center portion 400 has a longitudinal depth of approximately ⅜″. In one embodiment, the center portion 400 has a vertical height of approximately ⅝″. In one embodiment, the first longitudinal portion 402 is integral with the center portion 400 , and the second longitudinal portion 404 is integral with the center portion 400 . In one embodiment, the first hook 406 is integral with the first longitudinal portion 402 , and the second hook 408 is integral with the second longitudinal portion 404 .
In one embodiment, the center portion 400 of the system 100 includes 2 interlocking sections. Each interlocking section has a lateral edge where the 2 interlocking sections interlock with one another. The lateral edges of the 2 interlocking sections may be offset from a center of the center portion 400 by at least ¾″. In one embodiment, the center portion 400 includes a first interlocking section 602 and a second interlocking section 604 . The first interlocking section 602 has a recess 606 extending vertically through the first interlocking section 602 adjacent a lateral edge 608 of the first interlocking section 602 . The second interlocking section 604 has a protrusion 610 extending vertically across the second interlocking section 604 from a lateral edge 612 of the second interlocking section 604 . The protrusion 610 is generally complementary to the recess 606 such that the recess 606 is operable to receive the protrusion 610 , and the lateral edge 608 of the first interlocking section 602 and the lateral edge 612 of the second interlocking section 604 engage one another. In one embodiment, the recess 606 and the protrusion 610 are substantially cylindrical. In another embodiment, the recess 606 and the protrusion 610 have a substantially triangular cross-section. It is contemplated that the interlocking joint formed by the recess 606 and protrusion 610 may be in either the first longitudinal portion 402 or second longitudinal portion 404 . It is also contemplated that the recess 606 may be formed in the second interlocking section 604 while the protrusion 610 is formed on the first interlocking portion 602 within the scope of the claims.
Walls are typically made with either 2×4 construction or 2×6 construction. To adapt a system 100 designed for a 2×4 wall to a 2×6 wall, the center portion 400 may include an extension. The extension has vertical height and longitudinal depth equal to a vertical height and longitudinal depth of the rest of the center portion 400 . The extension has a first end having an adjacent recess, and a second end having an adjacent protrusion. The recess of the extension corresponds to the recess 606 of the first interlocking section 602 , and the protrusion of the extension corresponds to the protrusion 610 of the second interlocking section 604 . In one embodiment, the extension is approximately 2 inches from the first end to the second end.
In one embodiment, the outer face 314 of the first casing 302 of the door trim 300 has a profile, and the first longitudinal portion 402 has an inner face 702 with a profile generally complementary to the profile of the outer face 314 of the first casing 302 . In one embodiment, the first longitudinal portion 402 has an outer face 706 having a profile generally matching the profile of the outer face 314 of the first casing 302 . In one embodiment, the outer face 326 of the second casing 304 of the door trim 300 has a profile, and the second longitudinal portion 404 has an inner face 704 with a profile generally complementary to the profile of the outer face 326 of the second casing 304 of the door trim 300 . In one embodiment, the second longitudinal portion 404 has an outer face 708 having a profile generally matching the profile of the outer face 326 of the second casing 304 .
In one embodiment, the system 100 further includes a first filler section 720 , and a second filler section 722 . The first filler section 720 is located where the first longitudinal portion 402 meets the center portion 400 . First filler section 720 is configured to a butt a first lateral face 740 of the jamb 306 and the proximal face 310 of the first casing 302 of the door trim 300 . The second filler section 722 is located where the second longitudinal portion 404 meets the center portion 400 , and the second filler section 722 is configured to a butt a second lateral face 742 of the jamb 306 of the door trim 300 and the proximal face 322 of the second casing 304 of the door trim 300 .
Referring to FIGS. 5-7 , a method of installing the door trim floor cover system 100 on the door trim 300 to cover the gap 102 between the bottom 104 of the door trim 300 and the walking surface 106 of the flooring material under the door trim 300 includes positioning the inner face 702 of the first interlocking section 602 against the outer face 320 of the jamb 306 such that the inner face 702 of the first longitudinal portion 402 contacts the outer face 314 of the first casing 302 , a bottom of the first interlocking section 602 contacts the walking surface 106 of the foreign material, and the first book 406 engages the distal face 312 of the first casing 302 . An inner face 704 of the second interlocking section 604 is positioned against the outer face 320 of the jamb 306 of the door trim 300 such that the inner face 704 of the second longitudinal portion 404 contacts the outer face 326 of the second casing 304 , and the second interlocking section 604 is not in contact with the walking surface 106 of the foreign material (see FIG. 6 ). The second interlocking section 604 is been lowered to the walking surface 106 of the foreign material such that the recess 606 and protrusion 610 of the first and second interlocking sections 602 , 604 interlock with one another to retain the first hook 406 and second hook 408 in contact with the distal faces of the first and second casings 302 , 304 . If the door trim 300 includes the doorstop 308 , the method includes cutting off the doorstop 308 at a point approximately ⅝″ above the walking surface 106 of the foreign material under the door trim 300 (see FIG. 5 ). In one embodiment, completing installation of the system 100 on the door trim 300 includes caulking a seam 800 formed between the system 100 and the door trim 300 . The system 100 , door trim 300 , and caulk may all then be painted for consistency.
Referring to FIG. 8 , the system 100 is formed from a unitary section of malleable material in one embodiment. In this embodiment, the inner face 502 of the center portion 400 is placed against the outer face 320 of the jamb 306 for installation. The first and second longitudinal portions 402 , 404 are then bent toward one other (e.g., forced together via a C-clamp) and into contact with the first and second casings, respectively. Thus, the first and second hooks 406 , 408 engage the distal faces of the first and second casings, respectively. In this embodiment, the system 100 optionally includes bending points 900 at the junctions between first and second longitudinal portions 402 , 404 . The bending points 900 act as stress points that collapse when the first and second longitudinal portions 402 , 404 are forced together, preventing pending of the first and second longitudinal portions and ensuring a proper installation with the system 100 fitted to the door trim 300 .
In one embodiment, the system 100 is formed from a unitary section of resilient material. During installation, the first and second longitudinal portions 402 , 404 are temporarily pulled away from one another (i.e., spread apart) to enable the inner face 502 of the center portion 400 to be placed against the outer face 320 of the jamb 306 . When the first and second longitudinal portions 402 , 404 are released, the resilient material resumes its original shape, forcing the first and second hooks into contact with the distal faces of the first and second longitudinal portions, respectively.
This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
It will be understood that the particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention may be employed in various embodiments without departing from the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
All of the compositions and/or methods disclosed and claimed herein may be made and/or executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of the embodiments included herein, it will be apparent to those of ordinary skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims.
Thus, although there have been described particular embodiments of the present invention of a new and useful DOOR TRIM FLOOR GAP COVER SYSTEM it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
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A door trim floor gap cover system includes a trim piece operable to cover a gap between a bottom edge of door trim and a walking surface of a flooring material under the door trim (i.e., casing, jamb, and optional door stop). The trim piece may be one piece that bends about the door trim. The trim piece may be a resilient material that deforms while being positioned and is biased toward its original shape to hold onto the door casing. The trim piece may be more than one piece wherein a first portion is positioned on the casing and jamb and the second portion is then interlocked with the first portion to complete the trim piece, covering the floor gap. A pair of hooks extend behind the casing to engage a distal face of the casing, retaining the system against the door trim (casing and jamb).
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This application is a continuation of application Ser. No. 08/154,384, filed on Nov. 18, 1993, which was abandoned upon the filing hereof, which is a Continuation of application Ser. No. 07/895,011, filed on Jun. 8, 1992, now abandoned, which is a Continuation in Part of application Ser. No. 07/810,421, filed Dec. 20, 1991, now U.S. Pat. No. 5,249,104, which is a Continuation in Part of application Ser. No. 07/547,163, filed Jul. 3, 1990, now abandoned, which is a Continuation in Part of application Ser. No. 07/541,944, filed Jun. 22, 1990, now U.S. Pat. No. 5,057,974.
BACKGROUND OF THE INVENTION
a. Field of the invention
The present invention relates to a planar light emitting device or a planar illuminating device used for illuminating an advertisement, a signboard, a billboard, a guideboard, or the like. More particularly, the invention relates to a planar light emitting device having a uniform illumination over the entire light emitting device.
b. Description of the Related Art
Recent light emitting devices require a light emitting board having a thin thickness, and various kinds of illumination sources such as fluorescent lamps, light emitting diodes, incandescent lamps or the like are used to illuminate the light emitting devices. In many cases, the light sources are mounted on peripheral portions of the light emitting board. There is a strong need to illuminate the light emitting surface in a uniform manner. More specifically, light is introduced in a direction perpendicular to the light emitting surface from the peripheral portion of the light emitting board to thereby illuminate the light emitting surface. Since the light is introduced into the light emitting surface in a direction perpendicular to the light emitting surface from the peripheral portion of the light emitting board, it is very difficult to uniformly illuminate the light emitting surface due to the types of the light sources used for illumination and due to the number and the mounting position of the illumination tools.
The present inventor filed U.S. patent application Ser. No. 07/541,944 (now U.S. Pat. No. 5,057,974) to propose one countermeasure to this problem. According to the proposed method of that application, a reflecting member composed of a large number of reflecting units in the form of dots or lines with a density inversely proportional to a square of the distance as measured from each light source is provided under a lower surface of the light emitting surface, whereby the light reflected from the opposite surface is reflected by the reflecting units to uniformly illuminate the light emitting surface. The proposed method is suitable for a simple case where light sources for uniformly illuminating the object are used; however, there are still other difficulties involved in uniformly illuminating the object. In various cases, it is very difficult or sometimes impossible to provide dots or parallel lines with a density which is inversely proportional to the square of the distance from each light source due to the fact that the light sources are locally positioned at a peripheral portion of the light emitting surface and due to a deformed transparent substrate, the number, the type and the mounting position of the light sources. Also, even if the dots or parallel lines having a density inversely proportional to a square of the distance from the light sources are made, it sometimes would be impossible to illuminate the light emitting surface in a uniform fashion. For example, as shown in FIG. 3, when a linear, straight fluorescent lamp is provided on one side surface of the light emitting surface, the illumination of the central part of the fluorescent lamp is high, whereas the illumination of the end parts of the fluorescent lamp is low. Accordingly, it is difficult or impossible to illuminate the light emitting surface in a uniform fashion only by providing light reflecting surfaces composed of a large number of dots or lines having a distribution density inversely proportional to the square of the distance from each light source.
In order to solve this problem, the present inventor filed U.S. patent application Ser. No. 07/519,173 (now U.S. Pat. No. 5,138,782) and U.S. patent application Ser. no. 07/810,421. These applications are related to an improvement of the uniform illumination by providing a thin diffusion plate on the top surface of the light emitting surface. These methods would not be effective for the specific condition, since these methods still suffer from the problem that due to the shape of the light emitting surface of the light emitting device, the type and position of the light sources, or the irregularly reflected light from the reflection surface of the side walls of the light emitting device, a bright portion is generated in the light emitting surface even in a position remote from the light sources, whereas a dark portion is generated even at a position close to the light sources, resulting in the formation of illumination spots. Thus, even with the methods proposed in the applications, it would be difficult to obtain uniform illumination over the light emitting surface, and it would be safe to say that these methods would not bring about a satisfactory result.
SUMMARY OF THE INVENTION
In order to overcome these problems, according to the present invention there is provided a planar light emitting board characterized in that light emitting objects are prepared on the portion of the surface opposite the weak emitting portion of the board having a distribution density inversely proportional to the illuminance (intensity of the illumination) at each position of the light emitting surface of the board. Therefore, the board can have a uniform illumination of the light emitting surface by using light reflective objects drawn in opaque liquids (i.e., special inks or coating paints) having a high light reflectivity, or which are rough surfaces (i.e., having depressions of 0.01-2 mm) or many narrow and shallow grooves formed by using dies or other mechanical means, or small metal pieces or metallic film or the like having a high coefficient of reflectivity.
Therefore, a planar light emitting device according to the present invention comprises a light transmissive substrate made of transparent material with a predetermined exterior shape; light sources (i.e., fluorescent lamps, light emitting diodes or incandescent lamps) for introducing light into said light transmissive substrate; a light reflective layer provided around a periphery of the light transmissive substrate for preventing leakage of light; light reflective objects disposed on the surface opposite the light emitting surface of the substrate having a distribution density inversely proportional to the illuminance at each position of the rear surface of the substrate; and a light reflecting plate or sheet for covering rear surfaces of said light reflective objects.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a front view showing an illuminating device in accordance with an embodiment of the invention;
FIG. 2 is a longitudinal sectional view showing the device shown in FIG. 1;
FIG. 3 is a diagram showing an example of the division of the light emitting surface of the illuminating device shown in FIG. 1;
FIG. 4 is a view showing light reflective objects in the form of a plurality of lines on a back surface of the light emitting surface of the illuminating device shown in FIG. 1;
FIG. 5 is a view showing light reflecting objects in the form of a plurality of dots on a rear surface of the light emitting surface in accordance with another embodiment of the invention; and
FIG. 6 is a view showing light reflecting objects in the form of a plurality of dots on a back surface of the light emitting surface in accordance with still another embodiment of the invention.
FIG. 7 is a view showing an embodiment of the invention having a curved light transmissive substrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described by way of example with reference to the accompanying drawings.
FIGS. 1 to 4 show a first embodiment of the invention. In this embodiment, there is shown a desk-top type illuminating device having a rectangular light emitting surface. A substrate which is a main body having a light emitting surface is composed of a relatively thin plate which is made of transparent resin such as acrylic resin having high light transmissivity. A fluorescent lamp 6 is provided as a light source at a peripheral portion of the substrate 1 as shown in FIG. 2. Reflecting layers for blocking leakage of light and reflecting light into the substrate are provided around the periphery of the substrate except for a portion of the substrate where light is introduced from the light source. The reflecting layers may be formed of a frame member 5 for supporting and fixing the substrate 1, by applying an opaque coating having a high reflectivity onto the periphery of the substrate 1, or by attaching a metallic sheet such as aluminum having a high coefficient of reflectivity, and the reflecting layers can prevent leakage of the light from the substrate 1. It is preferable to apply a thin transparent sheet or plate 2 or a coating layer 2 made of transparent resin such as a fluororesin having a reflective index lower than that of the material of the substrate 1 on the emitting surface of the substrate 1 for keeping light in the substrate 1.
Light reflective objects 3 having a high coefficient of reflectivity are applied to a rear surface of the substrate opposite the light emitting surface for the purpose of adjusting a quantity of reflected light to make illumination of the light emitting surface uniform as described in detail later. A light reflecting plate 4 or light reflecting sheet 4 such as a white plastic sheet 4 covers a rear surface of the light reflective objects 3 for reflecting light in a direction perpendicular to the light emitting surface for emitting light from the light emitting surface.
Since the light transmissive substrate is thus formed, and even if no transparent sheet or plate 2 is applied on the emitting surface of the substrate 1, the light introduced from the side surface of the substrate 1 is advanced while reflecting obliquely with respect to the light emitting surface. As a result, the light is repeatedly reflected within the substrate 1 and advanced through the substrate, while the light perpendicular to the light emitting surface is only emitted from the light reflected by reflecting plate or sheet 4.
The light emitting surface of the substrate 1 was divided in a predetermined manner as shown in FIG. 3. The illumination at each section (i.e., A1, A2, . . . B1, B2 .... C1 .... ) was measured by means of a luminous meter. In view of the measurement results, in order to uniformly illuminate the light emitting surface, if an illumination at a certain position is low and it is necessary to increase the illumination at the position, the distribution density of the light reflective objects 3 which are in the form of a plurality of dots (i.e., small circles having a diameter of about 5 mm or less or small regular squares or the like) or a plurality of lines which are formed opposite the weak illumination position by a suitable method in which liquid having a high coefficient of reflectivity under dry conditions (i.e., a special ink or coating or the like) is applied, or a metallic sheet having a high coefficient of reflectivity is attached. Also, the objects may be substituted by rough surfaces with depressions having a depth of 0.01-2 mm or many narrow and shallow grooves formed by using a die or other mechanical means on the surface positions corresponding to the weak illumination positions. If the density of the light reflective objects is increased, the quantity of reflected light is increased so that the illumination of the light emitting surface corresponding to the position is increased to thereby keep illumination of the entire light emitting surface of the substrate 1 uniform.
In general, the illumination of the central portion of the fluorescent lamp is higher than that of the end portions thereof. Namely, the illumination gradient or distribution of the emitting surface is in the form of a mountain-like shape having a bottom at the light source 6, and the lowest illumination is at both side portions which are remote from the light source 6. Accordingly, if the light reflective objects 3 for keeping the illumination distribution of the light emitting surface located at the portions opposite to the light emitting surface uniform are parallel lines, the light reflective objects 3 are arranged so that the distribution density of the lines increases at both corner portions remote from the fluorescent lamp 6 as shown in FIG. 4. Further, in the light emitting device according to the present invention, the light reflecting plate 4 for reflecting light in a direction perpendicular to the light emitting surface and toward the light emitting surface is provided on the light reflective objects 3. The light reflecting plate or sheet 4 is used to reflect light from the light emitting surface and is in intimate contact with the light reflective objects 3.
The contour of the light emitting surface of the device according to the invention may be selected as desired. Also, the shape of the surface may be selected as a planar or curved surface as shown in FIG. 7. Also, it is possible to provide a colored light emitting surface by attaching a transparent color film onto the outer surface of the light emitting surface.
FIG. 5 shows another embodiment in which the substrate has a portion X at the light emitting surface where light of the fluorescent lamp 6 is not directly introduced. In this case, the light reflective objects 3 are provided in the foregoing method so that it is possible to provide a planar light emitting device having a light emitting surface with a uniform illumination.
FIG. 6 shows another embodiment in which light emitting diodes 7 are provided at desired positions within the transparent resin substrate 1. In this case, the light reflective objects 3 are applied to the back surface of the light emitting surface in the foregoing method so that is possible to provide a planar light emitting device having a light emitting surface with a uniform illumination.
The foregoing description is based upon the embodiment of the desk-top type device. However, it is apparent to those skilled in the art that the invention may be easily applied to illuminate a liquid crystal display panel from its backside or to illuminate a device fixed to a wall or a device suspended from other parts. Various modifications in applying the invention are possible. Further, by covering the surface of the light emitting device with a transparent plate in which display letters or figures are formed or by covering the device with an opaque plate in which the display pattern portion is transparent, it is possible to use the device to display a sign even at night.
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An illuminating device is disclosed in which light is introduced mainly from a light source provided at a peripheral portion of a light emitting surface thereby illuminating the light emitting surface. The illumination of the light emitting surface is kept uniform irrespective of a shape of the light emitting surface, a type of the light source, a number of light sources and a mounting position of the light sources. The device may be used as a display device.
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FIELD OF THE INVENTION
This invention relates to wound therapy. In particular, it provides a device and method for applying vacuum-assisted wound therapy.
BACKGROUND OF THE INVENTION
There are many orthopedic procedures that involve placing pins or screws into bone. External skeletal fixation involves stabilization of fractured bone segment by pins or screws which protrude through the overlying skin. The pins or screws may be connected to an external frame for stabilization. These external skeletal fixation appliances comprise swivel joints, connecting bars, sliding bars, articulations, and anchorage clamps intended to hold and position transcutaneous pins. For example, when a patient suffers a severe bone injury or undergoes limb-lengthening surgery, it is often necessary to stabilize the fracture area with an external fixation device.
Often, the transcutaneous pins or screws of an external fixation device must remain in place for an extended period. These appliances create a breach in the skin. Because of this breach, the resulting pin-site wound provides a path along which microorganisms present on the skin surface may move into deeper tissues. In addition, inflammation and localized edema at the wound site may lead to a loss of blood flow to the surrounding tissue, decreasing the tissue's ability to fend off infection and slowing the healing process.
The antiseptic effect of vacuum therapy is well-known. Maintaining vacuum pressure on the area around a wound site not only inhibits microbe migration to the wound, it also quickly reduces bacteria population and reproduction in the wound area. Vacuum-assisted wound dressings may comprise a thin film semi-permeable cover containing a perimeter adhesive for creating an air tight seal with the skin. A vacuum tube penetrates the cover. Such dressings are difficult to apply however, where a bone stabilization pin or screw extends through the skin. The vacuum supplied under the cover tends to collapse the thin film cover onto the skin. If used with a protruding pin, the film would tend to tent around the top of pin, and apply an unwanted destabilizing force to the pin.
An alternative vacuum device is disclosed in Argenta et al. (U.S. Pat. No. 5,636,643). Argenta discloses a wound cover that is either rigid or semi-rigid and which has a port for attachment to a vacuum source. The cover fits over the wound and is sealed against the surrounding skin to maintain the vacuum. The device is adapted for use over large open wounds such as burns, pressure sores, and wounds requiring skin grafts or flaps. While a protruding stabilization pin could conceivably be entirely captured within the dome of the rigid cover, the cover is a rather large and unwieldy device and may not be suitable for covering the small wound surrounding a pin. Similarly, such a device would not be suitable for situations in which several pins are used and connected to a common rack or brace, such as in the case of a badly shattered bone. There is also the risk that an external force could cause the pin to rupture the cover.
Yamamoto et al. (U.S. Pat. Nos. 4,856,504 and 4,915,694) disclose antimicrobial wound dressings and skin fixators suitable for use with orthopedic pins and percutaneous conduits (such as catheters), respectively. These devices comprise antimicrobial pads adapted to fit closely to the skin around a pin or conduit. The pad is then covered by a flange with an orthogonally projecting collar which fits around the pin and fits flush with and covers the antimicrobial pad. These devices are aimed at preventing infection around the wound in the patient's skin through use of traditional antiseptic medications and do not contemplate the use of vacuum-assisted healing techniques.
It is therefore apparent that a need exists for a device that can conveniently apply vacuum-assisted treatment to pin-site wounds.
SUMMARY OF THE INVENTION
In accordance with the present invention, a device is provided for applying therapeutic vacuum to a wound surrounding the shaft of a bone stabilization device that extends through the skin of a patient. By “bone stabilization device” is meant a transcutaneous element, such as a pin or screw, which is adapted for embedding in the bone of the patient and extending through the skin. The device of the invention comprises a hollow generally conical member defining an enclosed space through which the stabilization device may pass. The conical member has at a first end a first opening adapted to conform to the bone stabilization shaft. At an opposite second end, the device has a second opening adapted to enclose a wound in the skin surrounding the bone stabilization device shaft. The openings are dimensioned, respectively, for conforming to the bone stabilization device shaft, and for enclosing the wound surrounding the bone stabilization device shaft. The opening for enclosing the wound will typically be larger than the opening conforming to the bone stabilization device. The conical member has, preferably at a point intermediate the ends thereof, a port for connecting a suction tube to the conical member, to communicate a negative pressure from a vacuum source to a space defined by the conical member. The conical member has sufficient flexibility at the first end to contract against the bone stabilization device shaft to form an airtight seal therewith.
In one embodiment, the conical member has sufficient rigidity to generally maintain its conical shape and resist collapsing on to the wound during use. In another embodiment, an antimicrobial sponge or other soft object is placed between the conical member and the wound, and the conical member has sufficient flexibility to partially collapse onto the antimicrobial sponge.
One embodiment the device of the invention includes a sealable slit in the conical member extending from the conical member first and second openings. The slit facilitates placement of the device around a pin and wound site. A sealing device, such as a flexible adhesive tape, is used to close the slit. While use of a flexible adhesive for sealing the slit is contemplated, the slit may be closed and sealed by any means that will serve to maintain the integrity of the seal created by the mating of the structure to the skin and the stabilization device.
A method for applying a vacuum to a wound surrounding the shaft of a bone stabilization device that extends through the skin is provided, comprising, placing the device of the invention over a wound and a protruding bone stabilization device shaft such that the shaft passes through both openings of the conical member to enclose the wound, connecting the device to a vacuum source, and applying vacuum pressure to the device.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a perspective view of a wound treatment device for applying therapeutic vacuum to a wound surrounding the shaft of a bone stabilization device that extends through a patient's skin.
FIG. 2 shows a perspective view of an alternative embodiment of a wound treatment device for applying therapeutic vacuum to a wound surrounding the shaft of a bone stabilization device that extends through a patient's skin.
FIGS. 3A-3C show an enlarged perspective view of an alternate port design in three stages of operation—before insertion of the tube, with the tube inserted and withdrawing air, and after sealing.
FIG. 4 shows a perspective view of a further alternative embodiment of a wound treatment device for applying therapeutic vacuum to a wound surrounding the shaft of a bone stabilization device that extends through a patient's skin.
Although these Figures depict an embodiment of the contemplated invention, they should not be construed as foreclosing alternative or equivalent embodiments readily apparent to those of ordinary skill in the subject art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , a wound treatment device 10 is provided for applying a therapeutic vacuum for treating a wound 15 caused by a bone stabilization device 11 that protrudes through a patient's skin 13 . In the embodiment shown in FIG. 1 , the device 10 includes a hollow, preferably generally conical member 12 . At one end, the conical member 12 has a small opening conforming to the shaft of the bone stabilization device 11 . At the other and opposite end, the conical structure 12 has a larger opening that is dimensioned to enclose the wound 15 surrounding the bone stabilization device 11 . While the openings in the generally conical member 12 will typically be circular, it is noted that other shape openings are possible. For example, the body of the conical member may be oval in cross-section, and the opening contacting the skin will be oval. Likewise, the shape of the opening for engaging the shaft of the bone stabilization device is advantageously selected to conform to the cross-sectional shape of the shaft, if other than circular.
It is also contemplated that the openings may not be predetermined, instead being defined by the attachment of the member 12 to the bone stabilization device 11 . Thus, in the event that the stabilization device is rectangular, the upper opening would conform to the shape of the device upon application of negative pressure, as will become more apparent below.
Preferably, the conical member is comprised of a flexible, semi-rigid, airtight material so that when reduced pressure is applied, the walls of the conical member are drawn inwards toward the skin and stabilization device. In a preferred embodiment, the conical member is comprised of a flexible, semi-rigid polymer such as silicone or low linear density polyethylene. Ideally, the cone geometry is such that while the ends of the cone conform to the stabilization device and the skin respectively, the middle section of the cone is drawn inwards under the applied negative pressure. Use of a flexible but semi-rigid polymer in the conical member allows the structure to conform roughly to the surfaces of the stabilization device shaft and the patient's skin while also retaining its shape when the vacuum is applied. Whatever material is used, the conical member preferably has sufficient flexibility at the end having the smaller opening to contract against the stabilization device and form an air tight seal, but preferably has sufficient rigidity to generally maintain its conical shape and prevent the structure from collapsing onto the wound, as well as the ability to securely support the vacuum port and tube. The conical member should also have sufficient flexibility at the opposite end to form an airtight seal with the skin. The conical member 12 can be optionally secured to the stabilization device 11 and to the skin 13 by adhesive 14 . Any suitable adhesive which can adhere to the skin can be used.
As shown in FIG. 1 , the wound 15 is completely enclosed within the conical member 12 . Negative pressure is supplied to the interior of the enclosure formed by the member through a tube 16 . The tube 16 connects to the conical member 12 through a port 18 formed in the conical member 12 , preferably at a location that is between the ends of the conical member. Tube 16 connects the port 18 to a vacuum source (not shown) which supplies a negative pressure (vacuum) to the space inside the conical member 12 . The tube 16 may be either integrally connected to port 18 , or it may be capable of attachment by any commonly understood or suitable means. In a preferred embodiment, the tube measures ¼ inch in diameter and is comprised of a flexible polymer such as polycarbonate, e.g. LEXAN® brand polycarbonate.
While the port 18 and tube 16 are both shown as cylindrical in shape, it is also contemplated that either or both can be formed in a variety of shapes. For example, referring to FIGS. 3A-3C , the port 18 can be formed from two flaps of material that extend from the member 12 and which flaps are attached at their upper and lower ends, thereby defining a narrow slit. The tube 18 can be easily inserted into the slit when a vacuum is needed. After sufficient negative pressure is applied to the enclosure, the flaps can then be closed, such as by clipping or taping, and the tube 18 removed.
The level and duration vacuum pressure necessary to achieve a suitable antiseptic effect is well understood in the art. In a preferred embodiment, the vacuum pressure applied is 5 in Hg below atmospheric pressure until the bacterial count is reduced to a desired level. Although not shown, a sensing device can be located along the tube for monitoring bacterial count. Alternately, when substantially all the air is withdrawn from the enclosure, the enclosure could be sealed.
As shown in FIG. 2 , an alternative form of the device of the invention includes a slit 20 in the member which extends from one end to the other. This allows the device to be opened to fit around the shaft of a bone stabilization device which has already been inserted into the body of the patient, where access to the end of the stabilization device is blocked, for example, by a bar, rack, brace or frame or other structure, as shown in FIG. 2 . The slit is then sealed, preferably by means of flexible adhesive material, such as adhesive tape or glue 14 . This method of attachment enables the device to be used when the stabilization device is itself attached to a larger apparatus, such as in the case of a badly shattered bone where a series of pins or screws may be attached to a rack or brace 21 . It should be readily apparent that the shape of the member 12 in this embodiment need not be conical before application of pressure. Instead, the member 12 may be formed from flexible material that has a flat sheet with a square, trapezoidal, or other shape. The sheet is wrapped around the pin and sealed to the pin and the skin, thus defining the conical shape.
The embodiment of the device of the invention shown in FIG. 1 may be fitted to the patient by passing the bone stabilization device shaft axially through the openings in the conical member until the larger opening contacts the patient's skin. Where the protruding end of the bone stabilization device is connected to a rack or frame, the alternative embodiment of the device of the invention, as shown in FIG. 2 , is preferably employed. The stabilization device shaft passes through the slit in the conical member until the shaft extends through each opening in the conical member. The vacuum pressure is applied at either a constant or cyclical rate and for a time period sufficient to achieve the desired antiseptic effect as understood by those of ordinary skill in the art.
As shown in FIG. 4 , an alternative form of the device of the invention includes a conical member 12 that is sufficiently flexible to collapse under the pressure difference between external ambient pressure and the negative pressure inside the conical member. To protect the wound 15 , a soft element 22 , which may be a sponge, is placed between the conical member 12 and the wound. The soft element 22 may be treated with an antimicrobial substance. The antimicrobial sponge may be supplied in a package with the conical member 12 when the wound treatment device is supplied, or may be provided separately and combined with the conical member only when the wound treatment device 10 is applied to a patient. In some circumstances, the mechanical contact between the soft element 22 and the wound 15 , where gentle mechanical forces are transmitted to the wound from the conical member 12 through the soft element 22 , may mechanically stimulate the wound in such a manner as to promote healing. The use of the flexible conical member 12 without the soft element 22 is possible but in most circumstances less preferred.
All references cited herein are incorporated by reference. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof.
For example, although distinct embodiments have been described and shown in the several drawings, features from the different embodiments may be combined in a single embodiment. For example, the treatment device 10 shown in FIG. 4 may have either the connector 18 shown in FIG. 1 or the connector shown in FIGS. 3A to 3C . For example, the treatment device 10 shown in FIG. 4 may have a conical shape similar to that shown in FIG. 1 or may have the slit 20 shown in FIG. 2 .
Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indication the scope of the invention.
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A vacuum-assisted wound healing device is provided comprising an airtight hollow conical member surrounding a skin-breaching bone stabilization device, and a port for attaching a suction tube. The conical member has an opening at one end conforming to the circumference of the shaft of a bone stabilization device, and a opening at the other end to enclose a wound in a patient's skin surrounding the bone stabilization device. The device may be used to provide controlled reduced pressure to the wound site, reducing healing time and risk of infection.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 11/556,028, filed Nov. 2, 2006, which is a continuation of U.S. patent application Ser. No. 10/856,560, filed May 28, 2004, which in turn claims the benefit of U.S. Provisional Application No. 60/483,283, filed Jun. 27, 2003, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to techniques and a system for roaming across wireless networks. More specifically, embodiments of the invention allow for switching access across different networks from different network providers and/or different technologies.
[0003] In today's wireless mobile computing world, there are a variety of different mobile technologies that coexist for different applications and different ranges. Examples of some of these different technologies are discussed below in conjunction with FIG. 1 which graphically depicts several of the various technologies.
[0004] Shown in FIG. 1 are wireless wide area network (WWAN), wireless local area network (WLAN) and wireless personal area network (WPAN) technologies. WWAN technologies typically include cellular and related technologies such as GSM, GPRS, CDPD, CDMA, TDMA, WCDMA, etc. WWAN networks are high power, long range networks that typically have an access range on the order of several kilometers on up. WLAN technologies, on the other hand, are medium power, medium range networks that have an access range on the order of tens of meters while WPAN networks are low power, short range networks that typically have an access range of about 10 meters or less. Examples of WLAN technologies include the IEEE 802.11(a), (b), (e) and (g) technologies and examples of WPAN technologies include Bluetooth, HomeRF, IrDA and IEEE 802.15 technologies.
[0005] The Internet and Internet-based applications can be accessed by different devices over each of the wireless network types shown in FIG. 1 . In order to access the Internet using a specific wireless network technology a computing device with appropriate hardware (e.g., antenna) and software (e.g., protocols) is required along with appropriate credentials (e.g., a user account) that are recognized by the network service provider. Except in some very specific cases, credentials that enable access to a network require a priory subscription to a service on the network or are based on a pay-as-you-go approach (typically for a set time period) where the user receives a temporary user ID that is authorized for use on the network. For example, in order to access a WWAN, a user typically needs a plan with a cellular data provider and in order to access a WLAN network, a user may need a subscription with a WLAN provider, a temporary account with a provider (e.g., for network usage at an airport or coffee shop) or a relationship with an enterprise network.
[0006] The need for priory subscriptions and/or an existing relationship with network service providers limits the ability for individual user's of network services to roam from one network to another.
BRIEF SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention allow a user of network services to roam from one network to another without necessitating a priory subscription with each of the networks. Roaming access can be achieved through a single device that is able to connect to each of the different networks or through different devices where one device is able to connect to the first network technology and a second device is able to connect to the second network technology. Embodiments of the invention allow for switching among access across different networks from different network providers. Some embodiments of the invention allow seamless roaming across different networks from different providers while maintaining session and application state.
[0008] In one embodiment the method comprises establishing a connection between a wireless mobile device and a first wireless network. The connection allows the wireless mobile device to interact with an Internet-based application. A state of interaction between the wireless mobile device and the Internet-based application is tracked. The connection between the wireless mobile device and the first wireless network is terminated. The method further includes establishing a connection between the wireless mobile device and a second wireless network and sending, to the Internet-based application, data representing a state of interaction of the wireless mobile device with the Internet-based application prior to terminating the connection between the wireless mobile device and the first wireless network.
[0009] In another embodiment, the method comprises establishing a connection to a first wireless network with a mobile device, using the mobile device to interact with an Internet-based application through the first wireless network, tracking data related to a state of interaction with the Internet-based application, establishing a connection to a second wireless network with the mobile device, and sending data related to the state of interaction with the Internet-based application to the Internet-based application.
[0010] In a third embodiment, the method comprises establishing a connection between a wireless mobile device and a first wireless network. The connection allows the first wireless mobile device to interact with an Internet-based application. The method further comprises tracking a state of interaction between the first wireless mobile device and the Internet-based application, terminating the connection between the first wireless mobile device and the first wireless network, establishing a connection between a second wireless mobile device and a second wireless network. The second mobile device is different from the first wireless mobile device. Data representing a state of interaction of the first wireless mobile device with the Internet-based application prior to terminating the connection between the first wireless mobile device and the first wireless network is sent to the Internet-based application.
[0011] In a fourth embodiment, a system for facilitating roaming from one network to another is disclosed. The system comprises an authentication component configured to authenticate wireless mobile devices for use on a plurality of wireless networks and a synchronization manager component. The synchronization management component is configured to track a state of interaction between a wireless mobile device and an Internet-based application through a first wireless network, and in response to receiving an appropriate request, establish a session between the wireless mobile device and the Internet-based application through a second wireless network and send data representing the state of interaction to the Internet-based application.
[0012] These and other embodiments of the invention along with many of its advantages and features are described in more detail in conjunction with the text below and attached figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 graphically depicts a simplified comparison of several currently available mobile network technologies;
[0014] FIG. 2 is a block diagram of a system that allows mobile devices to roam across different networks according to one embodiment of the invention;
[0015] FIG. 3A schematically illustrates a sequence of events associated with a user logging onto a first network according to one embodiment of the invention;
[0016] FIG. 3B schematically illustrates a sequence of events occurring when the user in FIG. 3A roams from the first network to a second network according to one embodiment of the invention;
[0017] FIG. 4 is a flow chart illustrating steps associated with the events depicted in FIGS. 3A and 3B ;
[0018] FIG. 5 is a block diagram that illustrates an authentication process involving multiple UWNPs in a federation according to one embodiment of the present invention; and
[0019] FIG. 6 is a block diagram that illustrates an authentication process according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 2 is a block diagram of a system that allows mobile devices to roam across different networks according to one embodiment of the invention. Shown in FIG. 2 are mobile devices 10 , 12 and 14 that access Internet 30 through one or more of networks 20 , 22 . Mobile devices 10 , 12 , and 14 may be, for example, wireless-equipped laptop computers, internet-capable cellular phones, wireless-equipped personal digital assistants (PDAs) or any other mobile computing device that is able to connect to a wireless network to access one or more Internet-based services through the network. Networks 20 and 22 may rely on differing technology and/or use different service providers to enable mobile devices to connect to the networks. In some embodiments networks 20 and 22 can be different technologies deployed by the same or different service providers, different cells using the same technology but operated by different service providers, or can be different cells using the same technology and service provider.
[0021] Networks 20 and 22 may be based on any of the technologies shown in FIG. 1 or on any other appropriate wireless network technology. As examples, in one embodiment, network 20 may be a cellular based 3 G WWAN network and network 22 may be an 802.11(b) WLAN network. In another embodiment network 20 may be a 802.11(g) WLAN network operated by company X and network 22 may be a 802.11(g) WLAN network operated by company Y.
[0022] As shown in FIG. 2 , mobile device 10 is equipped with hardware that enables the device to access Internet 30 through network 20 ; mobile device 12 is equipped with hardware that enables the device to access Internet 30 through network 22 and mobile device 14 is equipped with hardware that enables the device to access Internet 30 through either network 20 or network 22 . Also shown in FIG. 2 are a computer system/server 40 for a universal wireless network provider (UWNP) and an application server 50 . UWNP 40 includes an authentication component 42 that authenticates mobile devices, such as mobile devices 10 , 12 and 14 across multiple networks such as networks 20 and 22 and a synchronization manager 44 that tracks the state of interaction between a wireless mobile device and various Internet-based applications the device is being used to interact with.
[0023] Application server 50 hosts one or more applications that are accessed over the web by computing devices such as personal computers and mobile devices 10 , 12 and 14 . Application server 50 may include multiple servers in a distributed computing system. In some embodiments, server 50 may implement one or more virtual private networks. A person of skill in the art will appreciate that there are thousands of different application servers in addition to application server 50 that can be accessed over the Internet providing thousands of different services and/or applications for use by computing devices such as mobile devices 10 , 12 and 14 .
[0024] Embodiments of the invention allow mobile devices to roam across multiple networks, for example from network 20 to network 22 , such that a connection to an Internet-based application, such as an application supported by application server 50 , that is initially established through a first network can be switched so that the connection is established through a second network. In some embodiments, the switch of the connection may be implemented to minimize the impact to the user of the network switch. In some cases, the user may not even notice that a connection change occurred. The connection may be switched during a single session in which the mobile device is continuously connected to Internet 30 , may be switched from a first session to a subsequent, second session where the mobile device is disconnected from Internet 30 for a time period and then reconnected in the second session at the same application state at which the device was disconnected from Internet 30 during the first session or may be switched from a first session to a subsequent, second session where different mobile devices are used to connect to Internet 30 during each session.
[0025] In some embodiments, users (e.g., owners of the mobile devices) may be required to register with UWNP 40 or otherwise be registered with UWNP 40 through other mechanisms. In some instances, the registration may be done on behalf of the user (e.g., the service provider may register the mobile device with the UWPN). Authentication component 42 of UWNP 40 authenticates the mobile device for usage on the networks. By way of example, in one embodiment, the mobile device may be authenticated by comparing a device ID to a database of device IDs that are registered with the UWNP 40 .
[0026] UWNP 40 also includes a synchronization manager 44 that provides session management services that enable roaming to be smoothly transitioned from one network to a second network for applications that are written to allow for such. The synchronization manager is a software program/engine that maintains the state of all active applications to support various roaming modes allowed by embodiments of the invention. In some embodiments the synchronization manager may be a program that executes on the mobile device (not shown in FIG. 2 ) rather than on the server-side. Also, in some embodiments the synchronization manager (or another software component executing on a UWNP server) provides identity management features that enable a user to project a single identity for himself to a service provider or application even when the user is accessing the network using different user names (e.g., a personal identity or a work identity) or different mobile devices (e.g., a wireless laptop computer or a cell phone).
[0027] The state of the interaction may be preserved by capturing a user's interaction events with a data model. For instance, the data model may represent the structure of a web form (e.g., an XForms data model) and the user interaction events may represent the user's interaction with the form. The interaction events may be captured and interpreted as to how the interactions affect the data model associated with the interaction. For instance, each character entered in a data field of a form affects the data model. At periodic intervals, the information may be stored and sent or otherwise synchronized with the synchronization manager. In one embodiment, the impact of a user's interactions may be stored as an XForms data model and periodically synchronized with a repository associated to the user session in the synchronization manager. Both interaction events and data model may be captured, stored, and synchronized with different granularities. By way of example, interactions may be captured each time an event occurs (event based), when a field is filled and an off focus event is received (field based), after several fields are filled (block based), at a form or page event, such as when a form is completed, or at other appropriate points in a user's interaction with a data model.
[0028] Some embodiments of the invention allow for three different modes of roaming: (1) suspend and resume mode; (2) connect/intermittently disconnected/disconnect mode and (3) multi-device roaming. Internet-based applications can be written to support one or more of the above roaming modes. Other modes and programming models that support a seamless switch between devices and/or networks can be implemented in other embodiments of the invention. Suspend and resume mode and connect intermittently disconnected/disconnect mode can be supported by a synchronization manager that executes on either the device side or server side of the system. Multi-device roaming, however, may require that the synchronization manager execute on the server-side of the system or somewhere in the network accessible from the different networks/devices that are used. Alternately, the state of the interaction that is saved on the first device may be transmitted to the second device.
[0029] Applications that support suspend and resume mode allow the application to be interrupted and subsequently resumed at the interrupted state at a later time using a different network (e.g., through an access network based on a different technology) or a different mobile device. In some embodiments, applications can be written to support a granular suspend and resume mode where they can be interrupted at any time but resumed only at specific points in the program. As one example of suspend and resume mode, if a user is completing an electronic form that requires the user to enter his first and last name, home address, home phone number and email address along with other information on a web site, the synchronization manager saves the data model requested by the web site (i.e., the form) and tracks information the user enters into the form with mobile device 60 . If the user's session is interrupted prior to completing the form, for example the user enters his first and last name and his address but not his home phone number, email address or other information, synchronization manager may maintain sufficient information so that when the user's connection with the website is reestablished, the form can be pulled back on an active screen with the user's name and address information reentered into the form by the synchronization manager so the user only has to complete the remaining phone number, email address and other fields of the form. In some embodiments, the user may be given the option whether to resume the form completion before the form is displayed on an active screen.
[0030] Applications that support connect/disconnect mode allow seamless roaming to be used when part of the application executes on the mobile device and part of the application executes on an application server 50 accessed through the Internet. Examples of such applications include applications that run on an embedded web server and have client-side logic that can emulate part of the application business logic on the client when the network is absent. Typically, the client business logic interacts with a local, client-side data store or repository. When the network is on, the data store after being updated by the business logic is synchronized with the backend data. Updates on the backend can be synchronized with the client using push technology, for example, upon an event or change, periodically by the client, or upon initiation from the client. Such applications often have additional mechanisms to deal with conflicts. Examples of such applications include Oracle's Web-to-Go, which is collection of components and services that facilitates development, deployment, and management of mobile Web applications, and the Blackberry™ email service.
[0031] In an application that supports multi-device roaming, the user can switch from a first mobile device 10 that accesses the application through a first network, such as network 20 , to a second mobile device 12 that accessed the application through a second network, such as network 22 while interacting with the application. The switch from mobile device 10 to mobile device 12 may include, for example, switching from a WAP phone that accesses an application through a WAP browser to a wireless PDA or kiosk that accesses the application through an XHTML (extended HTML) browser. As another example, a user may switch from a device that interacts with an application through a graphical user interface agent to a device that interacts with the application through a voice user agent. Multi-device roaming for other deployments of applications that use multi-modal interactions may also be supported by synchronization manger 44 .
[0032] Similar to suspend and resume mode, applications that support multi-device roaming can be written with different levels of granularity. Implementing multi-device roaming, however, requires that synchronization manager 45 be deployed on the server side (e.g., at UWNP 40 ) as opposed to solely on the mobile device itself.
[0033] Once a user is registered with a UWNP, a user may log onto a network associated with the UWNP to establish a first connection and establish the terms of the usage (e.g., the cost structure of the connection). The user may then wander into the range of a second network that is also associated with the UWNP and roam from the first network to the second network. Alternatively, the user may disconnect from the first network and subsequently connect to the second network. As used herein, a network is associated with the UWNP if there is some mechanism and/or agreement between the UWNP and an owner of the network for billing a user for use of the network through the UWNP.
[0034] One specific embodiment of the invention is described below in conjunction with FIGS. 3A, 3B and 4 , where FIGS. 3A and 3B schematically illustrate a sequence of events associated with a user logging onto a first network and roaming from the first network to a second network and FIG. 4 is a flow chart illustrating steps associated with the roaming process. For purposes of illustration only, the embodiment discussed with respect to FIGS. 3A, 3B and 4 can be envisioned to allow an individual on a business trip with a laptop computer (mobile device 60 ) that includes an 802.11(b) wireless network card to access the Internet from multiple locations using different networks within an airport. For example, the user may access the Internet from a first 802.11(b) network 62 in a frequent flyer lounge area and then roam to a second 802.11(b) network 64 located in an airport coffee shop prior to leaving the airport.
[0035] Referring to FIGS. 3A and 3B , networks 62 and 64 each have servers 66 , 68 that handle login requests to the networks and interface computers on the networks to the Internet. Upon entering the range of network 62 , mobile device 60 receives a request 70 from server 66 to login to network 62 ( FIG. 4 , step 100 ). Request 70 may be generated by the internet service provider (ISP) or mobile network operator (MNO) that runs network 62 from its server 66 . In response to request 70 , mobile device 60 may initiate an automatic or manual login process to network 62 ( FIG. 4 , step 102 ). Either process may include, for example, passing user identification information via a response 72 that enables UWNP 40 to authenticate device 60 for a connection to network 62 .
[0036] In response to receiving identification information from device 60 , server 66 sends a request 74 to UWNP 40 to check for billing authorization to establish that device 60 has an account with UWNP 40 and can thus be billed for usage of network 62 through UWNP 40 ( FIG. 4 , step 104 ). UWNP 40 authenticates device 60 and sends a response 76 back to server 66 indicting that device 60 is an approved client ( FIG. 4 , step 106 ) and server 66 then forwards appropriate credentials to device 60 via a response 78 ( FIG. 4 , step 108 ). Logging into network 62 implies that the user will be billed and pay for usage of the network. Billing/payment can be done with a credit card or any other billing approach accepted for mobile communications.
[0037] Once authorization is obtained to use network 62 , device 60 can remain connected to the network and access content from outside of the network (e.g., content over the Internet) for the duration of a session as long as the device is within the wireless range of network 62 ( FIG. 4 , step 109 ).
[0038] At the end of a session on network 62 , server 66 can pass usage information (e.g., the time that device 60 was connected to network 62 ) to UWNP 40 ( FIG. 4 , step 110 ) in order to facilitate subsequent billing for the connection or to allocate money already paid by the user of device 60 to the UWNP to the ISP/MNO associated with network 62 .
[0039] While mobile device 60 is accessing an application over the Internet (step 109 ), such as an application hosted by server 50 shown in FIG. 2 , through network 62 , the synchronization manager (not shown in FIG. 3A or 3 B) tracks the state of any and all applications run by the mobile device. In some embodiments, the state of interaction in an Internet-based application is only tracked if the application is registered with the UWNP to allow for such tracking. The information tracked by synchronization manager 44 can be subsequently used to re-establish a session with an appropriate Internet-based application on a new network or with a new device as described below. Depending on the granularity of data tracking supported by the Internet-based application, the session can be reestablished at exactly the same point where the connection was terminated (i.e., the invention allows for seamless roaming) or can be established at some other previously achieved point of interaction.
[0040] In some embodiments the synchronization manager or a separate identity management software component 46 also tracks the state of a user's interaction with an application when employing different identities on different networks. For example, a user may have an identity (user ID) such as John123 on network 62 that is not available on network 64 because either network 64 requires a different format for user identities or that particular identity was already used by another user on network 64 . In such a case when the user roams from network 62 to network 64 , an application that expects the user to have a particular identity may reject a new identity assigned by network 64 . Identity manager component 46 of UWNP 40 , however, communicates to the application via a cookie added to the message (that provides the appropriate identity) or other accepted approach (e.g., exchange between service or application that provides claims or credentials or that maps the identity of an identity known by the service) a single identity. In one embodiment this is done by storing a table for each registered user that tracks various identities of the user as known to different networks the user may access the Internet with, as known to different devices the user may access the Internet from and as known to different web sites the user has established identities with. In other embodiments federation solutions like Liberty Alliance (see http://www.projectliberty.org) or WS-Federation (a specification by IBM® and Microsoft® for sharing user and machine identities among disparate authentication and authorization systems) can be used to address these issues.
[0041] When device 60 enters the range of network 64 owned or operated by a different ISP/MNO than network 62 , server 68 sends a request 82 to device 60 that the device login to network 64 ( FIG. 4 , step 112 ). In response to request 82 , mobile device 60 may initiate an automatic or manual login process to network 64 that includes a response 84 ( FIG. 4 , step 114 ) similar to the process described above in conjunction with step 102 . Accordingly, response 84 may include user identification information that enables UWNP 40 to authenticate device 60 for a connection to network 64 . In some embodiments the user will have already established rights to roam to other networks associated with the UWNP in which case authorization can be automatically provided without requesting payment information from the user. In other embodiments the user will need to accept a new payment plan/deal to use the new network.
[0042] In response to receiving identification information from device 60 , server 68 sends a request 86 to UWNP 40 to check for billing authorization to establish that device 60 is authorized for use on network 64 or that the device can be appropriately billed for its usage of the network ( FIG. 4 , step 116 ). UWNP 40 sends a response 88 back to server 68 indicting that device 60 is an approved client ( FIG. 4 , step 118 ) and server 68 then forwards appropriate credentials to device 60 via a response 90 ( FIG. 4 , step 120 ) that enables device 60 to remain connected to network 64 and access content from outside of the network, for example, content over the Internet. Device 60 can than access applications and/or information over the Internet through network 64 while the device remains within the service range of the network ( FIG. 4 , step 121 ).
[0043] The synchronization manager allows the mobile device to continue any established interaction with an Internet-based application from step 109 in a manner such that the user may not notice a switch from the first network to the second network. In some embodiments upon logging onto the second network, UWNP allows the user to be presented with a list of applications that were being tracked from previous sessions. The user can then select which, if any, applications he would like to resume as if the interaction was a single continuous session. If the user selects to resume one or more of the possible applications, the synchronization manager passes sufficient information to the application so that the user resumes the application at the state at which he had previously left the application. During step 121 , the synchronization manager is also tracking any new applications or updates to the state of existing applications so that such states can be resumed in any subsequently started session as described above in conjunction with step 109 .
[0044] At the end of a session on network 64 , server 68 passes usage information to UWNP 40 on the device's use of network 64 ( FIG. 4 , step 122 ) in order to facilitate subsequent billing for the connection to network 64 or to allocate money already paid by the user of device 60 to the UWNP to the ISP/MNO associated with network 64 .
[0045] In some embodiments all exchanges between the UWNP and servers 66 , 68 as well as all authentication/authorization exchanges between device 60 and servers 66 , 68 are provided by secure web services such as SSL (secure sockets layer) communications. Also, in some embodiments, steps 102 - 108 and steps 114 - 120 may include one or more dialog boxes that allow the user to select from one or more different pricing schemes or packages. Similarly, there may be multiple ways to logon to an individual network such as network 62 or network 64 . In such cases, a user may select in step 102 to logon to the network through UWNP 40 in which case a link to the appropriate login page of the UWNP is provided to the user in step 102 .
[0046] A person of skill in the art will also appreciate that while in the example described above, as session on network 62 for device 60 terminated before device 60 was logged into network 64 it is possible for the session on network 62 to terminate after, or in response to, a connection being established with network 64 . Similarly, if device 60 is within range of both networks 62 and 64 , the user of the device may select which of the two networks to run applications through based on any of a number of possible criteria, such as, usage cost, a preference for one network over another, strength of signal, etc. In other embodiments, the session on network 62 may be terminated independent of the possibility of establishing a connection with network 64 or any other network.
[0047] Some embodiments of the invention allow for multiple UWNP service providers. In such cases the user may select different UWNPs to access different network providers and different UWNPs can be trusted by different ISPs/MNOs. In one specific embodiment a federation of UWNPs can exist that follows predefined protocols for establishing network identify information without compromising privacy and security of the information. An example of such identity protocols is described in U.S. patent application Ser. No. ______ {{21756-8 case/OID 2003-005-01}}, which is hereby incorporated by reference.
[0048] In some embodiments, if the user who is registered with a first UWNP (UWNP B) seeks to login to a network where the MNO is only associated with a second UWNP (UWNP A) that is different from the first UWNP, but both the first and second UWNPs are in a federation, the authentication process requires an additional step where UWNP A seeks authentication of the user by the federation by passing a message to UWNP B. FIG. 5 illustrates one such embodiment.
[0049] Shown in FIG. 5 , which is a block diagram that illustrates one embodiment of an authentication process involving multiple UWNPs, is a wireless network 130 controlled by an access provider, such as an MNO. When a user attempts to access network 130 , a server on the network (not shown) sends a request for authentication to a server 132 associated with UWNP A. The server at UWNP A recognizes that the user is registered with UWNP B and is not registered with UWNP A and seeks authentication of the user from a server 134 associated with UWNP B. The results of the authentication process are ultimately passed back to the user through server 132 and 130 . Once authentication is obtained, the user is then allowed to access a desired service or application hosted by a server 136 via the Internet.
[0050] In an embodiment where roaming will result in the user's interaction with an application being maintained at a particular state prior to the roaming, the synchronization manager interacts with the wireless mobile device and server hosting the application. As shown in FIG. 6 , a synchronization manager 138 passes information related to the suspended state of the application to application server 136 . By way of example, the information passed may includes user ID information associated with the session and, after the federation authorizes to pass the session, information associated to the user ID.
[0051] In further embodiments, the knowledge by the UWNP of a user's IP address and location (or other address information) can provide the capability to push notifications to the user from certain applications and/or improve universal messaging types of services. In one particular embodiment, the user may enter preferences with the UWNP as to the terms (e.g., where, when and how) such messages should be routed.
[0052] Having fully described several embodiments of the present invention, other equivalent or alternative methods of practicing the present invention will be apparent to those skilled in the art. For example, while certain embodiments discussed above illustrated use of the invention to allow for roaming across two different networks, the invention is able to allow roaming across three or even many more networks. Also, while the present invention has been described using a particular combination of hardware and software, it should be recognized that other combinations of hardware and software are also within the scope of the invention. These and other embodiments as well as alternatives and equivalents to the invention will be recognizable to those of skill in the art after reading the description of the present invention. The scope of the invention should not, therefore, be determined solely by reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents and alternatives.
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In one embodiment, a method of allowing a user to roam from one wireless network and interact with an Internet-based application is disclosed. The method comprises establishing a connection between a wireless mobile device and a first wireless network, wherein the connection allows the wireless mobile device to interact with an Internet-based application; tracking a state of interaction between the wireless mobile device and the Internet-based application; terminating the connection between the wireless mobile device and the first wireless network; establishing a connection between the wireless mobile device and a second wireless network; and sending, to the Internet-based application, data representing a state of interaction of the wireless mobile device with the Internet-based application prior to terminating the connection between the wireless mobile device and the first wireless network.
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BACKGROUND OF THE INVENTION
This invention relates to frequency synthesizers for wireless communications equipment and more particularly to such devices that include provisions for assuring the frequency synthesizer is generating the desired frequency prior to allowing, for example, the transmission of a radio frequency carrier.
Modern day wireless communications equipment often need the capability to routinely, rapidly, and reliably change between any two of, for example, a large number of potential radio frequency carriers with specific system critical parameters. This capability makes it possible to utilize efficient, high capacity, wireless communications technologies such as cellular telephone or trunked radio systems. This type of system, in turn, makes it feasible to satisfy, to a greater extent, the exploding demands of the wireless communications markets with a largely fixed frequency spectrum allocation.
The frequency synthesizer has enjoyed widespread usage and provides an economically effective way of generating, and rapidly changing between any two of, a large number of radio frequency carriers with desired parameters. To generate a specific radio frequency carrier, the frequency synthesizer must be programmed with an instruction corresponding to the desired radio frequency carrier. Some time after being programmed, depending on its dynamic characteristics, the frequency synthesizer should "LOCK" to the desired radio frequency carrier. To change the radio frequency carrier, the synthesizer must be reprogrammed, and allowed to "LOCK", to the new frequency. During this time the frequency synthesizer will be generating undesired, i.e., unauthorized, and often system-detrimental carrier frequencies. In an effort to avoid some problems associated with the above, prior devices simply presume the synthesizer has been correctly programmed and utilize an out-of-lock indication to preclude transmission until the synthesizer is actually locked.
This, however, may well present a problem. If the programming accuracy presumption is in fact incorrect but nevertheless the synthesizer locks to a frequency, the equipment may be allowed to transmit on either an unauthorized frequency or, almost certainly, a system-detrimental frequency. This situation could occur in any number of ways, including, a temporary or permanent hard fault in the programming system, or a soft fault such as, controller software errors or other possibly indeterminate, intermittent causes. The net effect of these problems is almost certainly communications failure for the user of the faulty piece of equipment and very likely other users, if the equipment is allowed to transmit on an undesired frequency. Indirectly, burdens may be imposed on all users while the system attempts to compensate for the errant equipments behavior.
To eliminate part of these problems, such as a permanent hard fault, known prior devices have used an approach whereby the synthesizer is first programmed to a non-useful frequency, allowed to lock, and then programmed to the desired frequency. By monitoring an out-of-lock detector for an "unlock," "lock," "unlock," and finally "LOCK" sequence of indications, a reasonable implication that the programming system is functioning, at least in part, can be made. This approach, while helpful, does not protect against soft or other indeterminate errors and is completely contrary to the requirement of rapidly changing to the new frequency.
Today's system requirements, routinely changing operating frequencies with flexible parameters, have dramatically increased the amount of information which must be successfully programmed. This only exacerbates an already potentially serious problem.
From the above it will be appreciated that a need exists for a frequency synthesizer programming system which provides enhanced assurance that the frequency synthesizer is locked on the desired frequency at all times and under all operating conditions.
SUMMARY OF THE INVENTION
This invention solves the aforementioned needs by providing a programmable frequency synthesizer arrangement having a programming feedback capability that is adaptable to avoid undesirable operation due to random hard and soft faults. The arrangement includes generating appropriate programming information for controlling the operation of the associated frequency synthesizer, receiving the programming information and, subject to the occurrence of random hard or soft faults, directing the operation of the frequency synthesizer, and then generating a feedback signal indicative of the programming information applied to the frequency synthesizer. A deterrence function generates a reference signal indicative of the appropriate programming information, compares this signal with the feedback signal, and then provides blocking of further undesirable operation of the frequency synthesizer whenever the above comparison indicates the occurrence of a random hard or soft fault.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention, itself, however together with further advantages thereof, may best be understood by reference to the accompanying drawings in which:
FIG. 1 is a diagram of a programmable frequency synthesizer arrangement in accordance with one embodiment of the present invention.
FIG. 2 is a diagram of a transceiver using the programmable frequency synthesizer of FIG. 1 in accordance with another embodiment of the present invention.
FIG. 3 is a diagram of a process flow chart in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, a frequency synthesizer arrangement is illustrated generally, which synthesizer includes programming feedback capability in accordance with the present invention. A fully programmable frequency synthesizer (10) consisting of a logic circuit (12), loop filter (13), and voltage controlled oscillator (VCO) (14), interconnected in frequency synthesizer fashion, as depicted, is used to generate an appropriate frequency synthesizer signal (15). This signal is then coupled to an injection control block (16). A processor (20) consisting, for example, of one or more microprocessor systems, performs the remaining interface and controller duties associated with operating the frequency synthesizer (10) as, for example, a source from which transmitter radio frequency carriers are derived.
the processor (20), acting as a controller and responding to a programming request such as, for example, "Freq. Ch." (21) or "PTT" (22), initiates a programming task by generating appropriate programming information suitable for controlling the operation of the frequency synthesizer (10). This programming task includes composing the appropriate programming information and making it available, as, for example, serial data indicated at (25), a clock signal at (26), and a latch pulse at (27), to register (30). Register (30), part of the logic circuit (12), is adapted to receive the appropriate programming information and apply at least part of this information to direct the operation of the frequency synthesizer (10). The above described programming task, including its functions and procedures, may be subject to an occurrence of a random hard and/or soft fault, which fault, in turn, may cause undesirable operation of the frequency synthesizer.
To avoid this undesirable occurrence, logic circuit (12) acts to generate a feedback signal that is representative of the programming information as above applied. This feedback signal, is supplied by an "AUX" (31), coming from register (30), as well as that from out-of-lock detector (33), included as part of the logic circuit (12).
In response to the feedback signals (35, 36), a deterrence arrangement, embodied in processor (20), compares the feedback signal and a reference signal, derived from the appropriate programming information, and, based on this comparison, functions to block further undesirable operation of the frequency synthesizer (10). More particularly, processor (20) compares the "AUX" signal (35) to an expected value, the reference signal, and, further, confirms the absence of an out-of-lock indication (36). In the event the above comparison implies undesirable operation (occurrence of a fault) or an out-of-lock indication is detected, the processor (20) will operate to block undesirable operation of the frequency synthesizer (10) by, for example, setting an alarm (38), not enabling injection via the connection labelled "Inj. En." (39) and/or repetitively initiating the programming task. Thus, undesirable operation can be effectively avoided by detecting and correcting for soft (non recurring) faults or detected and disallowed if caused by hard (recurring) faults.
An additional embodiment of the present invention, as shown in FIG. 2, represents such a frequency synthesizer arrangement as adapted in a wireless communications system with an associated transmitter and receiver. Elements of FIG. 2 which are identical to FIG. 1 have like reference numerals. FIG. 2 includes frequency synthesizer (10) coupled by injection control block (16) providing a transmit injection signal (44) to transmitter (45) and a receive frequency synthesizer (50), adapted to provide a receive injection signal (46) to receiver (47). Transmitter (45) uses the transmit injection signal (44) to generate a corresponding desired transmit radio frequency carrier which is then coupled to antenna (48). Receiver (47), coupled to antenna (48), uses the receive injection signal (46) to receive a corresponding radio frequency carrier and provide a corresponding desired receiver output (49).
Processor (20) provides a programming task and a deterrence arrangement, in a similar manner as described with reference to FIG. 1, for both the transmit frequency synthesizer (10) and the receive frequency synthesizer (50). The receive frequency synthesizer (50) feedback signal (75, 76) is coupled at (74) to processor (20) along with other receiver status signals indicated at (77) via a multiplexer (78). Processor (20), having initiated a receive frequency synthesizer (50) programming task in response to, for example, a "Freq. Ch." (81), performs, in response to the feedback signal (75, 76), a receiver deterrence function in the manner described previously that may result in setting an "Rx. Alarm" (82) and/or repetitively initiating the programming task.
Appreciation of the present invention and its various embodiments can be enhanced by reviewing the simplified process flow diagram of FIG. 3. This process flow diagram is representative of a subroutine executed by processor (20) during the operation of the present invention. As indicated the frequency synthesizer initiates the start of programming at step (100). At step (101), if the transmit frequency synthesizer needs to be programmed, a PTT hold-off signal is set, thereby disabling the transmit injection signal (44) via the connection labelled "Inj. En." (39) and injection control block (16). Processor (20) may then obtain the desired frequency (DF) at step (102) from, for example, memory and the current appropriate out-of-lock indication (lock status) (LS) (36 or 76). At step (103), if LS="LOCK" and the last frequency (LF)=DF the left path designated "no" is followed to step (110).
If either above equality is not satisfied, processor (20), following the path designated "yes," may set a desired change frequency state (DFS) at step (104). DFS may be set equal to a value derived from DF, for example, a parity check, a cyclic redundancy code (CRC), bit by bit echo, or as depicted at step (104), a value derived from the last change frequency state (LFS), for example, the inverse of LFS. LFS is representative of the most recent appropriate "AUX" signal (35 or 75). Given an appropriate programming information, including DF and DFS from above, an attempt to program the frequency synthesizer (10 or 50) is made at step (105). This attempt includes processor (20) generating the appropriate programming information, register (30 or 70) receiving at least part of the same and in response thereto directing the operation of the appropriate frequency synthesizer (10 or 50) and, further, generating a feedback signal (specifically "AUX" (31 or 71) supplies a change frequency state (CFS) and the out-of-lock detector (33 or 73) supplies LS) representative of the programming information as above applied for directing the operation of the frequency synthesizer. Processor (20) next assumes a deterrence arrangement whereby the feedback signal, specifically CFS (35 or 75) and LS (36 or 76), is retrieved at step (106) and compared to a generated reference signal indicative of the programming information, specifically DFS and "LOCK", at step (107).
If either equality (DFS=CFS, "LOCK"=LS) fails, processor (20) may set the appropriate alarm (38 or 82) at step (108) and then repeat steps (105, 106, and 107). Thus, processor (20), acting as a deterrence arrangement, is blocking further undesirable operation of the frequency synthesizer whenever the above comparison indicates the occurrence of a random hard or soft fault that has corrupted the appropriate programming information. If the step (107) equalities are satisfied, the path designated "yes" is taken to step (109) where LFS and LF are set equal to DFS and DF respectively. At this point in the process the programmable frequency synthesizer arrangement using programming feedback has determined that the frequency synthesizer programming was properly performed. At step (110) if a transmit frequency synthesizer was being programmed the PTT hold-off signal is cleared and "Inj En. (39)" is now subject to PTT (22) control.
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This disclosure discusses a programmable frequency synthesizer arrangement having programming feedback capability used to avoid undesirable operation due to random hard and soft faults. The arrangement operates by supplying appropriate programming information, receiving the same, subject to random hard or soft faults, and, in response, directing the operation of a frequency synthesizer (10). The feedback capability is accomplished by generating a feedback signal (35, 36) indicative of the programming information as applied to the frequency synthesizer, generating a reference signal representative of the appropriate programming information, comparing the two signals, and blocking undesirable operation of the frequency synthesizer if the comparison indicates the occurrence of a random hard or soft fault. Further disclosed is a wireless communications transceiver with the programmable frequency synthesizer arrangement.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/314,196, filed Aug. 22, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a temperature controlled case for storage and display of chilled and/or frozen products, especially in a store environment.
[0003] A typical cooling coil in a refrigerated case is constructed of metal, such as copper or aluminum. Since this material is metal, it is quite noticeable when mounted in a refrigerated case. Case manufacturers try to conceal this coil by placing an attractive cover over the coil or placing the coil in a hidden location, as under the product shelf. However, although these methods hide the coil, they do not make the case particularly attractive and may affect refrigeration efficiency.
[0004] Refrigeration case shelving is generally made from painted metal or stainless steel. This type of shelving may be used to cover a forced air evaporator mounted beneath the shelf, or there may be a gravity feed coil mounted above the shelving. However, the main purpose of the shelving is to hold and display the product within the refrigerated case. Therefore, in both of the foregoing applications, the actual cooling of the product is achieved from the gravity feed coil mounted above the shelf or from the forced air coil mounted below the shelf, which is not entirely satisfactory.
[0005] Therefore, it is a principal object of the present invention to provide an improved, temperature controlled case for storage and display of cooled and/or frozen products.
[0006] It is a further object of the present invention to provide a case as aforesaid which is efficient and at the same time esthetically pleasing.
[0007] It is an additional object of the present invention to provide a case as aforesaid which may be readily and effectively used in a commercial store environment.
[0008] It is a further object of the present invention to provide a coolant service case with coolant means above and below product storage.
[0009] It is a still further object of the present invention to provide a coolant service case as aforesaid with coolant means above the product and coolant means beneath the product, including coolant gravity coils and gravity louvers above the product and refrigerated pans beneath the product.
[0010] Further objects and advantages of the present invention will appear hereinbelow.
SUMMARY OF THE INVENTION
[0011] In accordance with the present invention, the foregoing objects and advantages are readily obtained.
[0012] The present invention provides a temperature controlled case for storage and display of chilled and/or frozen products. The coolant service case of the present invention includes at least one cooling coil above the product and a cooling shelf beneath the product, including separate coolant supply and discharge lines from a coolant supply means to the cooling coil and shelf. The coolant coils above the product desirably includes coolant gravity coils and gravity louvers with drains and preferably lighting included therein. In accordance with one embodiment, the coolant shelf beneath the product includes separate cooling sections for holding product. In accordance with a further embodiment, the shelf is divided into separate sections. In accordance with a still further embodiment, means are provided to warm the coolant for at least one of said cooling coil and shelf.
[0013] Further features and advantages of the present invention will appear hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The prosent invention will be more readily understandable from a consideration of the following illustrative drawing, wherein:
[0015] [0015]FIG. 1 is a cross-sectional view of a representative coolant service case of the present invention;
[0016] [0016]FIG. 2 is a partly schematic view of the indide bottom portion of a coolant service case of the present invention;
[0017] [0017]FIG. 3 is aperspective view of a coolant service case of the present invention without the upper coils;
[0018] [0018]FIG. 4 is a view similar to FIG. 3 showing the removal of one of the sections of the refrigerated shelf;
[0019] [0019]FIG. 5 is a sectional view showing various components of a refrigerated case of the present invention; and
[0020] [0020]FIG. 6 is a rear view of a refrigerated case of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] [0021]FIG. 1 shows a cross-section of a temperature controlled case ( 10 ) of the present invention. A secondary collant gravity coil ( 12 ) is situated mear the top of the refrigerated space ( 14 ). Mounted below the coil is a gravity louver assenbley ( 16 ) which is designed to both direct air flow through the refrigerated space and catch water falling from the coil above from condensation or melting during defrost cycles. A drain pan ( 18 ) directs the flow of water from the louvers ( 16 ) into piping ( 20 ) connected to the main case drain ( 22 ). The louver assembly ( 16 ) may also contain an integrated lighting system ( 24 ) to better illuminate the product.
[0022] Secondary coolant is also circulated through channels ( 26 ) inside refrigerated pans or shelf ( 28 ) which provide additional cooling. The pans or shelf may be insulated on their underside to prevent heat transfer to the unused space below. Above the pans or shelf, the products ( 30 ) are placed in containers, desirably made of a metallic or otherwise heat-conductive material. The secondary coolant flows to and from the cooling coils ( 12 ) and to and from the refrigerated shelf or pans inside of flexible hoses ( 32 ) which may be equipped with valved quick-disconnect fittings to facilitate removal of the coils or shelf for cleaning or other maintenance.
[0023] Supply ( 34 ) and return ( 36 ) headers for the coolant are placed preferably in the back of the case for connection to the refrigerated coils and shelf. Chilled secondary coolant flows into the supply header ( 34 ) through the secondary coolant supply line ( 38 ) and coolant flows out of the return header ( 36 ) through a secondary coolant return line ( 40 ), both of which may either be connected to a packaged chiller ( 42 ) or a centralized chiller for multiple cases or the entire facility.
[0024] The packaged chiller ( 42 ) may consist of a pump to provide flow of coolant and a heat exchanger to provide heat flow from the secondary coolant to a primary coolant, preferably a volatile refrigerant. Additional equipment may also be included to facilitate temperature controls, safety devices, and to provide defrost of the coils and pans.
[0025] The chiller ( 42 ) is preferably contained within a pedestal base ( 44 ) to be hidden from view of the customer. In some situations where a direct expansion system already exists within a store, a refrigerant liquid line ( 46 ) and suction line ( 48 ) can provide flow of a primary refrigerant to the packaged chiller, possibly through a refrigeration pit ( 50 ) already existing in the floor.
[0026] In a conventional manner, the coolant service case of the present invention includes an openable door 52 for access to stored products.
[0027] In accordance with the present invention, a refrigerated case shelf is provided that is refrigerated by a means of pumping a chilled liquid through the shelf and the shelves are divided into smaller sections for removal and case cleaning. The case selves are supplied a chilled liquid by means of a chilled liquid header system. The header system includes a chilled liquid inlet header and a chilled liquid outlet header. The shelves are connected to the header system via liquid tight connectors that allow the refrigerated shelves to be disconnected from the chilled liquid headers, without losing substantial amounts of the chilled liquid.
[0028] Today's case designs use refrigerated coils to cool the case. These coils may be mounted above and below the product shelves. However, it has been found that one single refrigerated shelf or plate has many disadvantages. The plate is generally large and difficult to manufacture. The large plate cannot be readily removed for cleaning bacterial contamination from the case. If the plate is made to be removed, having one single, large plate filled with liquid is not a practical construction. The weight of a single 6-8 foot plate filled with liquid is generally too great for store personnel to remove. Moreover, a single plate design also means that there would be a need for multiple sizes based on the case size. For example, one would need a 4 foot plate for 4 foot cases and an 8 foot plate for 8 foot cases. Typical case sizes include, 4, 6, 8 and 12 foot sizes. The multi-section refrigerated shelf and header design of the present invention overcomes these disadvantages. The manufacturing cost of a multi-shelf header design is greater, but it provides the best means of removing the refrigerated shelves for cleaning, for example, to remove food borne pathogens and bacteria from the case.
[0029] [0029]FIG. 2 shows the inside bottom of the case for the multi-plate design of the present invention with separate inlets and outlets. Multiple shelves ( 54 ) are shown with coolant liquid inlet lines ( 56 ) and coolant liquid outlet lines ( 58 ). Inlet lines ( 56 ) are connected to coolant liquid inlet header ( 60 ), which in turn is connected to chilled coolant supply lines ( 62 ), and coolant liquid outlet header is connected to coolant liquid outlet header ( 64 ), which in turn is connected to coolant outlet supply line ( 66 ). The supply lines are connected to a chilled liquid supply (not shown).
[0030] FIGS. 3 - 4 show the multi-plate design installed and with the removal of one plate. For convenience, the upper plates are not shown.
[0031] [0031]FIG. 3 shows the refrigerated shelf with four ( 4 ) separate shelf sections, as in FIG. 2.
[0032] [0032]FIG. 4 shows one of the refrigerated shelf sections disconnected from the chilled liquid headers ( 60 , 64 ) via the means of low liquid loss connectors ( 68 ). The connectors ( 68 ) provide an easy means for the store personal to remove the liquid filled shelves without spilling large amounts of the refrigerated liquid. In the above example, the refrigerated shelves are divided into separate sections, as four sections allowing much smaller and lighter sub-sections of shelving.
[0033] The present invention also provides a means of controlling the top coil temperature separately from the refrigerated shelf or pan temperature. This is shown in FIG. 5, which shows a view similar to that shown in FIG. 1. The control may be accomplished by restricting or stopping the flow of chilled liquid to and/or from the top coil ( 12 ) or the shelf or pans ( 28 ) via a liquid stop solenoid, flow regulator, flow valve, orifice, electronic valve or a change in line size or diameter. When the flow rate is slowed through the shelf or top coil, the temperature will rise, when the flow rate is increased, the temperature decreases. In addition, the present invention provides control of the top coil separately from the bottom coil to increase humidity in the case, and control of the top coil separately from the bottom coil for the purpose of defrosting the top coil or pan at different times and duration.
[0034] To control the top coil separately from the bottom shelves, the present invention desirably provides flow regulators ( 70 ) installed between the chilled liquid supply header (CLSH) ( 72 ) and the top coil ( 12 ), then another flow regulator ( 74 ) installed between the CLSH ( 72 ) and the bottom shelves ( 28 ). One of these could be piped directly to the CLSH with only one item having a flow regulator valve installed. This would allow one item, such as the shelves, to be controlled based on the CLSH temperature while the other item, the top coil, may be controlled separately. However, with the shelves being controlled by the CLSH, the CLSH will have to defrost along with the shelves, thus also causing the coil to enter a defrost stage. With separate flow regulating devices, the top coil and shelves can be defrosted separately and the CLSH would never need to defrost. FIG. 5 shows illustration of this system's piping, showing the upper coils ( 12 ), shelf ( 28 ), flow regulators ( 70 , 74 ), chilled liquid supply header ( 72 ), return header ( 76 ) and chiller ( 42 ).
[0035] During normal operation, it very important that the product temperature be precisely controlled. The case will hold the most expensive product in the supermarket and the most volatile to food borne pathogens, which cause over 6,000 deaths per year in the US. The FDA has mandated that a 41 degree product temperature be maintained at all times to prevent food borne illnesses. Therefore, the dual temperature control of the present invention allows flexible temperature control during normal operation.
[0036] When the case is refrigerating, the shelf temperature will be set at the temperature desired for the product. For example, if the product was fresh beef, the shelf temperature would be set at 30 degrees. Because the fresh meat sits directly on the refrigerated shelves, the meat will be held at 30 degrees. Then the coil temperature will be set at 28 degrees to maintain the air temperature in the case. By setting the shelf temperature higher than the coil temperature, a very slow convection cooling effect will happen inside the case, causing very slow air movement over the product.
[0037] In addition to controlling the temperature, when cycling the top coil's flow regulator based on the coil's actual temperature, the amount of moisture being removed from the case can be precisely controlled. In a conventional case, the top coil is controlled to maintain product temperature. However, in the case design of the present invention, the product temperature is mostly controlled by controlling the shelf flow regulator. The top coil is now available to be cycled based on the case's air and the coils temperature, which directly affect the case's humidity.
[0038] This is a significant case feature, since the product in the case is fresh meat, seafood or any other fresh product that may need to maintain a high moisture level. In the case of fresh beef, the weight, look, and freshness of the beef are mostly determined by the liquid content of the beef. If the top coil has to operate at a very low temperature, as is the case on a conventional case, the coil builds a very high frost level. This frost comes directly from two sources, one being the operating environment, such as the building the case is installed in, and two being from the fresh meat itself. When the fresh meat loses moisture in the form of frost on the top coil, the product loses weight and start to get a very dry look. The weight directly affects the profits from the sales of the meat. The dry look affects the customer's desire to buy the product. Both of which are very negative.
[0039] By controlling the top coils temperature exactly, using the top coils flow regulator, design of the present invention will maintain a much higher humidity, keeping more of the moisture in the fresh meat as opposed to turning the moisture into frost on the top coil. Moreover, the reason the top coil can be maintained at a separate and desired temperature level, is that the bottom shelves are controlled to maintain the actual product temperature by cycling the shelf flow regulator.
[0040] In a traditional case, the case enters defrost and stops defrosting as one unit. All coils and refrigeration devices enter defrost at the same time. When this happens the case temperature and product temperature rises, until the defrost cycle has ended. Then the product temperature and case temperature is pulled down to the level of normal operation. This momentary rise in product temperature two, three or four times a day, can directly affect the product life, color and bacterial growth. If this product rise happens to often, it can cause a real food safety issue in the case.
[0041] With the design of the present invention, one can defrost the top coil while still refrigerating the bottom pans. Next the pans can be defrosted will the top coil is still refrigerating. By defrosting these separately in this fashion, the product is always being cooled by one device, while the frost level is being reduced on the other. Reducing the frost level is a must in all refrigerated applications, in order to maintain case performance and cooling capacity. Since the product is always receiving cooling effect from one device, the product temperature change during a defrost cycle, is very minimal.
[0042] In addition to cycling defrost at different times, the defrost times and duration can vary. In this case, the refrigerated shelves or pans are not as affected by frost as the top coil is. Therefore, the top coil can be defrosted more times a day than the bottom pans. By reducing the amount of total defrosts, the product temperature will be better maintained.
[0043] In addition, the present invention provides for the installation of a heat exchanger in the case for the purpose of using store ambient air to generate warm fluid at the case to defrost or temperature control at least one of the top coil and refrigerated pans. This is illustrated in FIG. 6 which shows a rear view of a case of the present invention. In a conventional case, hot gas or an electric heater is used to generate heat in the case to defrost the case coils. These systems are direct expansion systems, using only a refrigerant gas. Since the design of the present invention uses a small secondary cooling loop that pumps a chilled liquid, such as glycol or water, that is much more environmentally friendly, one needs a way to defrost the coils, without a hot gas or electric heater. To generate a warm liquid, the present invention desirably installs a fan ( 80 ), coil ( 82 ) and a warm liquid defrost header ( 84 ).
[0044] The case operation for refrigeration will remain the same as previously mentioned, however, during a defrost cycle, the warm liquid will be pumped from the warm liquid defrost header ( 84 ) through the top coil or refrigerated pans. The warm liquid will quickly defrost the device, removing all frost from the device.
[0045] The use of a small air cooled coil ( 82 ), fan ( 80 ), header ( 84 ) and all associated valves needed to bypass the chilled liquid that is normally sent to the top coil and pans. The chilled liquid will be replaced with the warm fluid, thus causing a rapid thaw of the frost from the top coil and bottom pans.
[0046] The warm liquid for defrost could be generated in the above fashion or by using a storage vessel or a small holding tank ( 86 ) with heating means, as heating coils ( 82 ) or an electric heater. The most economic way to generate the warm liquid would be using the warm or ambient air ( 88 ) from the store environment. Also note, if the system does not have a plate heat exchanger at the case, generating warm liquid for defrost using this method would most likely not be used. The warm liquid generation and valves would be in the store's machine room where the plate heat exchanger would be installed.
[0047] Thus, referring to FIG. 6, which shows the rear of the present case, chiller ( 42 ) is connected to chilled liquid supply header ( 34 ) and return header ( 36 ) which in turn are connected to piping ( 88 ) for the coils and shelves (not shown in FIG. 6). Doors ( 90 ) are shown to provide access to the case. Warm liquid defrost header ( 84 ) is connected to heating coils ( 82 ) as described above.
[0048] Alternatively, the means to warm the secondary coolant can be accomplished by means of a ground loop system, where piping is installed in or below the foundation of the building to retrieve heat generated by the earth for the purpose of warming the secondary coolant. As a further alternative, one can warm the secondary coolant by using a solar collector that uses solar energy to heat the secondary coolant. As a still further alternative, one can warm the secondary coolant by using the discharge heat from the primary cooling system for the means of warming the secondary coolant. Still further, one can warm secondary coolant by using heat generated by electric heaters to heat air that is blown across a coil by use of a fan, where the secondary coolant travels through the coil.
[0049] It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
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A temperature controlled service case for storage and display of chilled or frozen products, including at least one compartment for product storage, at least one access opening providing entrance to the compartment, at least one shelf within the compartment for holding product, and refrigeration operatively associated with the compartment for maintaining a selected temperature therein. The refrigeration includes at least one cooling coil above the shelf with a cooling medium flowing therethrough, and cooling within the shelf with a cooling medium flowing therethrough. Coolant supply is also provided for supplying cooling medium to the cooling coil and shelf with separate coolant supply and discharge lines from the coolant supply to the cooling coil and shelf. In accordance with a further embodiment, the shelf is divided into separate sections. In accordance with a still further embodiment, means are provided to warm the coolant for at least one of said cooling coil and shelf.
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BACKGROUND OF THE INVENTION
It has long been recognized that covers for swimming pools are frequently so large and bulky that it is impractical to manage them in the absence of some sort of a reel or other apparatus. Accordingly, the prior art has been characterized by large numbers of reels some of which have been stationary, and some movable. At least one manufacturer offers two kinds of reel apparatus, one non-rollably supported on the decking and another movable therealong on wheels, the latter kind also having anchoring means which can be associated with cooperating anchor means in the decking.
Insofar as applicant is aware, there has never been a highly simple, economical, practical reel apparatus, wherein the shifting from the movable mode to the braked mode is effected extremely easily and with a minimum of apparatus, and wherein the braking apparatus is not at all unsightly and does not require association with the decking at a particular anchor region.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the apparatus, each end frame of the pool-cover reel has wheels on one side thereof and a relatively large braking area on another side thereof, the relationship being such that either such one side or such other side may be disposed adjacent the decking by tilting the end frame. In accordance with the method relative to such embodiment, the entire reel apparatus, with pool cover thereon, is rolled from a storage area to a position which preferably straddles one end of the pool, this occurring when the wheeled sides of the end frames are engaged with the decking. Then, the operator tilts each end frame to remove the wheeled side from the decking and cause the braking area to engage the decking. He then unwinds the pool cover from the now-braked reel. To retrieve the pool cover, crank means in the form of hand wheels are turned to roll up the pool cover, this occurring while the reel is in such position that there is no substantial resistance of the pool cover to leaving the water. Then, each frame is tilted back to its position at which the wheels engage the decking, and the entire apparatus is rolled to a storage area.
In accordance with the second embodiment, each end frame is itself a wheel, preferably having an axis the same as that of the rolled-up pool cover. One segment of each end frame is adapted to pivot laterally, when the wheel is in a rotated position such that the segment is not adjacent the decking, thereby exposing a relatively large chordal braking area. The chordal braking area of the wheel is increased, in area, by a braking area of the pivoted-away segment. In accordance with the method, the entire reel apparatus is wheeled into straddling relationship to the pool end, and each segment is pivoted to expose the chordal braking regions, this occurring while each segment is not adjacent the decking. The pool cover is then pulled to operative position and later retrieved by rotating crank means such as hand wheels. Then, each wheel is tilted until the chordal braking regions are not adjacent the decking, following which the segments are pivoted back to their positions forming continuations of the wheel-like end frames. The entire apparatus is then wheeled to a storage region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a pool having associated therewith a pool-cover apparatus constructed in accordance with a first embodiment of the present apparatus;
FIG. 2 is an end elevation of the apparatus as viewed from the right in FIG. 1;
FIG. 3 is a longitudinal sectional view of the apparatus, taken along line 3--3 of FIG. 2;
FIG. 4 is an end elevational view corresponding to FIG. 2 but showing an end frame in its braking condition, corresponding to that shown in phantom lines in FIG. 1;
FIG. 5 is an end elevational view of a second embodiment of the pool-cover apparatus, showing such second embodiment in its rolling condition permitting transport of the reel back and forth to a storage area;
FIG. 6 is an enlarged transverse sectional view taken along line 6--6 of FIG. 5; and
FIG. 7 is a view corresponding of FIG. 5 but showing the braked condition of the apparatus, such braked condition corresponding to that shown in phantom line in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of FIGS. 1-4 is presently preferred and is the contemplated production model.
Referring first to FIG. 1, a swimming pool is shown at 10 and the decking at 11. The pool-cover (reel) apparatus of the first embodiment is indicated generally at 12, being shown in solid lines in rolling condition and in phantom lines in braked condition. The apparatus 12 comprises an elongated roller (spool or spindle) element 13 which is preferably hollow as shown in FIG. 3. Roller 13 is preferably sufficiently long that the apparatus 12 can straddle the pool as shown in FIG. 1. Wound on element 13 is the pool cover 14, being preferably two layers of flexible synthetic resin between which are trapped bubbles of air.
End frames 16 and 17 are mounted at opposite ends of roller 13, and each end frame is tiltable about an axis parallel to that of roller 13. The end frames are disposed generally in planes perpendicular to the axis of roller 13. As shown in FIG. 3, cranks (hand wheels) 18 are disposed on the sides of frames 16 and 17 remote from roller 13, being mounted on stub shafts 19 which extend through bushings or bearings 20 in the frames 16 and 17. At their inner ends, these stub shafts are connected coaxially to roller 13. Thus, turning of either hand wheel 18 rotates roller 13 to roll-up the pool cover 14 when desired. Conversely, when the free end of the pool cover is pulled, the shafts 19 and hand wheels rotate freely.
End frames 16 and 17 are identical to each other, being mirror images about a vertical plane which extends between the end frames longitudinally of the pool. Each is illustrated as being solid and triangular, having rounded corners 21 adapted to operate as rocker or pivot regions. A flange 22 extends inwardly from the main body of each end frame 16 and 17, for two purposes. One such purpose is that the flange 22 on one side of each frame provides a mounting region for wheels 23 adapted to roll on decking 11. Each wheel 23 has an axis perpendicular to the main body of its associated end frame 16 or 17, the axis being at the shafts 24 shown in FIGS. 2 and 4.
At the remaining two sides of the triangular end frames 16 and 17, flanges 22 do not have any wheels. Instead, such sides serve as (to achieve the other purpose) large-area braking regions adapted to rest directly on decking 11 as shown in FIG. 4. These braking regions are caused to be sufficiently large that, in combination with the weight of the apparatus 12, the apparatus 12 will remain stationary when the operator pulls on the free end of pool cover 14 to unroll the cover.
Preferably, each end frame is an equilateral triange, and the stub shaft 19 is located at the center of such triangle.
In summary, each end frame 16 and 17 has one rotated position--the one shown in FIG. 2 and in solid lines in FIG. 1--at which it rolls on the decking so that the apparatus 12 may be readily moved from a storage region to the end of the pool 10. Each end frame also has another rotated position at which it is not adapted to roll but is, instead, in braked relationship relative to the decking. The braked position is shown in FIG. 4 and in phantom lines in FIG. 1.
In accordance with the method of the first embodiment of the invention, the reel apparatus 12 is stored at any region, preferably relatively remote from pool 10. When it is desired to cover the pool, the operator pushes on the apparatus 12 to roll it to the position shown in solid lines in FIG. 1, the wheeled side of flange 22 then being adjacent the decking so that the wheels 23 roll on the decking to make the transport of the entire apparatus 12 easy.
Then, the operator holds one of the lower corners 21, of end frame 16, either with his foot or with one of his hands. Simultaneously, he pulls on the upper corner 21 to tilt end frame 16 so that one of its braking sides is supported on the decking 11. Thus, for example, to shift from the position of FIG. 2 to that of FIG. 4, the lower-left corner 21 is held while the upper corner 21 is pivoted counterclockwise. During this movement, the lower-left corner (FIG. 2) first engages the decking and then pivots thereon in a rocking motion, about an axis parallel to that of roller 13. It is pointed out that it would have been equally possible to rotate clockwise from the FIG. 2 position, so that the other braking surface would engage the decking 11, operation being equally satisfactory regardless of the direction of tilting of each end frame.
The same operation is repeated relative to the other end frame 17. Then, the apparatus 12 being braked, the operator pulls on the free end of the pool cover 14 (by means of a rope or cord, not shown) and unwinds the pool cover so that it extends to the end of the pool remote from the apparatus, namely the right end as viewed in FIG. 1. The position of the apparatus 12 during the unwinding is caused to be such that the pool cover, preferably, does not engage an end lip of the pool decking. This is because it is not desired that the pool cover rub on the decking, since this would tend to wear out the cover. At the end of the pool-covering operation, the entire pool is covered, preferably by a cover that floats on the surface of the water in the pool.
To retrieve the cover, the operator merely turns one of the hand wheels 18 to rotate roller 13 in such direction as to roll-up the pool cover 14 thereon. Very preferably, this operation is performed when the apparatus 12 is in straddling relationship relative to the pool, and spaced a short distance toward the left end of the pool (as viewed in FIG. 1) so that there is some small region of the pool located on the left side (FIG. 1) of the apparatus 12. This straddling relationship permits the cover to be rolled up in a way which breaks the surface tension or other force tending to cause the cover to remain in contact with the surface of the water. Preferably, the pool cover loops back beneath the apparatus 12, and the hand wheel 18 is turned counterclockwise to rotate the pool cover 14 counterclockwise on the roller 13, all as viewed in FIG. 2.
Then, each end frame 16 and 17 is tilted about one of its corners 22 in a manner the reverse of that described above, so that the wheeled side of flange 21 is adjacent the decking 11 and the wheels 23 are supported on the decking. The entire apparatus is then rolled to a storage area.
Embodiment of FIGS. 5-7
In the present embodiment, the pool cover 14, and the associated roller and the stub shafts 19 and hand wheels 18, are the same as in the previous embodiment. However, the end frames are different. Such end frames are mirror imgaes of each other, and only one, numbered 26, will be described.
Each end frame 26 is a wheel which is, preferably, coaxial with its associated stub shaft 19 and thus with the roller 13 associated with the stub shaft. Wheel 26 is large in diameter, larger than that of the rolled-up pool cover 14, and the entire wheel 26 is adapted to roll on decking 11 when it is desired to transport the apparatus to or from the pool. The rotation of the wheels which form end frames 26 is very free and easy.
One segment, numbered 27, of wheel-frame 26 is not integrally associated therewith but instead is separate and pivotally connected thereto. Stated more specifically, the main body of wheel 26 is not complete but terminates along a chord 28 at which there is an inwardly-extending flange 29. The chordal flange 29 (FIG. 6) extends to a generally circular flange 31, the latter extending around all portions of wheel 26 except at the segment 27. Segment 27 has a flange 31a which forms an extension of circular flange 31 when the apparatus is in the solid-line position of FIGS. 5 and 6. Thus, flanges 31 and 31a roll on decking 11 during transport of the entire apparatus.
Segment 27 is pivotally connected to the remainder of frame or wheel 26 at a hinge 32 which is illustrated as being a piano hinge. Hinge 32 is disposed longitudinally of the chord 28 (FIG. 5) on the side of the end frame remote from the rolled-up pool cover 14. Means, for example corresponding male and female portions of the end frames along chord 28, are provided to maintain segment 27 in its rolling position except when it is deliberately moved to a position 180 degrees away from such rolling position as shown in phantom lines in FIG. 6. When segment 27 is in this latter position, the chordal region of the end frame 26 rests on decking 11, and there is sufficient braking area that the end frames will not slide on the decking when the pool cover 14 is unrolled in order to cover the pool. The pivoted-up segment 27 aids in preventing rolling.
The method relative to the embodiment of FIGS. 5-7 is as follows. With each entire wheel 26 in rolling condition, as shown in solid lines in FIG. 6 and also in FIG. 5, the large wheels which form the end frames are employed to roll the entire reel apparatus to the position adjacent the end of the pool as described relative to the previous embodiment. Then, one of the frames (wheels) 26 is rotated until the segment 27 is not adjacent the decking 11. It is then a very simple matter for the operator to rotate segment 27 from the solid line position of FIG. 6 to the phantom-line position thereof. Then, such end frame (wheel) 26 is rolled and tilted back until the region along chord 28 engages decking 11 as shown in FIG. 7. There is thus provided, in a very simple manner, an effective braking action. During this rolling back to the position at which braking is achieved, there is some tilting or rocking of each frame at a corner region, namely one of the corners 33 and 34 shown in FIG. 5.
The same operation is then performed relative to the frame at the other end of the pool-cover. Then, pool cover 14 is unrolled by pulling on its end, as described relative to the previous embodiment. When it is desired to retrieve the cover, either one of the hand wheels 18 is turned to roll up the pool cover on its associated roller element (corresponding to roller 13 in the previous embodiment).
When it is desired to remove the entire apparatus to a storage area, each end frame (wheel) 26 is rotated, by tilting or rocking on either of the corners 33 or 34 (FIG. 7), until the chordal region along chord 28 is no longer adjacent decking 11. Stated more particularly, the rocking at corner 33 is followed immediately by rotation along the circular flange 31. Then, the segment 27 is pivoted back to a position where it forms a continuation of the wheel. The wheels are then in completely operative rolling condition, and the apparatus is readily pushed to the storage region.
Collars 36 are provided on the stub shafts 19 to make sure that the rollers and rolled-up pool cover 14 do not engage the end frames in either embodiment.
The end frames of both embodiments are, preferably, injection molded of a suitable synthetic resin.
The result of the described apparatus is a very economical, practical, lightweight apparatus which may be readily shifted to any desired region and braked at any desired region. There is no predetermined anchoring area, no unsightly braking apparatus, and no necessity of providing anchor means in the decking.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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In the first embodiment of the apparatus, each end frame of the apparatus has one position at which wheels engage the decking surrounding the pool, and another position at which a braking region engages such deck. In accordance with the method, the operator rolls the apparatus to a desired location when each end frame is in the first-mentioned position, and then tilts each such end frame to the second-mentioned position. He then pulls the pool cover off of the now-stationary frame. In accordance with a second embodiment, each end frame is circular and operates as a wheel when it is desired to move the apparatus. To achieve braking, one edge region of each such wheel is pivoted to expose a chordal braking area. In accordance with the method relative to the second embodiment, the shifting from the rolling mode to the braking mode is effected when the indicated edge regions are at rotated positions such that they do not engage the decking.
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The present invention relates generally to novel approaches in generating transgenic plants exhibiting altered flower colour. More particularly, the present invention provides transgenic carnation plants and flowers cut therefrom exhibiting flower colouration not naturally associated with carnation plants. The present invention further contemplates methods for producing transgenic carnation plants with the altered flower colour.
Bibliographic details of the publications referred to in this specification are collected at the end of the description. Sequence Identity Numbers (SEQ ID NOs.) for the nucleotide sequences referred to in the specification are defined following the bibliography.
Throughout this specification, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element or integer or group of elements or integers but not the exclusion of any other element or integer or group of elements or integers.
BACKGROUND OF THE INVENTION
The rapidly increasing sophistication of recombinant DNA technology is greatly facilitating a broad spectrum of industrial processes from the horticultural to medical and allied health industries. The horticultural and related agricultural industries are particularly benefiting from the advances in recombinant DNA technology.
The floriculture industry in particular strives to develop new and different varieties of flowering plants, with improved characteristics ranging from disease and pathogen resistance to altered flower colour. Although classical breeding techniques have been used with some success, this approach has been limited by the constraints of a particular species' gene pool. It is rare, for example, for a single species to have a full spectrum of coloured varieties. Accordingly, substantial effort has been directed towards the use of recombinant DNA technology to generate transgenic plants exhibiting the desired characteristics.
The development of varieties of the major cutflower species such as carnation plants, for example, having flowers exhibiting a range of colours covering lilac, violet, purple and blue or various shades thereof, would offer a significant opportunity in both the cutflower and ornamental markets.
Flower colour is predominantly due to two types of pigment: flavonoids and carotenoids. Flavonoids contribute to a range of colours from yellow to red to blue. Carotenoids impart an orange or yellow tinge and are commonly the only pigment in yellow or orange flowers. The flavonoid molecules which make the major contribution to flow colour are the anthocyanins which are glycosylated derivatives or cyanidin, delphinidin, petunidin, peonidin, malvidin and pelargonidin, and are localised in the vacuole. The different anthocyanins can produce marked differences in colour. Flower colour is also influenced by co-pigmentation with colourless flavonoids, metal complexation, glycosylation, acylation, methylation and vacuolar pH (Forkmann, 1991).
The biosynthetic pathway for the flavonoid pigments (hereinafter referred to as the "flavonoid pathway") is well established (Ebel and Hahlbrock, 1988; Hahlbrock and Grisebach, 1979; Wiering and de Vlaming, 1984; Schram et al., 1984; Stafford, 1990). The first committed step in the pathway involves the condensation of three molecules of malonyl-CoA with one molecule of p-coumaroyl-CoA. This reaction is catalysed by the enzyme chalcone synthase (CHS). The product of this reaction, 2',4,4',6'-tetrahydroxychalcone, is normally rapidly isomerized to produce naringenin by the enzyme chalcone-flavanone isomerase (CHI). Naringenin is subsequently hydroxylated at the 3-position of the central ring by flavanone 3-hydroxylase (F3H) to produce dihydrokaempferol (DHK).
The B-ring of dihydrokaempferol (DHK) can be hydroxylated at either the 3', or both the 3' and 5' positions, to produce dihydroquercetin (DHQ) and dihydromyricetin (DHM), respectively (see FIG. 1). DHQ is an intermediate required for the production of cyanidin-based anthocyanins and DHM is an intermediate required for the production of delphinidin-based anthocyanins in the flavonoid pathway. Two key enzymes involved in this pathway are flavonoid 3'-hydroxylase (F3'H) and flavonoid 3',5'-hydroxylase (F3'5'H). The F3'H acts on DHK to produce DHQ. The F3'5'H is a broad spectrum enzyme catalyzing hydroxylation of DHK in the 3' and 5' positions and of DHQ in the 5' position (Stotz and Forkmann, 1982), in both instances producing DHM. The pattern of hydroxylation of the B-ring of anthocyanins plays a key role in determining petal colour.
Another key enzyme is dihydroflavonol-4-reductase (DFR) which has variable substrate specificity depending on its plant source and has the potential to act on any one or more of DHK, DHQ and DHM.
Many of the major cutflower species lack the F3'5'H and consequently cannot display the range of colours, resultant from synthesis of delphinidins and derivatives thereof, that would otherwise be possible. This is particularly the case for carnations which constitute a major proportion of the world-wide cutflower market. There is a need, therefore, to modify carnation plants to generate transgenic plants which are capable of producing the F3'5'H, thereby providing a means of converting DHK and DHQ to DHM, thereby influencing the hydroxylation pattern of the anthocyanins and allowing the production of anthocyanins derived from delphinidin. Flower colour is modified as a result and a single species is able to express a broader spectrum of flower colours.
SUMMARY OF THE INVENTION
In work leading up to the present invention, the inventors sought to genetically manipulate the flavonoid pathway in carnation plants to generate a range of plants with the capacity to direct DHK metabolism towards delphinidin in preference to or rather than pelargonidin or cyanidin. The resulting plants exhibit altered flower colouration relative to presently available carnation plants. The new transgenic carnation plants and more particularly flowers cut therefrom fulfill a long-felt need in the horticultural and more particularly the floricultural industry in relation to carnations. The technology of the present invention is also applicable to a range of other flowering plants such as roses and chrysanthemums.
Accordingly, one aspect of the present invention contemplates a method for producing a plant exhibiting altered flow colour, said method comprising selecting a plant which is substantially incapable of synthesizing a DFR which acts on DHK and introducing into said selected plant one or more genetic constructs comprising nucleotide sequences encoding a F3'5'H and a DFR which is capable of acting on DHM but substantially incapable of acting on DHK.
Accordingly, one aspect of the present invention contemplates a method for producing a plant exhibiting altered flower colour, said method comprising selecting a plant from which said first plant is to be derived wherein said selected plant is substantially incapable of synthesizing a DFR which acts on DHK and introducing into said selected plant one or more genetic constructs comprising nucleotide sequences encoding a F3'5'H and a DFR which is capable of acting on DHM but substantially incapable of acting on DHK.
More particularly, the present invention provides a method for producing a carnation plant exhibiting altered flower colour, said method comprising selecting a carnation plant from which said first carnation plant is to be derived wherein said selected plant is substantially incapable of synthesizing a DFR which acts on DHK in flowers and introducing into said selected plant one ore more genetic constructs comprising nucleotide sequences encoding a F3'5'H and a DFR which is capable of acting on DHM but substantially incapable of acting on DHK.
The present invention is exemplified herein using carnation plants. This is done, however, with the understanding that the instant invention extends to a range of flowering plants such as but not limited to roses and chrysanthemums. Reference hereinafter to carnations should be taken as reference to other suitable flowering plants.
Another aspect of the present invention is directed to a method for producing a carnation plant exhibiting altered flower colour, said method comprising the steps of:
(i) selecting a plant from which said carnation plant is to be derived wherein said selected plant is substantially incapable of synthesizing a DFR which acts on DHK in flowers;
(ii) transforming cells of said selected plant with one or more genetic constructs comprising nucleotide sequences which encode separately F3'5'H and DFR provided said DFR is capable of acting on DHM but substantially incapable of acting on DHK;
(iii) regenerating a transgenic plant from said transformed cells such that said regenerated plant is capable of expressing said F3'5'H and said DFR of step (ii); and
(iv) growing said plant under conditions to permit expression of said F3'5'H and said DFR of step (ii) in flowers.
Reference herein to altered flower colour includes alteration in the colour of any or all components of the flower including the petal, sepal and stamen. Conveniently, altered flower colour is shown by comparing the flower colour of a transgenic plant made in accordance with the present invention with a plant of the same species but which possesses a DFR which can act on DHK. In practical terms, a comparison may be made between the transgenic plant and the "selected" plant, i.e. the plant from which the transgenic plant is derived.
The present invention is predicated in part of the genetic manipulation of the anthocyanin pathway in carnation plants to direct metabolism of DHK preferentially towards DHM and delphinidin and derivatives thereof rather than through leucopelargonidin and pelargonidin derivatives or DHQ and leucocyanidin and cyanidin derivatives. Flowers of carnation plants lack a F3'5'H and, hence, DHK is unable to undergo metabolism down the delphinidin pathway which is required in order to produce flower colours in the range covering lilac, violet, purple and blue or various shades thereof. To achieve a preferential re-direction of DHK metabolic products down the delphinidin pathway, the inventors screened for and located white lines of carnations lacking a functional DFR. Expression of an introduced nucleic acid molecule results in a F3'5'H which is capable of directing DHK metabolism to DHM. Introduction and expression of a nucleic acid molecule encoding a non-indigenous DFR which is capable of acting on DHM but not DHK, then results in DHM metabolism being directed to leucodelphinidin thereby allowing subsequent conversion to other derivatives of delphinidin. Little or no metabolism occurs via the pelargonidin or cyanidin pathway.
In a particularly preferred embodiment, the flowers of the starting plant also lack a F3'H.
According to this preferred embodiment, the present invention contemplates a method for producing a carnation plant exhibiting altered flower colour properties, said method comprising selecting a carnation plant from which said first mentioned carnation plant is to be derived wherein said selected plant is substantially incapable of synthesizing either a F3'H or a DFR which can act on DHK in flowers and introducing into said selected plant one or more genetic constructs comprising nucleotide sequences encoding an F3'5'H and a DFR which is capable of acting on DHM but substantially incapable of acting on DHK.
More particularly, this aspect of the present invention is directed to a method for producing a carnation plant exhibiting altered flower colour, said method comprising the steps of:
(i) selecting a carnation plant from which said first mentioned carnation plant is to be derived, wherein said selected plant is substantially incapable of synthesizing either F3'H or a DFR which can act on DHK in flowers;
(ii) transforming cells of said selected plant which one or more genetic constructs comprising nucleotide sequences which encode separately F3'5'H and DFR provided said DFR is capable of acting on DHM but substantially incapable of acting on DHK;
(iii) regenerating a transgenic plant from said transformed cells such that said regenerated plant is capable of expressing said F3'5'H and said DFR of step (ii); and
(iv) growing said plant under conditions to permit expression of said F3'5'H and said DFR of step (i) in flowers.
The present invention is exemplified herein using petunia DFR as an enzyme capable of acting on DHM but not DHK. This is done, however, with the understanding that the present invention extends to a DFR enzyme from any plant providing it is capable of acting on DHM but not DHK. Similarly, a particularly useful F3'5'H is from petunia but other sources of F3'5'H include egg plant, lisianthus, gentian, pansy, china aster, anemone, grape, iris, hyacinth, delphinium and bell flower.
Reference herein to the ability of a plant to produce or not produce an enzyme such as DFR, F3'H and F3'5'H relates to its ability in flowers and not necessarily elsewhere in the plant.
A particularly preferred embodiment of the present invention relates to a method for producing a carnation plant exhibiting altered flower colour, said method comprising selecting a carnation plant from which said first carnation plant is to be derived wherein said selected plant is substantially incapable of synthesizing either F3'H or a DFR which can act on DHK in flowers, introducing into cells of said selected plant one or more genetic constructs comprising nucleotide sequences which separately encode a F3'5'H and a petunia DFR, regenerating a plant from said cells, and then growing said plant under conditions sufficient to permit expression of said F3'5'H and said petunia DFR such that said plant produces flowers of different colour relative to said selected plant. Preferably, the F3'5'H is of petunia origin.
The selected plant from which the subject transgenic plant exhibiting altered flower colour is derived may be a natural mutant for DFR such that it substantially does not produce DFR or produces reduced levels of this enzyme, or produces the enzyme with altered substrate specificities such as substantial inability to metabolize DHK. Preferably, however, the selected plant is a double mutant for DFR and F3'H. Mutants of these types wold generally have white flowers. Mutations may be single or multiple nucleotide substitutions, deletions and/or additions to the nucleotide sequences defining the enzymes. Alternatively, the mutations may be induced or directed by, for example, transposon tagging, oligonucleotide-directed mutagenesis, Agrobacterium-directed mutagenesis or viral-directed mutagenesis.
Alternatively, genetic constructs may be introduced to reduce expression of DFR and/or F3'H by, for example, antisense or co-suppression methods. In this aspect of the invention, a plant may be chosen with substantial inability to synthesize one of DFR or F3'H and a genetic sequence introduced to reduce expression of the other of said DFR or F3'H. Alternatively, a plant may be selected with substantial inability to synthesise one of DFR or F3'H and a mutation induced in the other of said DFR or F3'H, by any of the means mentioned above. In either case, the resulting plant would be a "selected" plant and a recipient for a F3'5'H and a DFR capable of acting on DHM but not DHK. A "selected" plant may also be considered a "parent" plant since it is from this plant that a transgenic plant exhibiting altered flower colour is derived in accordance with the methods of the present invention.
The altered flower colour contemplated by the present invention includes the ability of the carnations to produce a range of colours including lilac, violet, purple and blue flowers or various shades thereof from, for example, deep mauve to dark blue to a violet colour or their various shades or combinations thereof.
Another aspect of the present invention contemplates a transgenic plant exhibiting altered flower colour, said plant being substantially incapable of synthesizing a DFR which acts on DHK and which carries a nucleic acid molecule comprising a sequence of nucleotides which encodes a F3'5'H and a DFR which is capable of acting on DHM but substantially incapable of acting on DHK.
Preferably, the plant is a carnation, rose, gerbera or chrysanthemum. In accordance with this aspect of the present invention, the nucleic acid molecule may comprise multiple genetic constructs separately encoding DFR and F3'5'H or a single combined genetic construct encoding both enzymes but with expression being generally directed by two separate promoters. The term "nucleic acid molecule" encompasses single or multiple nucleic acid molecules.
In a preferred aspect of the present invention, there is provided a carnation plant exhibiting the following properties:
(i) a substantial inability to synthesize a DFR which acts on DHK;
(ii) an ability to synthesize a non-indigenous DFR which is capable of acting on DHM but is substantially incapable of acting on DHK; and
(iii) an altered flower colour relative to a carnation plant which expresses a DFR which acts on DHK.
Preferably, the carnation plant is also substantially incapable of synthesizing a F3'H. According to this preferred embodiment, there is provided a carnation plant exhibiting the following properties:
(i) a substantial inability to synthesize a F3'H;
(ii) a substantial inability to synthesize a DFR which acts on DHK;
(iii) an ability to synthesize a non-indigenous DFR which is capable of acting on DHM but is substantially incapable of acting on DHK; and
(iv) an altered flower colour relative to a carnation plant which expresses a F3'H and/or a DFR which acts on DHK.
The present invention extends to the flowers and in particular flowers cut from such transgenic carnations or from plants produced according to the methods herein disclosed.
A "non-indigenous" DFR is an enzyme not normally produced in carnation plants and, in one preferred embodiment, is from petunia. A "non-indigenous" DFR may alternatively have originated from a carnation plant but has undergone mutation to restrict its substrate specificity to DHM. The F3'5'H is also non-indigenous and in one aspect is preferably from petunia.
Another aspect of the present invention contemplates a method for producing carnation flowers exhibiting altered flower colour, said method comprising growing a transgenic flowering carnation plant for a time and under conditions for flowers to form and then optionally harvesting said flowers, said transgenic carnation plant having been genetically manipulated such that:
(i) it is substantially incapable of expressing a DFR which is capable of acting on DHK;
(ii) it is capable of expressing a non-indigenous F3'5'H; and
(iii) it is capable of expressing a non-indigenous DFR which is capable of acting on DHM but is substantially incapable of acting on DHK.
In accordance with this aspect of the present invention, the flowers exhibiting altered flower colour will now have the capacity to metabolise DHK to DHM and delphinidin and derivatives thereof of the flavonoid pathway.
Preferably, the transgenic plant is also substantially incapable of expressing a F3'H.
Other aspects of the present invention include the use of genetic sequences encoding separately a F3'5'H, a DFR which is capable of acting on DHM but is substantially incapable of acting on DHK, and optionally also a F3'H, in the genetic manipulation of a carnation plant substantially incapable of expressing or synthesizing an active DFR capable of acting on DHK or DHM, so as to allow the manufacture of a carnation plant exhibiting altered flower colour compared to a carnation plant which is capable of synthesizing a DFR capable of acting on DHK. In a related aspect, the present invention extends to flowers and in particular flowers cut from said carnation plants.
The present invention is further described by reference to the following figures and/or examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the pathways for conversion of dihydroflavonols to flavonols and anthocyanins. Abbreviations: DHK=dihydrokaempferol, DHQ=dihydroquercetin, DHM=dihydromyricetin, K=kaempferol, Q=quercetin, M=myricetin, F3'H=flavonoid 3'-hydroxylase, F3'5'H=flavonoid 3',5'-hydroxylase, FLS=flavonol synthase, DFR=dihydroflavonol-4-reductase, ANS=anthocyanidin synthase, 3GT=flavonoid 3-glucosyltransferase.
FIG. 2 is an autoradiographic representation of a Northern analysis comparing the expression levels of DFR and ANS mRNA in thirteen commercially-available white carnation cultivars. Arrows point to the relevant transcripts.
FIG. 3 is a diagrammatic representation of the binary expression vector pCGP1470, construction of which is described in Example 9. Tc resistance=the tetracycline resistance gene; LB=left border; RB=right border; surB=the coding region and terminator sequences for the tobacco acetolactate synthase gene; 35S=the promoter region from the cauliflower mosaic virus 35S gene; CHS=the promoter region from the snapdragon chalcone synthase gene; Hf1=the DNA sequence encoding petunia flavonoid 3',5'-hydroxylase; D8=terminator sequence from a petunia phospholipid transferase; MAC=the mannopine synthase promoter enhanced with cauliflower mosaic virus 35S gene sequences; DFR=the DNA sequence encoding dihydroflavonol-4-reductase; mas=the terminator sequence from the Agrobacterium tumefaciens mannopine synthase gene. Selected restriction enzyme sites are indicated.
FIG. 4 is a diagrammatic representation of the binary expression vector PCGP1473, construction of which is described in Example 10. Tc resistance=the tetracycline resistance gene; LB=left border; RB=right border; surB=the coding region and terminator sequences for the tobacco acetolactate synthase gene; 35S=the promoter region from the cauliflower mosaic virus 35S gene; CHS=the promoter region from the snapdragon chalcone synthase gene; Hf1=the DNA sequence encoding petunia flavonoid 3',5'-hydroxylase; D8=terminator sequence from a petunia phospholipid transferase; genomic DFR=the DNA sequence encoding dihydroflavonol-4-reductase. Selected restriction enzyme sites are indicated.
FIG. 5 is an autoradiographic representation of a Southern hybridization of DNA isolated from leaf tissue from White Unesco, which had been transformed with a genetic construct (pCGP1470) containing the tobacco acetolactate synthase gene as selectable marker, and the nucleic acid molecule encoding F3',5'H and DFR. Carnation genomic DNA was digested with the restriction endonuclease XbaI and the Southern blot was probed with a 32 P-labelled 730 base-pair fragment of the petunia F3',5'H coding region. Filters were washed in 0.2×SSC/1% w/v SDS at 65° C. Lanes 1-12 represent DNA samples isolated from independent transgenic plants whilst lane 13 is non-transformed White Unesco (negative control). No bands were detected in the non-transformed negative control. Lane 14 represents 33 pg of pCGP1470 plasmid DNA digested with XbaI.
FIGS. 6A-6B are autoradiographic representations of Northern blots of F3',5'H and DFR RNA in petals. Total RNA(10 μg/lane) was analysed from petals of White Unesco plants transformed with pCGP1470 (lanes 1-7), and petals of non-transgenic White Unesco flowers (lane 8). No bands were detected in the non-transformed negative control in lane 8. Lane 9 represents 10 μg of RNA isolated from Petunia hybrida cv. Old Glory Blue. A: Northern blot was hybridized with 32 P-labelled DNA from a 730 bp EcoRV fragment of a petunia F3',5'H cDNA clone and washed in 2×SSC/1% w/v SDS at 65° C. for 0.5 hour. B: Northern blot was hybridized with a 32 P-labelled 1.2 kb SacI/XbaI DNA fragment of a petunia DFR cDNA clone from plasmid pCGP1403 (see Example 8a).
FIG. 7 is a black and white representation of a colour photographic plate representing a non-transgenic control White Unesco flower (the white flower on the left) and a flower from a White Unesco plant transformed with pCGP1470. The transformed plant produces a flower which is lilac/violet in colour.
Original colour plates are available for inspection from the Applicant.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Strategy for Altering Flower Colour Using DFR Mutant Cultivars
The flowers of some plants such as, for example, rose, carnation and gerbera, produce two types of anthocyanidins, depending on their genotype--pelargonidin and cyanidin. In the absence of F3'H activity, pelargonidin is produced; in its presence, cyanidin is produced. Pelargonidin is usually accompanied by kaempferol, a colourless flavonol. Cyanidin pigments are usually accompanied by either quercetin or both kaempferol and quercetin. Both pelargonidin and kaempferol are derived from DHK; both cyanidin and quercetin are derived from DHQ (FIG. 1). A number of enzymes, including DFR, ANS and 3GT are required for the conversion of dihydroflavonols (DHK, DHQ and DHM) to the coloured anthocyanins. A third type of anthocyanidin, delphinidin, cannot be produced in flowers of these plants, owing to the natural absence of F3',5'H activity.
In carnation, the DFR enzyme is capable of metabolising two dihydroflavonols, DHK and DHQ, to leucoanthocyanidins which are ultimately converted to anthocyanidin pigments which are responsible for flower colour. DHK is converted to leucopelargonidin giving rise to red-coloured carnations and DHQ to leucocyanidin producing crimson carnations (Geissman and Mehlquist, 1947; Stich et al., 1992b) (see FIG. 1). Carnation DFR is also capable of converting DHM to leucodelphinidin (Forkmann et al., 1987). However, naturally-occurring carnation lines do not contain a flavonoid 3',5'-hydroxylase enzyme and therefore do not synthesise DHM.
The petunia enzyme has a different specificity to that of the carnation DFR. It is able to convert DHQ through no leucocyanidin, but it is not able to convert DHK to leucopelargonidin (Forkmann et al., 1987). In petunia lines containing the F3',5'H enzyme, the petunia DFR enzyme can convert eh DHM produced by the action of F3',5'H to leucodelphinidin, which is further modified giving rise to delphinidin--the pigment responsible for blue-coloured flowers (see FIG. 1). Even though the petunia DFR is capable of converting both DHQ and DHM, it is able to convert DHM far more efficiently, favouring the production of delphinidin (Forkmann et al., 1987).
Carnation is transformable with a nucleic acid molecule encoding the petunia F3',5'H from another species, thereby allowing the production of DHM and ultimately the accumulation of delphinidin (International Patent Application No. PCT/AU94/00265; [WO94/28140]). However, the efficiency of delphinidin product in many of these plants is low due to the competition of carnation DFR with the F3',5'H enzyme for DHK or DHQ as substrate. The accumulation of significant amounts of delphinidin may, therefore, be limited by the action of the carnation DFR.
The inventors have shown that the efficiency of delphinidin product is markedly increased by transformation of a DFR mutant cultivar with an appropriate genetic construct. In such a line there is no accumulation of anthocyanin, due to the absence of DFR enzyme activity. However, when a nucleic acid molecule encoding the petunia DFR enzyme is used to transform this line, together with a nucleic acid molecule encoding flavonoid 3',5'-hydroxylase and both enzymes are expressed, DHK is then converted to leucodelphinidin by the introduced enzymes and ultimately to delphinidic pigments by the plant's endogenous enzymes. If the DFR mutant line is also a F3'H mutant, there is little or no production of DHQ and therefore the only anthocyanins produced by the transgenic plants are delphinidin derivatives. In the presence of the F3'H, cyanidin pigments may also be produced, but delphinidin is the major anthocyanin produced because the petunia DFR is more efficient at utilizing DHM than DHQ as a substrate. Flowers from carnation plants genetically manipulated in this manner produce a range of flower colours covering lilac, violet, purple and blue or various shades thereof. Exemplification of the application of this strategy in accordance with the present invention in the production of carnations with altered flower colour is provided by the following examples.
EXAMPLE 2
Screening of Dianthus caryophyllus (carnation) Cultivars
a. Flavonol analysis of carnation flowers
To identify carnation cultivars having genotypes suitable for application of the strategy of Example 1, white-flowered cultivars were obtained. Flavonols were extracted from each and analysed by thin layer chromatography (TLC), as described in Example 16a. The only flavonol detected in all of these cultivars was kaempferol, indicating that F3'H activity was absent, or substantially reduced, in the flowers of all cultivars.
b. Northern analysis of white carnation cultivars
Northern analysis was then performed, as described in Example 14. After the RNA was transferred from the gel to a Hybond-N filter (Amersham), the filter was probed with the 290 bp BamHI/HindIII cDNA fragment of ANS (described in Example 6) labelled with 32 P. The 1.2 kbp Asp718/BamHI partial DFR clone (described in Example 7) was also labelled with 32 P and used to probe duplicate filters. Prehybridisation (1 hour at 42° C.) and hybridization (16 hours at 42° C.) were carried out as described in Example 14. Filters were washed in 2×SSC, 1% w/v SDS at 65° C. for 1 to 2 hours and then 0.2×SSC, 1% w/v SDS at 65° C. for 0.5 to 1 hours. The Northerns were autoradiographed overnight at -70° C.
This analysis indicated that two of the tested carnation cultivars had no DFR message, while still producing significant levels of ANS mRNA (see FIG. 2). These two carnation cultivars, White Unesco and White Diana, thus appeared to be of the correct genotype for application of this strategy.
c. Leucoanthocyanidin feeding experiments
To confirm that White Diana and White Unesco were not mutated in any of the genes necessary for conversion of leucoanthocyanidin to anthocyanin, precursor feeding experiments were carried out. Petal segments of White Unesco and White Diana were placed in 1 mg/mL solutions of leucopelargonidin and leucocyanidin and incubated for 16 hours at room temperature. Anthocycanin synthesis occurred near the cut edges of the petals in each case. Leucopelargonidin feeding led to the synthesis of pelargonidin, and leucocyanidin led to the synthesis of cyanidin. Anthocyanidin identity was determined by TLC analysis (see Example 16b). Either of these two cultivars was thereby shown to be a suitable candidate for genetic manipulation utilizing the DFR mutant strategy. Further exemplification is provided with cv. White Unesco.
EXAMPLE 3
Biological Reagents
All restriction enzymes and other reagents were obtained from commercial sources and used generally according to the manufacturer's recommendations.
The cloning vector pBluescript II (KS + ) was obtained from Stratagene. The SmaI-cut pUC18 cloning vector was obtained from Pharmacia.
EXAMPLE 4
Bacterial Strains
The bacterial strains used in the following examples were:
Escherichia coli:
XL1-Blue
supE44, hsdR17(r k -, m k +), recA1, endA1, byra96(Nal r ), thi-1, relA1, lac-, [F'proAB, lacI q , lacZΔM15, Tn10(tet r )](Bullock et al., 1987).
DH5α
supE44, Δ(lacZYA-ArgF), U169, .o slashed.80lacZΔM15, hsdR17(r k -, m k +), recA1, endA1, gyrA96(Nal r ), thi-1, relA1, deoR (Hanahan, 1983; BRL, 1986).
Agrobacterium tumefaciens:
AGL0 Lazo et al. (1991)
EXAMPLE 5
Plant Growth Conditions
Unless otherwise stated, plants were grown in specialised growth rooms with a 14 hour day length at a light intensity of 10,000 lux minimum and a temperature of 22° C. to 26° C.
EXAMPLE 6
Isolation of a Carnation Anthocyanidin Synthase cDNA Clone
a. Polymerase Chain Reaction Primers
A Polymerase Chain Reaction (PCR) method was employed to isolate a DNA fragment representing carnation anthocyanidin synthase (ANS). Degenerate oligonucleotides were designed to conserved regions of 2-oxoglutarate-dependent dioxygenase sequences from plants. Oligonucleotides were synthesized on an Applied Biosystems PCR-Mate DNA synthesiser using phosphoramidite chemistry. The oligonucleotides synthesized were:
SEQ ID NO:15' AC(A,G)TC(A,G)GT(A,G)TGIGC(T,C)TCIACICC 3' SEQ ID NO:25' TGGGA(A,G)GA(T,C)TA(T,C)ITITT(T,C)CA 3'
b. Isolation of an ANS Fragment from Carnation Petals
Total RNA was extracted from petals of carnation cv. Laguna flowers at stage 1(Stich et al., 1992a) using the method of Turpen and Griffith (1986). Oligo dT (12-18)-primed cDNA was synthesized from 50 μg of total RNA by Superscript™ (BRL) according to the manufacturer's instructions. The cDNA was purified by S200 spun-column chromatography (Pharmacia) followed by ethanol precipitation. PCR amplification was carried out on 50 ng of cDNA in the presence of 10 mM Tris-HCl (pH 8.3), 50 mM KCl, 2 mM MgCl 2 , 0.01% gelatine, 0.2 mM dATP, 0.2 mM dCTP, 0.2 mM dGTP, 0.2 mM dTTP, 0.4 μM each primer and 1.25 units Taq polymerase (Cetus). The reaction mix (50 μL) was cycled once at each of 95° C. for 3 min; 48° C. for 1 min; 72° C. for 1 min; and then 39 times at each of 95° C. for 1 min; 48° C. for 1 min; 72° C. for 1 min. A DNA fragment of 290 base pairs (bp) was produced.
c. Sequence analysis of carnation ANS fragment
The 290 bp fragment was isolated by Sea Plaque™ low gelling temperature agarose (FMC) electrophoresis in a TAE running buffer (40 mM Tris, 50 mM acetic acid, 50 mM EDTA). The DNA was extracted from the agarose by heating to 65° C., phenol extraction and ethanol precipitation. The fragment was then ligated into a ddT-tailed vector prepared as described by Holton and Graham (1991). Sequencing of plasmid clones was performed using Prism™ Ready Reaction Dye Primer chemistry and a DNA Sequencing System 373A (Applied Biosystems). When compared with the petunia ANS cDNA (Weiss et al., 1993) using FASTA (Pearson and Lipman, 1988) the carnation sequence showed 83% homology at the amino acid level. This 290 bp cDNA fragment was used in Northern analysis of a range of white carnation cultivars (as described in Example 2b).
EXAMPLE 7
Isolation of a Carnation Dihydroflavonol-4-reductase (DFR) cDNA Clone
a. Construction of a cDNA library
Total RNA was extracted from carnation cv. Laguna petals at stage 9 (Stich et al., 1992a). Polyadenylated RNA was selected using the Oligotex (Qiagen) purification system according to the manufacturer's instruction. A directional cDNA library was constructed using 2 μg of poly(A) + RNA, as a template for cDNA synthesis, and Superscript™ (BRL) according to the manufacturer's instructions. DNA Polymerase I (Klenow fragment) was used to synthesize second strand cDNA which was blunted and ligated to EcoRI adapters. After digestion with XhoI, the cDNA was size-fractionated on a S200 column (Pharmacia). One third of the cDNA was ligated with 1 μg of Uni-Zap™ XR vector (Stratagene). Ligation was carried out at 4° C. for 4 days and then packaged using Packagene™ (Promega). The resultant library contained 1.5×10 5 plaque forming units (p.f.u.) and was amplified by eluting the bacteriophage from the agar plates into phage storage buffer (100 mM NaCl, 10 mM MgCl 2 , 10 mM Tris-HCl (pH 7.4), 0.05% w/v gelatine).
b. Screening of the cDNA library
Approximately 100,000 p.f.u. were plated (at 10,000 pfu/plate) onto NZY plates and incubated at 37° C. for 8 hours and then at 4° C. for 1 hour. Thereafter, duplicate colony lifts were taken onto Colony/Plaque Screen™ filters (DuPont) and treated as recommended by the manufacturer. Prior to hybridization, the duplicate filters were prewashed in a solution of 50 mM Tris-HCl pH 8.0, 1 M NaCl, 1 mM EDTA, 0.1% w/v sarcosine (prewashing solution) at 42° C. for 30 minutes followed by similar washes in 0.4 M NaOH and in neutralising solution (0.5 M Tris-HCl pH 8.0, 1.5 M NaCl). After rinsing in 2×SSC, the colony lifts were prehybridized (42° C., 1 hour) and hybridized (42° C., overnight) in a solution of 6×SSC (0.6 M NaCl, 0.06 M sodium citrate), 0.5% w/v sodium dodecyl sulphate (SDS), 0.1% polyvinyl-pyrrolidone (PVP), 0.1% w/v bovine serum albumin (BSA), 0.1% ficoll, 0.01 M ethylenediaminetetra-acetic acid (EDTA), and 100 mg/mL denatured herring sperm DNA. The full-length = P-labelled petunia dihyroflavonol 4-reductase (DFR) cDNA clone from pCGP1403 (Example 8) was used for hybridization. Filters were washed at 65° C. in 2×SSC/1% w/v SDS and exposed to Kodak XAR film with an intensifying screen at -70° C. for 16 hours.
c. Sequence analysis of the carnation DFR cDNA clone
The clones isolated were sequenced using Prism™ Ready Reaction Dye Primer chemistry and a DNA Sequencing System 373A (Applied Biosystems). One clone was found to have homology with the petunia DFR. This clone contained a 1.2 kilobase pair (kbp) cDNA insert and appeared to be a partial DFR clone only.
Double-stranded DNA sequence of the entire cDNA insert was obtained using a shotgun clone sequencing strategy. The DFR cDNA fragment was purified, self-ligated and sheared by ultrasound (four times seven-second bursts at 20 watts from a Branson sonicator with a microprobe attached). The fragment ends were prepared using T4 DNA polymerase and size fractionated in the range of 350 to 600 bp using agarose gel electrophoresis in TAE running buffer. Fragments were purified using Geneclean (Bio101), ligated into SmaI-cut pUC18 and individual clones were sequenced. Comparison of the carnation sequence with the Swissprot protein database using the FASTA program (Pearson and Lipman, 1988) showed that there was 66.9% identity at the amino acid level with the petunia DFR cDNA and 65.7% with the snapdragon DFR. This 1.2 kbp partial DFR clone was used in Northern analysis of a range of white carnation cultivars (as described in Example 2b).
EXAMPLE 8
Isolation of Petunia DFR Genetic Sequences
a. Isolation of a functional DFR cDNA clone
To isolate a full-length petunia DFR cDNA, 200,000 clones of a Petunia hybrida cv. Old Glory Blue λZAP cDNA library (Holton et al., 1993) were screened using a 32 P-labelled 1 kb fragment of a petunia DFR cDNA clone described previously (Brugliera et al., 1994). Twenty clones hybridized strongly with this probe. These clones were picked and plasmids were excised in vitro. DNA sequence analysis revealed that eight of these clones contained the entire protein coding region of DFR, when compared with published sequences (Beld et al., 1989; Huits et al., 1994).
One of the eight full-length petunia DFR cDNA clones, contained in plasmid pCGP1403, was used to screen a carnation cDNA library, as described in Example 7. This full-length clone was further subcloned into a plant expression vector to test for function, as follows. A 1.5 kb Asp718/BamHI fragment of pCGP1403, which contained the DFR cDNA, was ligated with an Asp718/BamHI digest of the vector pCGP40 (International Patent Application No. PCT/AU92/00334 [WO 93/01290]. The resulting plasmid (pCGP1406) contained the petunia DFR cDNA between the MAC promoter (Comai et al, 1990) and the mannopine synthase (mas) terminator (Comai et al, 1990). A BglII digest of this plasmid was used in the construction of pCGP1470, as described in Example 9.
The cDNA clone in plasmid pCGP1406 was shown to be functional by bombardment of Petunia hybrida cv. Br140 petals. Br140 lacks DFr activity due to a mutation at the an6 genetic locus, so the flowers are white and do not produce anthocyanins. However, after bombardment of petals with pCGP1406, coloured cells were produced due to anthocyanin synthesis, indicating that the DFR gene fragment present in this plasmid was functional.
b. Isolation of a functional DFR genomic clone
A genomic library was made from Petunia hybrida cv. Old Glory Blue DNA in the vector λ2001 (Holton, 1992). Approximately 200,000 p.f.u. were plated out on NZY plates, lifts were taken onto NEN filters and the filters were hybridised with 400,000 cpm/mL of the 32 P-labelled 1 kb petunia DFR cDNA fragment (see 8a, above). Hybridising clones were purified, DNA was isolated from each and mapped by restriction enzyme digestion. A 13 kb SacI fragment of one of these clones was isolated and ligated with SacI-cut pBluescriptII to create pCGP1472. The genomic clone in plasmid pCGP1472 was also shown to be functional by bombardment of Petunia hybrida cv. Br140 petals. After bombardment of petals with pCGP1472, coloured cells were produced, due to anthiocyanin synthesis. Finer mapping indicated that a 5 kb BglII fragment contained in the entire DFR gene. This 5 kb fragment was used in the construction of pCGP1473, as described in Example 10.
EXAMPLE 9
Construction of pCGP1470
Plasmid pCGP485 (International Patent Application PCT/AU94/00265 [WO94/28140] was digested with PstI to release a 3.5 kb genetic construct consisting of a snapdragon CHS promoter sequence, a petunia Hf1 cDNA fragment and a petunia phospholipid transfer protein terminator sequence (International Patent Application PCT/AU92/00334 [WO/93/01290). The overhanging 3'-ends of the fragment were removed with T4 DNA polymerase according to standard protocols (Sambrook et al., 1989) before ligation into the SmaI site of the binary vector pWTT2132 (DNAP). The resultant clone was designated pCGP1452.
A 3.4 kb genetic construct containing the MAC promoter (Comai et al., 1990), a petunia DFR cDNA (Example 15) and the mannopine synthase (mas) terminator (Comai et al., 1990), was isolated from pCGP1406 as a BglII fragment (see Example 8a). The resulting 5'-overhang was "filled in" using DNA Polymerase I (Klenow fragment) according to standard protocols (Sambrook et al., 1989). The fragment was then ligated into PstI restricted, T4 DNA polymerase-treated pCGP1452 to create pCGP1470. A map of pCGP1470 is presented in FIG. 3.
EXAMPLE 10
Construction of pCGP1473
A 5 kb BGl II fragment from a petunia DFR genomic clone, pCGP1472 (described in Example 8b), was isolated and the resulting 5'-overhand was "filled in" using DNA Polymerase I (Klenow fragment). The fragment was ligated into the PstI-restricted. T4 DNA polymerase-treated pCGP1452 to create pCGP1473. A map of pCGP1473 is presented in FIG. 4.
EXAMPLE 11
Transformation of E. Coli and A. tumefaciens
Escherichia coli strains DH5α and XL1-Blue, used for routine manipulations, were transformed using the method of Inoue et al. (1990).
The plasmids pCGP1470 and pCGP1473 were introduced into Agrobacterium tumefaciens strain AGL0 by adding 5 μg of plasmid DNA to 100 μL of competent Agrobacterium tumefaciens cells prepared by inoculating a 50 mL MG/L (Garfinkel and Nester 1980) culture and growing for 16 hours with shaking at 28° C. The cells were then pelleted and resuspended in 1 mL of 20 mM CaCl 2 . The DNA-Agrobacterium mixture was frozen by incubation in liquid nitrogen for 2 min and then allowed to thaw by incubation at 37° C. for 5 min. The cells were then mixed with 1 mL of MG/L media and incubated with shaking for 4 hours at 28° C. Cells of A. tumefaciens carrying pCGP1470 or pCGP1473 were selected on MG/L agar plates containing 50 μg/mL tetracycline. The presence of the plasmid was confirmed by Southern analysis of DNA isolated from the tetracycline-resistant transformants.
EXAMPLE 12
Transformation of Dianthus caryophyllus (carnation) cv. White Unesco with nucleic acid molecules encoding DFR and F3'5'H
a. Plant Material
Carnation cv. White Unesco cuttings were obtained from Van Wyk and Son Flower Supply, Victoria, Australia. The outer leaves were removed and the cuttings were sterilised briefly in 70% v/v ethanol followed by 1.25% w/v sodium hypochlorite (with Tween 20) for 6 min and rinsed three times with sterile water. All the visible leaves and axillary buds were removed under the dissecting microscope before co-cultivation.
b. Co-cultivation of Agrobacterium and Carnation Tissue
Agrobacterium tumefaciens strain AGL0 (Lazo et al., 1991), containing the binary vector pCGP1470 or pCGP1473, was maintained at 4° C. on LB agar plates with 50 mg/L tetracycline. A single colony was grown overnight in liquid LB broth containing 50 mg/L tetracycline and diluted to 5×10 8 cells/mL next day before inoculation. Carnation stem tissue was co-cultivated with Agrobacterium for 5 days on MS medium supplemented with 3% w/v sucrose, 0.5 mg/L benzlaminopurine, 0.5 mg/L 2,4-dichlorophenoxy-acetic acid (2,4-D), 100 μM acetosyringone and 0.25% w/v Gelrite (pH 5.7).
c. Recovery of Transgenic Carnation Plants
For selection of transformed stem tissue, the top 6-8 mm of each co-cultivated stem was cut into 3-4 mm segments, which were then transferred to MS medium (Murashige and Skoog, 1962) supplemented with 0.3% w/v sucrose, 0.5 mg/L BAP, 0.5 mg/L 2,4-D, 1 μg/L chlorsulfuron, 500 mg/L ticarcillin and 0.25% w/v Gelrite. After two-three weeks, explants were transferred to fresh MS medium containing 0.3% sucrose, 0.16 mg/L thidiazuron (TDZ), 0.5 mg/L indole-3-butyric acid (IBA), 2 μg/L chlorsulfuron, 500 mg/L ticarcillin and 0.25% w/v Gelrite and care was taken at this stage to remove axillary shoots from stem explants. After 3 weeks, healthy adventitious shoots were transferred to hormone free MS medium containing 3% w/v sucrose, 3 μg/L chlorsulfuron, 500 mg/L ticarcillin, 0.25% w/v Gelrite. Shoots which survived 3 μg/L chlorsulfuron were transferred to MS medium supplemented with 3% w/v sucrose, 500 mg/L ticarcillin, 5 μg/L chlorsulfuron and 0.25% w/v Gelrite for shoot elongation.
After 2-3 weeks, leaves were pulled from the shoots which had survived selection and were placed on a regeneration medium consisting of MS medium supplemented with 0.22 mg/L TDZ, 0.5 mg/L IBA, 3 μg/L chlorsulfuron, 500 mg/L ticarcillin and 0.25% w/v Gelrite, to obtain shoot regeneration in the presence of selection. Regenerated shoots were transferred to hormone-free MS medium containing 5 μg/L chlorsulfuron, 500 mg/L ticarcillin and 0.25% w/v Gelrite for 2-4 weeks, then to hormone-free MS medium containing 200 mg/L ticarcillin and 0.4% w/v Gelrite, in glass jars, for normalisation. Suncaps (Sigma) were placed on top of the glass jars to hasten the normalisation of shoots. All cultures were maintained under a 16 hour photoperiod (120 μE/m 2 /s cool white fluorescent light) at 23° C.±2° C. Normalised shoots, approximately 1.5-2.0 cm tall, were rooted on 3 g/kg IBA rooting powder and acclimatised under mist. A soil mix containing 75% perlite/25% peat was used for acclimation, which was carried out at 23° C. under a 14 hour photoperiod (200 μE/m 2 /s mercury halide light) and typically lasted 3-4 weeks. Plants were fertilised with a carnation mix containing 1 g/L CaNO 3 and 0.75 g/L of a mixture of microelements plus N:P:K in the ratio 4.7:3.5:29.2.
EXAMPLE 13
Southern Analysis
a. Isolation of Genomic DNA from Carnation
DNA was isolated from 0.3-0.5 grams of leaf tissue using the method of Lassner et al. (1989).
b. Southern Blots
Approximately 1 μg of genomic DNA was digested with XbaI and electrophoresed through a 1% w/v agarose gel in a running buffer of TAE. The DNA was then denatured in denaturing solution (1.5 M NaCl/0.5 M NaOH) for 0.5 to 1.0 hour, neutralised in 0.5 M Tris-HCl (pH 7.5)/1.5 M NaCl for 0.5 to 1.0 hour and the DNA was then transferred to a Hybond-N (Amersham) filter in 20×SSC.
Filters were hybridized with 32 P-labelled DNA (10 8 cpm/μg, 2×10 6 cpm/mL) from a 730 bp EcoRV fragment of a petunia Hf1 cDNA clone. Filters were washed in 2×SSC/1% w/v SDS at 65° C. for 1 hour and then 0.2×SSC/1% w/v SDS at 65° C. for 1 hour.
Southern analysis of putative transgenic carnation plants obtained after selection on chlorsulfuron confirmed the integration of the genetic construct comprising the nucleic acid molecule encoding F3'5'H into the genome, as shown in FIG. 5. Northern analysis of flowers from carnation plants transformed with pCGP1470, performed as described in Example 14, below, confirmed that the introduced nucleic acid molecules defining F3'5'H and DFR were both expressed (see FIG. 6).
EXAMPLE 14
Northern Analysis
Total RNA was isolated from tissue that had been frozen in liquid nitrogen and ground to a fine powder using a mortar and pestle. An extraction buffer of 4 M guanidine isothiocyanate, 50 mM Tris-HCl (pH 8.0), 20 mM EDTA, 0.1% v/v Sarkosyl, was added to the tissue and the mixture was homogenised for 1 minute using a polytron at maximum speed. After the suspension was filtered through Miracloth, it was centrifuged in a JA20 rotor for 10 minutes at 10,000 rpm. The supernatant was transferred to a clean tube and 0.2 grams of CsCl was added for each mL of supernatant. The CsCl was dissolved by mixing and samples were then layered over a 10 mL cusion of 5.7 M CsCl, 50 mM EDTA (pH 7.0) in 38.5 mL Quick-seal centrifuge tubes (Beckman) and centrifuged at 42,000 rpm for 12-16 hours at 23° C. in a Ti-70 rotor. Pellets were resuspended in TE/SDS (10 mM Tris-HCl (pH 7.5), 1 mM EDTA, 1.0% w/v SDS) and extracted with phenol:chloroform (1:1) saturated in 10 mM EDTA (pH 7.5). Following ethanol precipitation the RNA pellets were resuspended in Te/SDS.
RNA samples were electrophoresed through 2.2 M formaldehyde/1.2% w/v agarose gels using running buffer containing 40 mM morpholino-propanesulphonic acid (pH 7.0), 5 mM sodium acetate, 0.1 mM EDTA (pH 8.0). The RNA was transferred to Hybond-N filters (Amersham) as described by the manufacturer and probed with the appropriate 32 P-labelled cDNA fragment (10 8 cpm/μg, 2×10 6 cpm/mL). Prehybridization (1 hour at 42° C.) and hybridization (16 hours at 42° C.) were carried out in 50% v/v formamide, 1 M NaCl, 1% w/v SDS, 10% w/v dextran sulphate. Degraded herring sperm DNA (100 μg/mL) was added with the 32 P-labelled probe for the hybridization step.
Filters were washed in 2×SSC/1% w/v SDS at 65° C. for 1 hour and then 0.2×SSC/1% w/v SDS at 65° C. for 1 hour. All filters were exposed to Kodak XAR film with an intensifying screen at -70° C. for 48 hours.
EXAMPLE 15
Altered flower phenotype
The expression of the introduced nucleic acid molecules representing F3'5'H and DFR in the DFR/F3'H mutant carnation cultivar White Unesco had a marked effect on flower colour. The flowers of the non-transgenic plants are white, whereas the transgenic plants produced flowers which were a lilac/violet colour. The colour changes observed may also be described in terms of numbers from the Royal Horiticultural Society's Colour Chart. In general, the changes can be described as moving the colour from white to the purple/violet/blue hues represented by many, but not all, of the colour squares between 80 and 98.
Although not wishing to limit the possible colour changes which may be achieved, some of the colours observed in flowers of transformed White Unesco plants could be described, approximately, as having changed from white (untransformed) to 84B/C (transformed). Furthermore, the use of a stronger promoter to direct expression of the introduced nucleic acid molecules may allow production of even higher amounts of delphinidin pigment, thereby causing the development of colours of bluer hue. It should be remembered that other biochemical and physiological conditions such as petal pH, extend of co-pigmentation and degree of acylation of anthocyanins will also affect the individual outcome. These can be manipulated by transformation of other suitable cultivars, or by co-transformation with nucleic acid molecules affecting pH co-pigmentation or acylation. This may enable the development of colours of bluer hue. The citing of specific colours achieved should not be interpreted as defining or limiting the possible range.
EXAMPLE 16
Flavonoid analyses
a. TLC analysis of flavonols
Approximately 0.5 gram of fresh carnation petal tissue was added to 1 mL of 2 M HCl in a 1.5 mL microcentrifuge tube (Eppendorf) and heated in a boiling water bath for 30 minutes. Cellular debris was pelleted by centrifugation at 14,000 rpm for 5 minutes and 500 μL of supernatant was transferred to a clean microcentrifuge tube. Flavonoids were extracted with 200 μL ethylacetate and centrifuged briefly to separate the phases. The upper (ethylacetate) phase was transferred to a new microcentrifuge tube, dried down under vacuum in a SpeedVac Concentrator (Savant) and resuspended in 15 μL ethylacetate and a 2 μL aliquot was spotted onto a cellulose TLC sheet (20 cm×20 cm, Merck) and run for approximately 3-4 hours in Forestal solvent (30 parts acetic acid: 3 parts HCl: 10 parts water). The TLC plate was then allowed to air dry and the flavonols were viewed under ultraviolet light.
b. TLC analysis of anthocyanidins
Two carnation petals were added to 1 mL of 2 M HCl in a 1.5 mL microcentrifuge tube (Eppendorf) and heated in a boiling water bath for 30 minutes. Cellular debris was pelleted by centrifugation at 14,000 rpm for 5 minutes and 500 μL of supernatant was transferred to a clean microcentrifuge tube. Anthocyanidins were extracted with 200 μL of iso-amylalcohol (IAA) and centrifuged briefly to separate the phases. The upper phase (IAA) was transferred to a new tube, dried down under vacuum and resuspended in 20 μL of IAA and a 1 μL aliquot was spotted onto a cellulose TLC sheet (20×20 cm, Merck) and run for approximately 3-4 hours in Forestal solvent. The TLC plate was allowed to air dry and the anthocyanidins could be viewed under normal light.
c. HPLC analysis of anthocyanidins
Anthocyanins were extracted and hydrolysed by incubating approximately 0.5 g carnation petals with 1 mL of 2 M HCl at 100° C. for 30 minutes. Anthocyanidins were extracted with 200 μL of IAA. One quarter of this mixture was dried down under vacuum and resuspended in 200 μL of 50% acetonitrile and 0.5% TFA (tri-fluoro acetic acid). A 5 μL aliquot was analysed by HPLC via gradient elution using gradient conditions of 50%B to 60%B over 10 minutes, then 60%B for 10 minutes and finally 60%B to 100%B over 5 minutes, where solvent A consisted of TFA:water (5:995) and solvent B consisted of acetonitrile:TFA:water (500:5:495). An Asahi Pac ODP-50 cartridge column (250 mm×4.6 mm, internal diameter) was used for the reversed phase chromatographic separations. The flow rate was 1 mL/minute and the temperature was 40° C. The detection of anthocyanidins was carried out using a Shimadzu SPD-M6A three-dimensional detector at 400-650 nm.
EXAMPLE 17
Bombardment of petals with DNA-coated microprojectiles
Particle bombardment using 1 μm gold particles were performed essentially as described by Sanford et al. (1993). The biolistic Bio-Rad PDS-100 helium-driven gun with 1100 psi rupture disks was used for all bombardments. Petals were dissected from opening carnation flower buds and placed on top of a plate of MS medium (+0.25% gelrite) before bombardment. Each plate was bombarded twice with an independently-prepared batch of DNA-coated gold particles. The plasmid DNA used for bombardment was purified using either a CsCl gradient method (Sambrook et al., 1989) or a Qiagen column (Qiagen). One microgram of DNA was used per shot.
EXAMPLE 18
32 P-Labelling of DNA Probes
DNA fragments (50 to 100 ng) were radioactively labelled with 50 μCi of [α- 32 P]-dCTP using an oligolabelling kit (Bresatec). Unincorporated [α- 32 P]-dCTP was removed by chromatography on a Sephadex G-50 (Fine) column as described by Sambrook et al. (1989).
Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications. The invention also includes all of the steps, features, compositions and compounds referred to or indicated in this specification, individually or collectively, and any and all combinations of any two or more of said steps or features.
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Weiss, D., van der Luit, A. H., Kroon, J. T. M., Mol, J. N. M. and Kooter, J. M. Plant Molecular Biology 22: 893-897, 1993.
Wiering, H. and de Vlaming, P., Inheritance and Biochemistry of Pigments. In: Petunia Sink, K. C. (ed.) Springer-Verlag, Berlin, Germany, pp 49-65, 1984.
__________________________________________________________________________# SEQUENCE LISTING - - - - <160> NUMBER OF SEQ ID NOS: 2 - - <210> SEQ ID NO 1 <211> LENGTH: 23 <212> TYPE: DNA <213> ORGANISM: Artificial Sequence <220> FEATURE: <223> OTHER INFORMATION: Synthesized <220> FEATURE: <221> NAME/KEY: modified base <222> LOCATION: 12 <223> OTHER INFORMATION: n is inosine <220> FEATURE: <221> NAME/KEY: modified base <222> LOCATION: 18 <223> OTHER INFORMATION: n is inosine <220> FEATURE: <221> NAME/KEY: modified base <222> LOCATION: 21 <223> OTHER INFORMATION: n is inosine - - <400> SEQUENCE: 1 - - acrtcrgtrt gngcytcnac ncc - # - # 23 - - - - <210> SEQ ID NO 2 <211> LENGTH: 20 <212> TYPE: DNA <213> ORGANISM: Artificial Sequence <220> FEATURE: <223> OTHER INFORMATION: Synthesized <220> FEATURE: <221> NAME/KEY: modified base <222> LOCATION: 13 <223> OTHER INFORMATION: n is inosine <220> FEATURE: <221> NAME/KEY: modified base <222> LOCATION: 15 <223> OTHER INFORMATION: n is inosine - - <400> SEQUENCE: 2 - - tgggargayt ayntnttyca - # - # - # 20__________________________________________________________________________
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The present invention relates generally to novel approaches in generating transgenic plants exhibiting altered flower colour by the introduction of a nucleotide sequence encoding dihydroflavonol-4-reductase (DFR) which preferably acts on dihydromyricetin (DHM). More particularly, the present invention provides transgenic carnation plants and flowers cut therefrom exhibiting flower colouration not naturally associated with carnation plants. The present invention further contemplates methods for producing transgenic carnation plants with the altered flower colour.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to gas turbine engines. More particularly, the invention relates to gas turbine engines having center-tie rotor stacks.
[0002] A gas turbine engine typically includes one or more rotor stacks associated with one or more sections of the engine. A rotor stack may include several longitudinally spaced apart blade-carrying disks of successive stages of the section. A stator structure may include circumferential stages of vanes longitudinally interspersed with the rotor disks. The rotor disks are secured to each other against relative rotation and the rotor stack is secured against rotation relative to other components on its common spool (e.g., the low and high speed/pressure spools of the engine).
[0003] Numerous systems have been used to tie rotor disks together. In an exemplary center-tie system, the disks are held longitudinally spaced from each other by sleeve-like spacers. The spacers may be unitarily-formed with one or both adjacent disks. However, some spacers are often separate from at least one of the adjacent pair of disks and may engage that disk via an interference fit and/or a keying arrangement. The interference fit or keying arrangement may require the maintenance of a longitudinal compressive force across the disk stack so as to maintain the engagement. The compressive force may be obtained by securing opposite ends of the stack to a central shaft passing within the stack. The stack may be mounted to the shaft with a longitudinal precompression force so that a tensile force of equal magnitude is transmitted through the portion of the shaft within the stack.
[0004] Alternate configurations involve the use of an array of circumferentially-spaced tie rods extending through web portions of the rotor disks to tie the disks together. In such systems, the associated spool may lack a shaft portion passing within the rotor. Rather, separate shaft segments may extend longitudinally outward from one or both ends of the rotor stack.
[0005] Desired improvements in efficiency and output have greatly driven developments in turbine engine configurations. Efficiency may include both performance efficiency and manufacturing efficiency.
[0006] U.S. patent application Ser. No. 10/825,255, Ser. No. 10/825,256, and Ser. No. 10/985,863 of Suciu and Norris (hereafter collectively the Suciu et al. applications, the disclosures of which are incorporated by reference herein as if set forth at length) disclose engines having one or more outwardly concave inter-disk spacers. With the rotor rotating, a centrifugal action may maintain longitudinal rotor compression and engagement between a spacer and at least one of the adjacent disks. This engagement may transmit longitudinal torque between the disks in addition to the compression.
SUMMARY OF THE INVENTION
[0007] One aspect of the invention involves a turbine engine having a first disk and a second disk, each extending radially from an inner aperture to an outer periphery. A coupling, transmits a torque and a longitudinal compressive force between the first and second disks. The coupling has first means for transmitting a majority of the torque and a majority of the force and second means, radially outboard of the first means, for vibration stabilizing of the first and second disks.
[0008] In various implementations, the second means may include spacers (e.g., as in the Suciu et al. applications or otherwise). The first means may comprise radial splines or interfitting first and second pluralities of teeth on the first and second disks, respectively. The first plurality of teeth may be formed at an aft rim of a first sleeve extending aft from and unitarily-formed with a web of the first disk. The second plurality of teeth may be formed at a forward rim of a second sleeve extending forward from and unitarily-formed with a web of the second disk. The first and second disks may each have an inboard annular protuberance inboard of the respective first and second sleeves. The second means may comprise a spacer having an outwardly longitudinally concave portion having a thickness and a longitudinal extent effective to provide an increase in said force with an increase in rotational speed of the first and second disks. The engine may have a high speed and pressure turbine section and a low speed and pressure turbine section. The first and second disks may be in the low speed and pressure turbine section. The engine may be a geared turbofan engine. A tension shaft may extend within the inner aperture of each of the first and second disks and be substantially nonrotating relative to the first and second disks. The engine may include a vane stage having a number of vane airfoils and having a sealing portion radially inboard of the vane airfoils for sealing with the coupling second means. A third disk may extend radially from an inner aperture to an outer periphery. A second coupling may transmit a torque and a longitudinal compressive force between the third and second disks. The second coupling may include first means for transmitting a majority of the torque and a majority of the force and second means, radially outboard of the first means, for vibration stabilizing. The engine may lack off-center tie members holding the first and second disks under longitudinal compression.
[0009] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a partial longitudinal sectional view of a gas turbine engine.
[0011] FIG. 2 is a partial longitudinal sectional view of a low pressure turbine rotor stack of the engine of FIG. 1 .
[0012] FIG. 3 is a radial view of interfitting splines of two disks of the stack of FIG. 2 .
[0013] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0014] FIG. 1 shows a gas turbine engine 20 having a high speed/pressure compressor (HPC) section 22 receiving air moving along a core flowpath 500 from a low speed/pressure compressor (LPC) section 23 and delivering the air to a combustor section 24 . High and low speed/pressure turbine (HPT, LPT) sections 25 and 26 are downstream of the combustor along the core flowpath 500 . The engine further includes a fan 28 driving air along a bypass flowpath 501 . Alternative engines might include an augmentor (not shown) among other systems or features.
[0015] The exemplary engine 20 includes low and high speed spools mounted for rotation about an engine central longitudinal axis or centerline 502 relative to an engine stationary structure via several bearing systems. A low speed shaft 29 carries LPC and LPT rotors and their blades to form a low speed spool. The low speed shaft 29 may be an assembly, either fully or partially integrated (e.g., via welding). The low speed shaft is coupled to the fan 28 by an epicyclic transmission 30 to drive the fan at a lower speed than the low speed spool. The high speed spool includes the HPC and HPT rotors and their blades.
[0016] FIG. 2 shows an LPT rotor stack 32 mounted to the low speed shaft 29 across an aft portion 33 thereof. The exemplary rotor stack 32 includes, from fore to aft and upstream to downstream, an exemplary three blade disks 34 A- 34 C each carrying an associated stage of blades 36 A- 36 C (e.g., by engagement of fir tree blade roots 37 to complementary disk slots). A plurality of stages of vanes 38 A- 38 C are located along the core flowpath 500 sequentially interspersed with the blade stages. The vanes have airfoils extending radially inward from roots at outboard shrouds/platforms 39 formed as portions of a core flowpath outer wall 40 . The vane airfoils extend inward to inboard platforms 42 forming portions of a core flowpath inboard wall 43 . The platforms 42 of the second and third vane stages 38 B and 38 C have inwardly-extending flanges to which stepped honeycomb seals 44 are mounted (e.g., by screws or other fasteners).
[0017] In the exemplary embodiment, each of the disks 34 A- 34 C has a generally annular web 50 A- 50 C extending radially outward from an inboard annular protuberance known as a “bore” 52 A- 52 C to an outboard peripheral portion 54 bearing an array of the fir tree slots 55 . The bores 52 A- 52 C encircle central apertures of the disks through which the portion 33 of the low speed shaft 29 freely passes with clearance. Alternative blades may be unitarily formed with the peripheral portions 54 (e.g., as a single piece with continuous microstructure) or non-unitarily integrally formed (e.g., via welding so as to only be destructively removable).
[0018] Outboard spacers 62 A and 62 B connect adjacent pairs of the disks 34 A- 34 C. In the exemplary engine, the spacers 62 A and 62 B are formed separately from their adjacent disks. The spacers 62 A and 62 B may each have end portions in contacting engagement with adjacent portions (e.g., to peripheral portions 54 ) of the adjacent disks. Alternative spacers may be integrally with (e.g., unitarily formed with or welded to) one of the adjacent disks and extend to a contacting engagement with the other disk.
[0019] In the exemplary engine, the spacers 62 A and 62 B are outwardly concave (e.g., as disclosed in the Suciu et al. applications). The contacting engagement with the peripheral portions of the adjacent disks produces a longitudinal engagement force increasing with speed due to centrifugal action tending to straighten/flatten the spacers' sections. The exemplary spacers 62 A and 62 B have outboard surfaces from which one or more annular sealing teeth (e.g., fore and aft teeth 63 and 64 ) extend radially outward into sealing proximity with adjacent portions of the adjacent honeycomb seal 44 .
[0020] The spacers 62 A and 62 B thus each separate an inboard/interior annular inter-disk cavity 65 from an outboard/exterior annular inter-disk cavity 66 (accommodating the honeycomb seal 44 and its associated mounting hardware).
[0021] Additional inter-disk coupling is provided between the disks 34 A- 34 C. FIG. 2 shows couplings 70 A and 70 B radially inboard of the associated spacers 62 A and 62 B. The couplings 70 A and 70 B separate the associated annular inter-disk cavity 65 from an inter-disk cavity 72 between the adjacent bores. Each exemplary coupling 70 A and 70 B includes a first tubular ring-like structure 74 ( FIG. 3 ) extending aft from the disk thereahead and a second such structure 76 extending forward from the disk aft thereof. The exemplary structures 74 and 76 are each unitarily-formed with their associated individual disk, extending respectively aft and forward from near the junction of the disk web and bore.
[0022] At respective aft and fore rims of the structures 74 and 76 , the structures include interfitting radial splines or teeth 78 in a circumferential array ( FIG. 3 ). The exemplary illustrated teeth 78 have a longitudinal span roughly the same as a radial span and a circumferential span somewhat longer. The exemplary teeth 78 have distally-tapering sides 80 extending to ends or apexes 82 . In the exemplary engine, the sides 80 of each tooth contact the adjacent sides of the adjacent teeth of the other structure 74 or 76 . In the exemplary engine, there is a gap between each tooth end 82 and the base 84 of the inter-tooth trough of the opposite structure. This gap permits longitudinal compressive force to reinforce circumferential engagement and maintain the two structures tightly engaged. Snap couplings or curvic couplings or other spline structures could be used instead of the exemplary spline structure.
[0023] In the exemplary engine, the couplings 70 A and 70 B transmit the majority of longitudinal compressive force and longitudinal torque along a primary compression path between their adjacent disks. A much smaller longitudinal force may be transmitted via the couplings 62 A and 62 B which may primarily serve to maintain position of and stabilize against vibration of the disks. A particular breakdown of force transmission may be dictated by packaging constraints. In the exemplary engine, the fore and aft ends of the LPT rotor engaging the shaft 29 are formed by fore and aft hubs 90 and 92 extending respectively fore and aft from the associated bores 52 A and 52 C. The relative inboard radial position of these hubs renders impractical a relatively outboard force transmission. An outward shifting of the hubs would increase longitudinal size and, thereby, create packaging and other problems. Thus, the couplings 70 A and 70 B are advantageously radially positioned near the connections of the disk bores 52 A and 52 C to the associated hubs 90 and 92 .
[0024] The relative inboard position of the main compression and torque carrying couplings may provide design opportunities and advantages relative to alternate configurations. The use of geared turbofans has decoupled the design speed of the low speed spool from the design speed of the fan. This presents opportunities for increasing the speed of the low speed spool. Such increased speeds (e.g., typical operating speeds in the 9-10,000 rpm range) involve increased loading. To withstand increased loading, it may be desired to remove outboard weight such as outboard flanges and bolts that tie the disks together and transmit torque and/or force. A similar opportunity could be presented in the turbine section of the intermediate spool of a three-spool engine (e.g., wherein the fan is directly coupled to the low speed spool).
[0025] In the exemplary engine, the low speed shaft 29 is used as a center tension tie to hold the disks of the rotor 32 in compression. The disks may be assembled to the shaft 29 from fore-to-aft (e.g., first installing the disk 34 A, then installing the spacer 62 A, then installing the disk 34 B, then installing the spacer 62 B, then installing the disk 34 C, and then compressing the stack and installing a locking nut or other element 96 ( FIG. 2 ) to hold the stack precompressed).
[0026] Tightness of the rotor stack at the disk outboard peripheries may be achieved in a number of ways. Outward concavity of the spacers 62 A and 62 B may produce a speed-increasing longitudinal compression force along a secondary compression path through the spacers 62 A and 62 B. Additionally, the static conditions of the fore and aft disks 34 A and 34 C may be slightly dished respectively forwardly and aft. With rotation, centrifugal action will tend to straighten/undish the disks 34 A and 34 C and move the peripheral portions 54 of the disks 34 A and 34 C longitudinally inward (i.e., respectively aft and forward). This tendency may counter the effect on and from the spacers 62 A and 62 B so as to at least partially resist their flattening. By at least partially resisting this flattening, good sealing with the honeycomb seals 44 may be achieved across a relatively wide speed range.
[0027] The foregoing principles may be applied in the reengineering of an existing engine configuration or in an original engineering process. Various engineering techniques may be utilized. These may include simulations and actual hardware testing. The simulations/testing may be performed at static conditions and one or more non-zero speed conditions. The non-zero speed conditions may include one or both of steady-state operation and transient conditions (e.g., accelerations, decelerations, and combinations thereof). The simulation/tests may be performed iteratively. The iteration may involve varying parameters of the spacers 62 A and 62 B such as spacer thickness, spacer curvature or other shape parameters, vane seal shape parameters, and static seal-to-spacer separation (which may include varying specific positions for the seal and the spacer). The iteration may involve varying parameters of the couplings 70 A and 70 B such as the thickness profiles of the structures 74 and 76 , the size and geometry of the teeth 78 , the radial position of the couplings, and the like.
[0028] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when applied as a reengineering of an existing engine configuration, details of the existing configuration may influence details of any particular implementation. Accordingly, other embodiments are within the scope of the following claims.
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A turbine engine has a first disk and a second disk, each extending radially from an inner aperture to an outer periphery. A coupling, transmits a torque and a longitudinal compressive force between the first and second disks. The coupling has first means for transmitting a majority of the torque and a majority of the force and second means, radially outboard of the first means, for vibration stabilizing.
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DISCLOSURE OF THE INVENTION
1. Field of the Invention:
This invention relates to concrete masonry blocks and more particularly to concrete masonry blocks that have external plates anchored through the blocks. Further, the invention relates to a method of constructing a wall having concrete masonry blocks with external plates at predetermined locations so that heavy objects can be supported from the external plates secured in concrete masonry blocks in the wall. A method for forming concrete masonry blocks with external plates and internal anchors is also shown.
2. Brief Description of the Prior Art:
Concrete masonry blocks have been used in the building of buildings throughout most industrialized countries of the world. Concrete masonry blocks come in many different sizes and shapes. A typical rectangular concrete masonry block used in building a wall will have two external faces so that when the concrete masonry block is installed in the wall, the external faces will be on either side of the wall. Internally, within the concrete masonry blocks, a pair of vertical holes extend upward through the concrete masonry blocks. Typically, one end of the concrete masonry block is fluted and the other end of the concrete masonry block is smooth. The width of the concrete masonry block may vary depending on the strength desired in the wall.
In government buildings, especially prisons, concrete masonry blocks are used because they are structurally strong, functional, and are easy to maintain. However, in many governmental buildings, especially prisons, it is important to be able to anchor items to the wall, which items would not touch the floor. In the past, it has been a very labor intensive process to suspend items from the wall. For example, a hole will have to be drilled through concrete masonry blocks forming the wall and anchor plates installed on either side of the wall. The anchor plates would have to be installed in a way that would not be easily removable. The installing of anchor plates in the wall after the wall is built is very time consuming, labor intensive, and expensive.
Just some of the things that are typically attached to the wall that would require anchor plates would be shelf hooks, privacy panels, grab bars, bunk beds, sliding devices, mounting of doors, television stands, or ceiling plates. These are only some of the items that may have to be attached to the wall in a governmental facility such as a prison.
There is a long felt unmet demand for better ways to attach to concrete walls throughout the industrialized countries of the world. It may be a facility such as a public restroom, cafeteria, school, or any other similar facility that needs to be structurally strong, functional, and easy to maintain. Any public facility that has items suspended from the wall rather than sitting on the floor is much easier to clean and maintain.
Fricker, U.S. Pat. No. 5,197,255, shows an anchoring device for attaching flat panels to a wall. The Fricker patent does not appear to be that close to the present invention.
Kline, U.S. Pat. No. 5,402,616, shows the imbedding of a metal weldment into the concrete slab structure. Again, this patent does not appear to be very close to the present invention.
Parkes, U.S. Pat. No. 3,236,545, shows a replacement block that is used for electrical outlets and conduits. Parker does not talk about supporting items from the wall structure.
Woodruff, U.S. Pat. No. 4,414,674, shows an electric furnace thermal insulating module that does not appear to be close to the present invention.
The patents cited hereinabove were the patents found in the patentability search conducted by applicant. None of the prior art found by applicant suggests in any way the anchoring of external plates to the surface of concrete masonry blocks with internal anchors during the forming of the concrete masonry blocks.
Dec-Tech, Inc. from Covington, La. has been offering for sale a steel block that can be substituted for a concrete masonry block. The steel blocks by Dec-Tech, Inc. are not formed with concrete. Also, because the steel blocks do not have concrete, the Dec-Tech, Inc. steel blocks do not have anchors extending through concrete to hold the plates in position.
SUMMARY OF THE INVENTION
It is an object of the present invention to show concrete masonry blocks having an external plate or plates that are anchored in the concrete at the time the concrete masonry block is formed.
It is another object of the present invention to have a series of different types of concrete masonry blocks having external plates anchored therethrough, the design of the external plate and the concrete masonry blocks depending on the needs of the end user.
It is a further object of the present invention to have a series of concrete masonry blocks with external plates and anchors extending therethrough, such concrete masonry blocks include the following:
a. Full length, double sided plates with end caps.
b. Half length, double sided plates with end caps.
c. Full length, double sided plates.
d. Half length, double sided plates.
e. Full length, single sided plates.
f. Half length, single sided plates
g. Half blocks with full length, double sided plates and end caps
h. Half blocks with double sided plates.
i. Upper half, single sided plates.
j. Full length, double sided plates with different anchor designs.
k. Full length, single sided plates with different anchor designs.
It is a further object of the present invention to provide other designs of external plates on concrete masonry blocks having anchors formed within the concrete masonry blocks at the time of casting.
It is yet another object of the present invention to construct a wall having external plates at various locations in the wall to which items can be suspended from the wall.
It still another object of the present invention to determine the type of external plate that is needed and to include the particular type of external plate in the wall at the time of construction of a wall to support items from the wall.
It is yet another object of the present invention to provide a method of forming concrete masonry blocks having external plates and embedded anchors at the time of casting the concrete masonry blocks so that when the concrete masonry blocks are cured, the external plates are securely anchored to the external surface of the concrete masonry blocks.
It is yet another object of the present invention to provide indexing for positioning the external plates and anchors within molds used to form the concrete masonry blocks.
A concrete casting machine using a mold and supporting pallet is normally used to form concrete masonry blocks. In the present invention, the supporting pallet feeds into the concrete casting machine, and while the casting machine is open, external steel plates and anchors are placed at predetermined locations on the supporting pallet. The mold is then lowered into position on the supporting pallet with the external plates and anchors being received inside of the mold. Concrete mix is used to fill the mold box. Normally the mold is vibrated to insure the concrete fills up all of the voids in the mold box.
Next, the compression portion of the mold pushes down into the mold box to compress the concrete mix in the desired shape of a block having external plate or plates with internal anchors. The mold is stripped from the concrete masonry block, the concrete masonry block is removed from the concrete casting machine, and the concrete masonry block is moved to the kiln chamber for heating and solidifying the concrete. The anchors are formed inside the concrete masonry block at the time it is made with the external plates being on the external surface or surfaces of the concrete masonry block.
A wide variety of different types of blocks with external plates can be made. The only limitation is the expense and cost to the end user.
When building a wall that needs external plates for attachment of items to the wall, the wall will be built using normal concrete masonry blocks, but at predetermined locations, blocks with external plates will be installed. Thereafter, items to be suspended from the wall can be anchored to the plate by any convenient means such as welding, though other types of anchoring devices could be used.
By use of external plates already anchored in preformed concrete masonry blocks, the large amount of time, labor, and expense involved in installing plates for suspension of items from the wall has been eliminated. While the concrete masonry blocks with external plates, known as M-Bed Block Systems, is a more expensive block, it more than makes up for the cost differential in the reduced labor and costs. As is known by those skilled in the art, the concrete masonry wall should be reinforced by pouring concrete in the center openings and having reinforcing rods in the poured concrete.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a through 1k are a series of perspective views of different types of concrete masonry blocks made according to the present invention with the internal anchors being shown in broken lines.
FIGS. 2a through 2c are the top plane view, front elevational view, and end view of the concrete masonry block illustrated in FIG. 1j.
FIGS. 3a through 3g are planned perspective views of sections of walls utilizing different concrete masonry blocks made according to the present invention.
FIG. 4 is a perspective view of a concrete casting machine used to form concrete masonry blocks made according to the present invention.
FIG. 5 is perspective view of a supporting pallet containing indexing to properly locate the external plates and anchors on the supporting pallet prior to insertion into a mold of a concrete masonry blocks casting machine.
FIG. 6 is an exploded perspective view of the upper and lower portions of the mold with the supporting pallet and external plates and anchors prior to being inserted into the mold box.
FIG. 7 is a partial perspective view illustrating positioning of external plates and anchors on the supporting pallet prior to being received in a mold box of a concrete masonry casting machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
First, the applicant will describe some of the many different types of concrete masonry blocks that can be formed with external plates anchored through the concrete masonry blocks. Second, a detailed description of one of the many blocks will be given as further reference. Third, illustrative sections of walls will be shown to demonstrate how M/Bed Blocks made according to the present invention would be used. Fourth, how the M/Bed Blocks that have external plates and internal anchors are formed will be illustrated and discussed in a series of views.
In FIG. 1a, a full length block 10 is shown with double sided external plates and end cap 12. The full length block 10 has vertical holes 14 and 16 therein as is standard in most blocks. One end of the full length block 10 has flutes 18 on either side thereof.
Imbedded in the concrete of the full length block 10 are four identical anchors that will be designated hereinafter for identical type anchors as reference numeral 20. The anchors 20 are welded to the left side 24 and right side 26 of the double sided external plates and end cap 12. The anchors 20 located at the fluted end 28 are imbedded in the fluted concrete 30. The anchors 20 located at the center of the full length block 10 are imbedded in the center concrete 32.
The end cap 34 is formed integrally with the left side 24 and right side 26 of the double sided external plates and end cap 12. While the double sided external plate and end cap 12 may vary in thickness and material, it is presently envisioned that 3/16 inch thick steel plates will be used. Likewise, while the types of anchors and the thickness thereof can vary, it is currently envisioned that the anchors 20 will also be 3/16 inch steel plates bent to the configuration as shown.
In referring to the subsequent FIGS. 1b through 1k, the same numbers that were used to designate the same parts in connection with FIG. 1a will be used for subsequent figures. Only the parts that are different will be described in detail hereinbelow.
In FIG. 1b, a full length block 10 is shown that has half length, double sided plates with end caps 36. Again, the anchors 20 extend through the center concrete 32 and are welded on either end to the left side 38 and right side 40 of the half length, double sided plates 36. The end cap 34 is the same as previously described.
Because the left side 38 and right side 40 of half length, double sided plates 36 are placed in the concrete masonry at the same time the full length block 10 is formed, the external surfaces of the block are basically smooth even at the terminal end 42 of the left side 48 and right side 40 of half length, double sided plates 36.
In FIG. 1c, a full length block 10 is shown with double sided external plates with a left plate 44 and a right plate 46. The left plate 44 and the right plate 46 are connected together by anchors 20 welded to the respective left plate 44 or right plate 46. The anchor 20 on the fluted end 28 extends through fluted concrete 30. Anchors 20 that are in the middle extend through the center concrete 32. Anchors 20 that are on the flat end 48 of full length block 10 extend through flat end concrete 50.
In FIG. 1d, a full length block 10 is shown with double sided half plates having a left half plate 52 and a right half plate 54. Anchors 20 that are located at the center of the full length block 10 extend through the center concrete 32. Anchors 20 that are at the flat end 48 extend through the flat end concrete 50. Again, the anchors 20 are connected to the left half plate 52 and the right half plate 54 by welding the ends thereto.
FIG. 1e shows a full length block 10 with a full length, single sided plate 56. The anchors 58 are made from an appropriate size steel to withstand the stress. It is believed that 3/16 inch steel cut and bent to the configuration as shown will withstand the stress. The anchors 58 only have end lips 22 on the right side of the full length, concrete masonry block 10. The anchors 58 are abutted against and welded to the full length, single sided plate 56. The anchors 58 at the fluted end 28 extend through fluted concrete 30 with the end lips 22 being imbedded in concrete on the right side of the full length block 10. Likewise, anchors 58 at the center of full length concrete masonry block 10 extend through center concrete 30 with the end lips 22 being imbedded in concrete on the right side of full length block 10. The anchors 58 located on the flat end 48 of the full length block 10 extend through the flat end concrete 50 with the end lips 22 being anchored in concrete on the right side of full length block 10.
In FIG. 1f, a full length block 10 is shown with a single sided, half length plate 60. Anchors 58 are welded to the single sided plate 60 with the center anchors extending though center concrete 32 and the flat end anchors 58 extending through flat end concrete 50. Again, the end lips 22 are imbedded in the concrete on the right hand side of the full length concrete masonry block 10.
FIG. 1g shows a half length block 62 that has double sided, external plates with end cap 64. Anchors 66 extend through the fluted concrete 30 at the fluted end 28 and are welded on either end thereof to the left side 68 and the right side 70 of the double sided, external plates with end caps 64. The double sided external plates 64 have an end cap 72 similar to the end cap shown in FIG. 1a.
FIG. 1h shows a half length block 62 having double sided, external plates made up of left side 68 and right side 70. Again, anchors 66 are welded on either end thereof to either the left side 68 or the right side 70 of the external plates. On the fluted end 28, the anchor 66 extended through the fluted concrete 30. On the flat end 48, the anchors 66 extend through the flat end concrete 50. In both FIGS. 1g and 1h, a vertical hole 74 extends upward through the half length block 62.
In FIG. 1i, a full length block 10 is shown with an upper half, single sided plate 76. Anchors 58 hold the upper half, single sided plate 76 in position. The anchors 58 extend through fluted concrete 30, center concrete 32, and flat end concrete 50. The end lips 22 are imbedded in the concrete on the right hand side of full length block 10. The anchors 58 are welded to the upper half, single sided plate 76.
FIG. 1j shows a full length concrete masonry block 10 with single sided plate 46 on one side and an upper half single sided plate 76 on the other side. The lower anchors 58 have end lips 22 to hold in the concrete. Upper anchors 66 used in FIG. 1j consist of a flat piece of metal cut and welded to plate 46 and plate 76. Again, the anchors 66 are imbedded in fluted concrete 30, center concrete 32, and flat end concrete 50.
FIG. 1k is similar to FIG. 1e except it uses a different type of anchor. FIG. 1k shows a full length concrete masonry block 10 with a full length, single sided plate 56. The anchors 78 are made from fibbed rebar and are welded on the right end to full length, single sided plate 56. Again, the anchors 78 go through fluted concrete 30, center concrete 32, and flat end concrete 50.
To illustrate in more detail the physical construction of one of the concrete masonry blocks shown in FIGS. 1a through 1k, FIG. 1j has been selected for illustration purposes. Referring to FIGS. 2a, b, and c in combination, the physical layout of a typical concrete masonry block having external steel plates is illustrated. Again, the same numbers will be used as were used in FIG. 1j for illustration purposes. The anchors 58, as they connect from left plate 44 to right plate 46, are clearly illustrated. Also, the burying of the anchors 58 in either the fluted concrete 30, center concrete 32, or flat end concrete 50 is also illustrated. By viewing FIGS. 1a through c in combination, the physical structure of a typical block having external plates and anchors as shown in the present invention is clearly illustrated.
Assume that blocks such as illustrated in FIGS. 1a through 1k have been made. The purpose of FIGS. 3a through 3g is to illustrate how those blocks would be used in a typical wall. Like numbers that are used to illustrate wall sections will be used in all of the FIGS. 3a through 3g. Only a short section of the wall will be illustrated to demonstrate the different types of uses of blocks having external plates as shown in the present invention.
Referring to FIG. 3a, a block wall section 80 is illustrated. The plain blocks 82 do not have any external plates formed therein. However, two blocks are made according to the present invention and have external plates 84. The external plates 84 are at a height that is typically used to mount shelves. Shelf hooks would be welded or anchored to external plates 84 by any convenient means. In the typical block wail section 80, the wall would need to be poured and reinforced with reinforcing rods to maintain the structural integrity of the wall. This is especially true when an object of heavy weight is to be supported from the external plates 84.
Block wall section 80 as shown in FIG. 3b has a total of four half plates 86. The half plates 86 are arranged in such a configuration that two of the half plates are located one above the other with the other two half plates being on the same plane, but a few feet apart. The half plates 86 as illustrated in FIG. 3b are of a typical height on which a television stand could be mounted. By simply attaching mounting brackets to the half plates 86, a television stand could then be supported by the block wall section 80. Again, all the remainder of the blocks will be plain concrete masonry blocks 82.
Referring to FIG. 3c, half plates 86 are mounted in the wall and arranged so that they are paired with each pair having two half plates in a vertical arrangement. All of the pairs of half plates 86 are on the same plane. The configuration as shown in FIG. 3c is arranged at a typical height so that bunk beds could be attached to the wall 80. By welding or attaching appropriate hooks to the half plates 86, bunk beds could then be suspended from the wall 80. Again, the remainder of the blocks could be plain concrete masonry blocks 82.
FIG. 3d shows a wall section 80 constructed primarily of plain blocks 82, but having two half plates 86 arranged a couple of feet from the bottom of the wall. The half plates 86 are in the same plain and would typically be used to attach grab bars thereto.
In FIG. 3e, a wall section 80 is illustrated constructed primarily of plain concrete masonry blocks 82. However, in FIG. 3e, vertical rows 88 of half plates 86 are shown. The vertical rows 88 are used to attach privacy panels or other types of dividers as may typically be used in restrooms.
Referring to FIG. 3f, the wall section 80 is shown that has a doorway 92 located therein. Surrounding the doorway are a combination of full length blocks having half length, double sided plates with end caps 36 and half length blocks having double sided, external plates with end caps 64. The door structure (not shown) would be attached to the combination of half length, double sided plates with end caps 36 and the double sided, external plates with end caps 64.
If the door is a sliding door, the lower part could have a full length, double sided external plate and end cap 12 with full length, double sided plate 94.
At the top of the doorway 92, full length, double sided plates 94 may be mounted in a row. These full length, double sided plates 94 that are mounted in the horizontal row at the top of the doorway 92 can be used for a number of different purposes. First, if the door is a sliding type door, it can be used to mount the door (not shown). Second, if some type of sliding device needs to be suspended from the wall, full length, double sided plates 94 provide an excellent way to mount the sliding devices. While FIG. 3f has been described as full length, double sided plates 94, they could be single sided, full length plates.
FIG. 3g shows a corner section 96 of a typical wall utilizing the present invention. In the corner section 96, there are two horizontal rows 98 and 100 of full length plates made according to the present invention. The horizontal row 100 of the external plates could be used to mount sliding devices thereto. The upper horizontal row 98 would be what is typically used in prisons to mount ceiling plates to prevent escape of the prisoners.
It should be realized that any number or combination of external plates made according to the present invention could be installed in the wall depending on what the end user wants to accomplish with the invention.
FIG. 4 shows a typical concrete masonry block casting machine illustrated by reference numeral 102. While many different types of casting machines could be used, for the purposes of the present illustration, a Fleming machine is illustrated. However, concrete casting machines made by Columbia or Besser could also be used. Concrete mix 104 is stored in a hopper 106. The concrete mix 104 feeds from the hopper 106, on the belt conveyor 108, to the intake 110 of the concrete casting machine 102.
Pallets 112 also feed into the casting machine 102 by means of conveyor 114. Mold 116 is positioned in the concrete casting machine 102 in the conventional way. Mold 116 determines the type of concrete masonry block being case. The operation of the concrete casting machine 102 is typical with the exception of the portions described hereinbelow.
Referring to FIG. 5, a perspective view of a typical pallet 112 that would be used to form concrete masonry blocks according to the present invention is shown. The pallet 112 has a combination of rounded humps 118 that would typically extend about one eighth of an inch high. The rounded humps 118 can then be used to position the external plates on the pallet 112. For example, a double sided external plate with end cap 12 is illustrated on pallet 112. The double side external plate and end cap 12 is pushed securely against the corner humps 120 and the side humps 122.
The humps 120 and 122 inside the steel plates. If outside, the mold 116 must be indented to accommodate the humps 120 and 122. If inside, the concrete in the formed block will contain an indentation when formed, but the indentation will be filled with mortar when the block is installed in a wall.
Inside of the concrete masonry casting machine 102, the external plates and/or anchors must be located inside of the mold 116. Referring to FIG. 6 , an exploded perspective view of how the external plates and molds fit together is illustrated. The double sided, external plate and end cap 12 is positioned on the pallet 112 by pushing against the corner humps 120 and the side humps 122. When the lower part of the mold box 124 moves down, the double sided, external plates and end cap 12 are received inside of the mold box 124. If it is necessary to secure the double sided, external plates 12 in position, electromagnets 126 may be included in the mold box 124. It is not known at the present time whether the electromagnets 126 will be necessary to hold the double sided, external plate and end cap in position.
Once the lower part of the mold box 124 is filled, the upper portion of the mold 128 comes down and presses the concrete mix to form a block in the desired shape as dictated by the mold 116 including the lower part 124 and upper part 128.
Between the making of concrete masonry blocks by the concrete casting machine 102, the number and shape being determined by the mold 116, the operator must position the external plates into position on the pallet 112. In the Fleming machine, it is open for a period of time during which the steel plates may be inserted and positioned on the pallet 112. This is illustrated in FIG. 7. The pallet also must rest in a very accurate position against side rails 130 and against a stop 132 so that everything is properly aligned with the mold 116. The stop 132 may be lowered by motor 134 when the cast masonry blocks are to be removed.
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The present invention is directed toward a concrete masonry block used to construct masonry walls in a building. The concrete masonry block has an external plate or plates that are anchored through the concrete masonry block. The external plate or plates many cover a small or substantial portion of the external surfaces of the concrete masonry block. The casting machine that casts the concrete masonry block receives the external plate or plates and anchors into the mold prior to casting the concrete masonry block. During casting, concrete is formed around the anchors, but inside the external plates. Thereafter, walls are built using some of the cured concrete masonry blocks with external plates at preselected locations to anchor things to the wall by attaching to the plates. Such masonry blocks are particularly useful in constructing buildings that must be structurally strong, functional, and easy to maintain.
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RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Application 60/670,084, filed on Apr. 11, 2005, and entitled BALANCE AND VESTIBULAR DISORDER DIAGNOSIS AND REHABILITATION, which is incorporated herein by reference. The present application also claims priority to U.S. Provisional Application 60/719,523, filed on Sep. 22, 2005, and entitled BALANCE AND VESTIBULAR DISORDER DIAGNOSIS AND REHABILITATION, which is also incorporated herein by reference.
TECHNICAL FIELD
[0002] The present application is directed to the display of ocular movement. More particularly, the present application is directed to the display of ocular movement by manipulating aspects of the display.
BACKGROUND
[0003] Ocular movement is observed by clinicians in order to diagnose various medical disorders including visual, vestibular, and/or neurological problems that the subject may be experiencing. The subject is asked to view a visual display that provides a stimulus to the subject. The stimulus may be voluntary, in that the subject chooses to visually respond to the stimulus, or the stimulus may be involuntary in that the eyes of the subject involuntarily respond to the stimulus. The ocular movement resulting from the stimulus is revealing to the clinician.
[0004] In order to assist the clinician in diagnosing the problem being experienced by the subject, the ocular movement may be captured on video and displayed within a graphical user interface of a computer application. The computer application may make measurements of the ocular movement of each eye which can be graphed and analyzed. The display of the video of the ocular movement assists the technician running the test by allowing the technician to make sure that the eyes are being properly tracked by the computer application. Furthermore, the display of the video of the ocular movement assists the physician by allowing the physician to see the ocular movement without directly staring at the patient while the patient is observing and responding to the stimulus. Furthermore, this video may be recorded for future playback by the physician.
[0005] To capture this video, goggles having cameras for each eye are placed onto the subject. The cameras capture the video footage of the ocular movement of each eye and provide the video stream to the computer application so that the ocular movement can be displayed and tracked. However, for the ocular movement to be properly obtained, the goggles must be properly located on the face of the subject so that each eye is being adequately recorded. This requires that the technician administering the test must spend lengthy amounts of time properly adjusting the goggles to get the best video capture.
[0006] This need for adjustment of the goggles presents many problems. Because one subject has facial features that may vary drastically from another, the amount of physical adjustment to the goggles may not provide ideal video capture of the ocular movement since the adjustment may fail to properly center the eyes within the video frames being captured. Additionally, the size of the eyes within the video frame may be inadequate for proper tracking and/or viewing. Furthermore, the subject may be having the ocular movement test performed due to a balance or dizziness disorder such that moving the head of the subject while attempting to physically adjust the goggles positioning may be uncomfortable or even unbearable.
SUMMARY
[0007] Embodiments of the present invention address these issues and others by providing control of the display of the ocular movement via the user interface being used to display the ocular movement. Such control may include panning of the video being displayed in order to change the position of the eyes within the video window, such as to center each eye on the horizontal and vertical axes. Such control may additionally or alternatively include zooming in or out of the video being displayed, such as to zoom in to make the pupil larger for proper tracking and/or to zoom in to eliminate artifacts such as parts of the goggles that may be captured by the cameras. Such control may additionally or alternatively include enlarging the video window to increase the size on the display screen of the video of ocular movement being shown, such as to allow the technician or clinician to move some distance from the display screen and continue to see the ocular movement.
[0008] One embodiment involves obtaining a sequence of digitized video frames of the ocular movement at a first resolution. A portion of each frame of the sequence of digitized video frames of the ocular movement is displayed, the portion being at a second resolution lower than the first resolution and being displayed at a first display resolution.
[0000] A first user input is received while displaying in sequence the portion of each frame, and in response to the received first user input, the portion is panned within the subsequent frames of the ocular movement being displayed.
[0009] Another embodiment is a computer system for displaying ocular movement. The computer system includes a first input receiving a sequence of digitized video frames of the ocular movement at a first resolution and a memory storing at least a portion of each digitized video frame being received. The computer system also includes a second input receiving a first user input and a processor that initiates displaying in sequence a portion of each frame of the sequence of digitized video frames of the ocular movement. The portion is at a second resolution lower than the first resolution and is displayed at a first display resolution, and in response to the received first user input the processor initiates panning the portion within the subsequent frames of the ocular movement being displayed.
[0010] Another embodiment is a computer readable medium having instructions encoded thereon that perform acts that include obtaining a sequence of digitized video frames of the ocular movement at a first resolution. The acts further include displaying in sequence a portion of each frame of the sequence of digitized video frames of the ocular movement, the portion being at a second resolution lower than the first resolution and being displayed at a first display resolution. Additionally, the acts include receiving a first user input while displaying in sequence the portion of each frame, and in response to the received first user input panning the portion within the subsequent frames of the ocular movement.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows an example of an operating environment for the various embodiments for displaying ocular movement, including goggles and a computer running a testing application.
[0012] FIG. 2 shows an example of the computer running the testing application to generate the display of ocular movement according to an embodiment.
[0013] FIG. 3 shows one example of the relationship of video capture and display processing modules and operations according to an embodiment.
[0014] FIG. 4 shows one example of the operational flow performed by the testing application when controlling the display of ocular movement according to an embodiment.
[0015] FIG. 5-D show the various resolutions of the video frames used to display the ocular movement according to one illustrative embodiment.
[0016] FIG. 6 shows a screenshot of an instant where one frame for a right eye and a left eye is being displayed and where the right eye and the left eye are at full frame.
[0017] FIG. 7 shows a screenshot of an instant where one frame for the right eye and one frame for the left eye have been zoomed to a portion of full frame.
[0018] FIG. 8 shows a screenshot of an instant where one frame for the right eye has been panned horizontally from the frame shown in FIG. 7 .
[0019] FIG. 9 shows a screenshot of an instant where one frame for the left eye has been panned horizontally from the frame shown in FIG. 7 .
[0020] FIG. 10 shows a screenshot of an instant where one frame for the right eye has been panned vertically from the frame shown in FIG. 8 .
[0021] FIG. 11 shows a screenshot of an instant where one frame for the left eye has been panned vertically from the frame shown in FIG. 8 .
[0022] FIG. 12 shows a screenshot of an instant where one frame for the right eye and one frame for the left eye have been magnified to an increased display resolution.
DETAILED DESCRIPTION
[0023] Various embodiments are disclosed herein for displaying ocular movement. According to illustrative embodiments disclosed herein, the display of a sequence of video frames of the ocular movement allows for panning of the position of the right and/or left eye within display windows. According to various embodiments, the display of the sequence of video frames allows for zooming in or out on the video frames of ocular movement and/or increasing the display resolution of the video frames thereby making them visible from a distance.
[0024] FIG. 1 shows one example of an operating environment where ocular movement is displayed in accordance with the illustrative embodiments. In this example, a subject 102 is wearing goggles 104 that have video capture ability. For example, the goggles may shine infrared light toward each eye and a separate infrared camera for each eye records the infrared video of the ocular movement. It will be appreciated that various other manners of initially generating the video signal are possible, such as using tri-pod mounted cameras, using visible light cameras as opposed to infrared cameras, and so forth.
[0025] In this example, the goggles 104 feeds a video signal to a control box 114 which powers the cameras and infrared emitters of the goggles 104 and then outputs the video signal, e.g., an NTSC signal, to a computer 108 . The control box 114 may pass through the video signal to the computer 108 or may digitize the video signal, compress the digitized video signal, and so forth prior to sending the digitized video signal to the computer 108 .
[0026] The computer 108 may employ video signal capture techniques to digitize, compress, and otherwise process the video signal where the control box 114 passes the video signal. Where the control box 114 has already digitized the video signal, the computer 108 may compress the digitized video signal if necessary and may perform additional video processing techniques. The computer 108 may store the digitized video signal for subsequent playback and/or for transport.
[0027] The computer 108 may also display the video, either in substantially real-time as the video of the ocular movement is being captured or after some delay, on a video screen 112 . A technician or clinician may view the ocular movement on the display screen 112 and may manipulate the display of the ocular movement in accordance with the various embodiments disclosed herein by interacting with user input devices of the computer 108 .
[0028] The computer 108 may also generate a stimulus display that is then shown to the subject 102 . In the example shown, the stimulus display signal is provided to a projector 110 which then projects the stimulus display so that it is visible by the subject 104 . In this particular example, the stimulus is a dot 106 that the subject 102 may stare at. The dot may move so that the subject 102 must move his or her eyes to follow the movement of the dot 106 . It will be appreciated that the stimulus may be of various forms, such as optokinetic stimuli, saccades, smooth pursuit, and the like. It will also be appreciated that other manners of displaying the stimulus are available, including placing a video display device such as a liquid crystal display, plasma display, and the like in front of the subject 102 rather than projecting the image onto a wall or screen.
[0029] FIG. 2 shows one example of the computer 108 . This computer 108 includes a processor 202 , memory 204 , input/output (I/O) 206 , mass storage 210 , a first display adapter 208 and a second display adapter 222 . The processor 202 may be a general purpose programmable processor, an application specific processor, hardwired digital logic, and so forth. The memory 204 may include volatile and non-volatile memory, may be separate from the processor 202 or may be integrated with the processor 202 . For embodiments where the computer 108 is performing various tasks such as real-time tracking and analysis in addition to displaying the ocular movement, a dual core processor implementing simultaneous parallel threads may be desirable to prevent reduction in speed of the display of the ocular movement.
[0030] The mass storage 210 is accessed by the processor through a data bus 201 . Examples of the mass storage 210 include magnetic drives and/or optical drives. The mass storage 210 may store an operating system 212 , a testing application 214 , and a database 216 . The processor 202 may access the operating system 212 to perform basic tasks and to execute the testing application 214 .
[0031] The testing application 214 provides logical operations performed by the processor 202 to obtain the video frames of the ocular movement and to initiate the display of the ocular movement via one of the display adapters. The testing application provides for manipulation of the display of the ocular movement, such as panning, zooming, and magnification. Additionally, the testing application may provide logical operations performed by the processor 202 to initiate the display of the stimulus via one of the display adapters and to record the video of the ocular movement. The testing application may provide many other features as well, such as but not limited to tracking the movement of the pupils, recording the data points representing the movement and displaying the movement in a graph, analyzing the movement in relation to set criteria, and displaying charts that are representative of the analyses.
[0032] The testing application 214 may also maintain a database 216 of test data for each subject. The test data may include the digitized and compresses video sequences, the measured data points, and the analyses. The database 216 may be used to revisit the testing, including the video, data points, and analyses at some later time after the initial testing has been completed. Furthermore, the database entries may be transportable to computer systems at remote locations.
[0033] The processor 202 , the memory 204 , and storage 210 each in their various forms represent examples of computer readable media. Computer readable media contain instructions for performing the logical operations of the various embodiments. Computer readable media include storage media, such as electronic, magnetic, and optical storage, as well as communications media such as wired and wireless data connections.
[0034] In order to initially obtain the ocular movement, the computer 108 utilizes a port of I/O system 206 , such as a universal serial port, standard serial port, IEEE 1394 port, and the like to receive the incoming video signal(s) from one or more cameras 220 , such as cameras of goggles 104 or cameras mounted to tri-pods or otherwise in a fixed position and focused on the subject 104 . As discussed above, in certain embodiments the video signal(s) may already be digitized and even compressed prior to being received through a port of I/O system 206 . In other embodiments, the video signal(s) may be analog such that a function of the I/O system 206 is to digitize the video signal(s). Further discussion of receiving the video signal is provided in relation to FIG. 3 .
[0035] The computer system 108 of FIG. 2 also includes user interface devices (UID) 218 that allow a technician or clinician to interact with the computer, namely, the testing application 214 being implemented by the computer 108 . The UID 218 may include a keyboard, mouse, touchscreen, voice command input, and the like. The testing application 214 is responsive to the user input when displaying the ocular movement in order to manipulate the display. The testing application itself may display graphical user interface controls, examples of which are shown below in relation to FIGS. 6-12 , in order to receive user input via the mouse, touch screen, or other similar input device.
[0036] To generate the display of the ocular movement, the computer system 108 utilizes a display adapter 208 to generate display signals that are sent to a display monitor 112 . Examples of such display signals include video graphics adapter (VGA) signals and the various advanced forms of that standard, such as super VGA, extended VGA, and so on. Additionally, to generate the stimulus if one is provided, the computer system 108 utilizes a display adapter 222 to generate display signals that are sent to a display monitor or projector 110 .
[0037] FIG. 3 shows the various modules and operations involved in providing the display of ocular movement and in providing additional features of the testing application. At procedure operation 302 , the clinician selects whether to begin a calibration or testing procedure for a subject. The calibration may be used in order to computer how many video frame pixels equate to a single degree of movement of the eyes of the subject. This calibration may be done where the movement of the eyes is to be measured, graphed, and analyzed by the testing application but is otherwise unnecessary for embodiments of displaying the ocular movement. Either the calibration or the testing procedure triggers a stimulus to be produced that causes the eyes of the subject to move, either voluntarily or involuntarily depending upon the test that is chosen.
[0038] The stimulus is displayed at display operation 304 . At state 306 , the ocular movement occurs as the eyes of the subject attempt respond to the stimulus being displayed. Video signals 308 are generated by the cameras where the video signals are a sequence of video frames, each frame providing an image of at least one eye of the subject so that the sequence of video frames shows the ocular movement. At digitization operation 310 , each incoming video frame is digitized, and then at memory operation 312 , the digitized video frame is loaded into memory.
[0039] In one embodiment where the video source is an NTSC video source, the frames arrive as individual fields, an odd field and an even field. Each field contains 480 interlaced lines, i.e., every other line contains information where the odd lines contain information for the odd field and the even lines contain information for the even field. The fields are receives every 1/60 th of a second so that a new frame is arriving every 1/30 th of a second. At image processing operation 314 of this particular embodiment, the odd and even fields are de-interlaced, such as by interpolation, to produce an odd field 332 and an even field 334 . As the odd field 332 and even field 334 have been de-interlaced, they are each full frames occurring every 1/60 th of a second.
[0040] It will be appreciated that other non-NTSC video sources are also possible in other embodiments and in that case, the frames may be non-interlaced frames occurring every 1/60 th of a second such that de-interlacing is not needed to produce 60 full frames per second. It will also be appreciated that in alternative embodiments, the odd field and even field of an interlaced frame may be combined to produce a full frame that refreshes 30 times per second.
[0041] The image processing operation 314 may perform various operations upon the de-interlaced odd field 332 and even field 334 of this embodiment. For example, a histogram stretch of the image intensity may be performed to improve the contrast of the frames. The intensity range of the original image may not span the entire available range, and the histogram stretch spreads the intensities through the entire range.
[0042] The image processing operation 314 may also perform operations to reduce the amount of data being handled. For an NTSC signal, the digitization and subsequent de-interlacing may result in a 640 pixel by 480 pixel frame. However, a lesser image may be desirable in order to reduce the amount of storage needed, especially considering that a separate video stream may be provided for each eye. So, the image processing operation 314 may decimate each frame to 320 pixels by 240 pixels. Additionally, only a portion of frame may be desired for display such that the frame is cropped, either before or after decimation. Further discussion of decimation and cropping is provided below in relation to FIGS. 4 and 5 A- 5 D.
[0043] At this point, the de-interlaced fields that serve as frames can be displayed at display operation 316 . Here the frames are displayed in sequence on the display screen. As discussed below in relation to FIGS. 5A-5D , the display resolution may be different than the original resolution of the digitized frame and may even be different than the resolution of the decimated frame. Interpolation may be used to display a frame having a resolution less than that of a display window in order to fill the display window with the frame. Operating systems such as the Windows® operating system by Microsoft Corp. of Redmond, Wash. provide display functions that take one image size and fill a display window of any given resolution by stretching the image along either or both axes via interpolation. Thus, the testing application may make use of the display functions of the underlying operating system. Alternatively, the testing application may implement a built-in interpolation to provide a frame that fills the display window.
[0044] During the display of the frames, user input may be received to allow the clinician to manipulate the display of the ocular movement at input operation 318 . In one embodiment, the manipulation of the ocular movement may be a zoom input 320 , a right eye horizontal pan input 322 , a right eye vertical pan input 324 , a left eye horizontal pan input 326 , a left eye vertical pan input 328 , or an enlarge input 330 . The user input may take the form of selecting a control displayed in a graphical user interface, such as a control button or scroll bar, via a mouse click or touchscreen selection, or may take the form of one or a combination of keystrokes on a keyboard or a similar user initiated action.
[0045] In addition to these controls on the contents of the display window, timing controls may also be provided for purposes of receiving user input. For example, a stop or pause button may freeze the display with the current frame and re-start the sequence from the current frame. A time scale slider may be presented to allow the viewer to move the slider around on the scale to jump the video forward or backward in time. Each video frame has a time associated with it such that the time corresponding to the position of the slider points to a particular frame. That frame can be obtained from memory or mass storage and displayed to begin the sequence of frames from that point.
[0046] As discussed above, the testing application may provide additional features beyond displaying the ocular movement. Upon the fields 332 , 334 being obtained, these fields may be analyzed to detect the location of the pupil within the frame at detection operations 336 and 338 and the change in location of the pupil from one frame to the next can be measured at measurement operation 340 .
[0047] When the testing application is performing calibration, the measured pupil movement in terms of pixels can be used to compute the number of pixels per degree of ocular movement at computation operation 342 . This pixels-per-degree constant can then be stored in memory at save operation 344 for subsequent use in graphing and analysis of the ocular movements.
[0048] When the testing application is performing an ocular movement test, the measured pupil movement can then be used to graph the movement at graph operation 348 , with each of the data points being saved from memory to the database in mass storage. Post test analyses may be performed at analysis operation 352 , such as determining whether the velocity of the ocular movement is within a normal range, and the results of this analysis may be saved to the database at save operation 354 .
[0049] Additionally, the sequence of video frames may be compressed and saved to the database in relation to the measured points and results of the analyses. For example, the sequence of video frames may be compressed using a Haar wavelet transformation in order to save storage space and to make the database information more easily transported.
[0050] FIG. 4 shows one example of a set of logical operations performed by the testing application to perform the sequence of image processing, image display, and user input operations of FIG. 3 . As discussed below, the clinician may zoom in on the image to remove artifacts that are otherwise present within the display window, such as the nosepiece of the goggles, to allow for easier viewing of the ocular movement and to aid in other features of the testing application, such as the pupil tracking where artifacts in the frame may cause problems. Furthermore, zooming provides the ability to pan within the frame so that the eye may be centered for better viewing and to aid in the other features so that physical adjustment of the goggles is unnecessary to properly center the eye. Additionally, the display window and frame within it may be enlarged to facilitate viewing from a distance.
[0051] In this illustrative embodiment shown in FIG. 4 , the testing application receives the full frame, such as one of the de-interlaced fields, at frame operation 402 . FIG. 5A shows an example of such a full frame, where in this example, the full frame is 640 pixels by 480 pixels. The full frame is then decimated at decimate operation 404 to produce a smaller frame but covering the same boundaries as the initial full frame. FIG. 5B shows an example of such a full frame after decimation, where the 640 pixel by 480 pixel frame is now 320 pixel by 240 pixel but still covers the same boundaries so that the content is the same but with less image precision. The decimated frame is then displayed in a normal display window having a particular display resolution at display operation 406 . For example, the normal display window may call for a display resolution of 320 pixels by 240 pixels to fill the window such that the decimated frame of FIG. 5B fills the display window without interpolation.
[0052] At query operation 408 , it is detected whether user input has been received to zoom, pan, or enlarge the frames being displayed. If there has yet to be a zoom, then there is no pan function available since the whole frame is being displayed. Upon the user selecting to zoom in on the full frame by some amount, the next full frame is then received at frame operation 410 . Then, the full frame is cropped based on the amount of zoom that has been requested via the user input at crop operation 412 . The center position of the frame is maintained as the center position of the resulting frame once it has been cropped since this is the first zoom attempt and no pan has been applied.
[0053] After cropping, which results in a frame that is less than 640 pixels by 480 pixels and that has boundaries moved inward, the resulting frame is then decimated at decimation operation 414 . The cropped and decimated frame is now less than 320 pixels by 240 pixels. However, the cropped and decimated frame is now displayed in the normal display window of 320 pixels by 240 pixels by using interpolation to fill the window at display operation 416 . FIG. 5C shows an example of a cropped and decimated frame that has been expanded to 320 pixels by 240 pixels via interpolation in order to fill the display window.
[0054] After having displayed the cropped and decimated frame, the process of cropping and decimating repeats for all subsequent frames being displayed until the clinician alters the zoom setting, pan setting, or requests and enlargement. It should be noted that the process of cropping and decimating may apply to both a sequence of video frames being received for the right eye as well as the sequence of video frames being received for the left eye. The zoom option may be presented to apply to both the right eye video and the left eye video, or to apply to one or the other at the option of the clinician.
[0055] Upon query operation 408 detecting that the clinician has requested to pan one of the ocular movement video displays, then the next full frame is received at frame operation 418 . Then, the full frame is cropped in accordance with the amount of zoom that has been previously set. However, in performing the cropping, the center position is not maintained for the cropped frame relative to the original frame. Instead, the center position is moved based on the amount of horizontal or vertical panning that has been input by the clinician. After cropping based on the amount of zoom and pan that has been input thus far, then the cropped frame is decimated at decimation operation 414 and the cropped and decimated frame is displayed at display operation 416 .
[0056] Again, after having displayed the cropped and decimated frame, the process of cropping based on zoom and pan and decimating repeats for all subsequent frames being displayed until the clinician alters the zoom setting, pan setting, or requests and enlargement. Upon query operation 408 detecting that the clinician has requested an enlargement of the display window and hence the frame being displayed, the next full frame is then received at frame operation 422 . Query operation 424 detects whether a zoom has been set. If so, then the zoom can be preserved for the enlargement and the full frame is cropped based on the zoom, with the center position being changed for the cropped frame based on the amount of panning that has been set thus far at crop operation 430 . The cropped frame is then decimated at decimation operation 434 and then the cropped and decimated frame is displayed in an enlarged display window via interpolation at display operation 432 . An enlarged frame is shown in FIG. 5D , where the frame has been enlarged from a resolution of less than 320 pixels by 240 pixels to a display resolution of 560 pixels by 420 pixels via interpolation.
[0057] If the zoom has not been set, then the full frame is decimated at decimation operation 426 and then the decimated frame is displayed in an enlarged display window via interpolation at display operation 428 . After the image is displayed, either as a cropped and decimated frame at display operation 432 or as a decimated frame at display operation 428 , then query operation 434 detects whether the clinician has selected to return the display window to the normal resolution. If not, then the process repeats for the subsequent frames to crop when necessary based on zoom and pan, decimate, and display in the enlarged display window. Once the clinician has selected to return the display of the frame sequence to the normal size window, then operational flow returns to query operation 408 where it is again detected whether the clinician has provided input to alter the zoom, pan, or enlargement of the frames being displayed.
[0058] FIG. 6 shows an example of a screenshot 600 from a testing application where two video signals of ocular movement are being displayed, one video signal for a right eye of a subject and one video signal for a left eye of the subject. The screenshot provides two normal sized display windows, a first display window 602 showing the right eye of the subject and a second display window 604 showing the left eye of the subject. This screenshot shows full frames as they are initially displayed prior to receiving any zoom, pan, or enlargement request by the clinician. As can be seen, the eyes of the subject are not centered within the display windows and are not aligned relative to one another so that it would be difficult for a clinician to watch the ocular movement of the two eyes. Furthermore, artifacts are present within the displayed frames, namely a nosepiece of goggles being worn by the subject and being used to capture the video signals.
[0059] Rather than physically adjusting and re-positioning the goggles on the face of the subject in an attempt to properly center and align the eyes within the display windows, the clinician utilizes video frame manipulation controls, such as controls provided in the graphical user interface of the display. The manipulation controls of this particular example include vertical scrollbars 606 and 610 as well as horizontal scrollbars 608 and 612 that may be used to pan the frames vertically and horizontally to thereby control what portions of the frames are displayed within the window. However, these scrollbars are not active within this screenshot because the full frame is being displayed as no zoom input has yet been received.
[0060] In order to zoom in on the frames being displayed, zoom controls are provided. A zoom in button 620 allows the clinician to click the button and zoom in by a set amount per click. Likewise, a zoom out button 622 allows the clinician to click the button and zoom out by a set amount per click. The zoom in is achieved in this example by cropping the frame, either before or after decimating, and then displaying the cropped and decimated frame in the display window via interpolation. The amount of cropping per click, and hence the amount of zoom to be achieved per click, or per unit of time (e.g., 0.5 seconds) that the zoom button is being pressed, is a matter of design choice but one example is a reduction of 5% of the pixels per click or per unit of time pressed. Rather than having a single button to click zoom in and another single button to click to zoom back out, it will be appreciated that other manners of receiving a zoom in or zoom out are possible, such as by presenting a range of percentages of zoom, either numerically or as a scale, and receiving a selection of that percentage.
[0061] The zoom in button 620 and zoom out button 622 may be set to work with only a single display window, and therefore a single eye, or with both windows and both eyes. A set of checkboxes or other manner of receiving a user selection may be presented for this purpose. As shown, a right eye zoom checkbox 614 , a left eye zoom checkbox 618 , and an independent eye zoom checkbox 616 are presented, and the clinician may check or uncheck these boxes to control which windows are zoomed. Clicking the independent eye zoom 616 unchecks the checkboxes 614 and 618 and allows the clinician to then check either box to re-establish zoom for that corresponding display window. Clicking the independent eye zoom 616 again re-establishes zoom for both display windows. FIG. 7 , discussed below, shows the result of zooming in.
[0062] In addition to providing the zoom and pan options, an enlarge button 624 may be provided. The clinician may wish to enlarge the display windows, and hence the size of the eyes being displayed such as if the clinician plans to step away from the display screen but wishes to continue viewing the ocular movement from a distance. The result of using the enlargement option is discussed below in relation to FIG. 12 .
[0063] The graphical user interface of the screenshot 600 may include additional sections beyond the video display windows 602 , 604 . For example, a dialog box 626 may be presented that lists the different tests that have been performed or that are to be performed along with an identification of the current subject. Furthermore, a menu bar 628 may be presented to allow the clinician to select various testing options, such as the particular type of test to perform.
[0064] Once the clinician selects the zoom in button 620 , assuming the zoom is set to work with both display windows, the size of the objects in the frame are enlarged but less of the frame is shown in the display window as illustrated in the screenshot 700 of FIG. 7 . After zooming, it can be seen that the center position has been maintained and the content of the display windows has grow in size. However, it can further be seen that the eyes are still not centered nor aligned with one another.
[0065] Now that the zoom has occurred, the pan controls become functional since there is more of the frame than what is being displayed in the display windows 602 , 604 . The scrollbar 606 now has a slider 605 , the scrollbar 608 now has a slider 607 , the scrollbar 610 now has a slider 609 , and the scrollbar 612 now has a slider 611 . The clinician can click and hold on one of these sliders and then move the slider within its corresponding scrollbar to result in a corresponding change to the portion of the frame being displayed. For example, the movement of slider 605 upward causes the center of the cropping to be shifted downward so that content toward to the bottom of the full frame becomes visible in the display while content toward the top of the full frame is cropped out.
[0066] FIG. 8 shows a screenshot 800 after the clinician has moved the slider 607 to the right to thereby shift the center of the cropping to the left. This has the effect of moving the right eye of the subject (the eye of the left display window) to the right, and since the right eye was to the left of center, the movement of the slider 607 to the right has moved the right eye closer to horizontal center. The artifacts, namely the nosepiece of the goggles, are now almost eliminated from the frame.
[0067] FIG. 9 shows a screenshot 900 after the clinician has moved the slider 611 to the right to thereby shift the center of the cropping to the left. This has the effect of moving the left eye of the subject (the eye of the right display window) to the right, and since the left eye was to the left of center, the movement of the slider 611 to the right has moved the left eye closer to horizontal center.
[0068] FIG. 10 shows a screenshot 1000 after the clinician has moved the slider 605 to downward to thereby shift the center of the cropping upward. This has the effect of moving the right eye downward, and since the right eye was above center, the movement of the slider 605 downward has moved the right eye closer to vertical center. The artifacts, namely the nosepiece of the goggles, are now completely eliminated from the frame.
[0069] FIG. 11 shows a screenshot 1100 after the clinician has moved the slider 609 to upward to thereby shift the center of the cropping downward. This has the effect of moving the left eye upward, and since the left eye was below center, the movement of the slider 605 upward has moved the left eye closer to vertical center. As can be seen in FIG. 11 , the eyes of each display window 602 , 604 are now substantially centered in the horizontal and vertical axes and are substantially aligned with the opposite eye. The clinician now has a good view of both eyes and can relate movement of one eye relative to the other. This has been accomplished without physically adjusting or re-positioning the goggles on the patient.
[0070] FIG. 12 shows a screenshot 1200 after the clinician has decided to enlarge the eyes by selecting the enlarge button 624 . In the example shown, the clinician has chosen to enlarge the frames after having zoomed in and panned to center and align the eyes. It will be appreciated that the clinician may utilize the enlarge option prior to zooming or if after zooming, prior to panning. As the display windows 1202 and 1204 are now larger than the display windows 602 and 604 , the clinician can step away from the screen but still adequately view the ocular movement. Should the clinician wish to return to a normal display window size, the clinician can select the enlarge button 624 once more. As shown, the zooming and panning features are not provided while the video display windows are enlarged. However, it will be appreciated that in other embodiments, the zoom in, zoom out, and panning features may also be provided while the video display windows are enlarged.
[0071] While the invention has been particularly shown and described with reference to various embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made therein without departing from the spirit and scope of the invention.
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Ocular movement of a subject is displayed in one or more windows of a user interface allowing a technician and/or clinician to observe the ocular movement such as to properly administer various tests for visual, vestibular, and neurological disorders as well as for diagnosing such disorders. When displaying the ocular movement, the video of the ocular movement being displayed may be panned to adjust the position of each eye within a display window as desired, such as to center the pupils and to provide a common horizontal location for both left and right pupils. Additionally, zooming in or out on the video of ocular movement may be provided to allow artifacts of the video stream to be effectively cropped from the display window and to allow the details of the ocular movement to be adequately visible. Furthermore, the display window size may be increased such that the details of the ocular movement are enlarged to allow the clinician and/or technician to better see those details even from a distance.
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BACKGROUND OF THE INVENTION
In one aspect, this invention relates to the extraction of N-methyl-2-pyrrolidone (NMP) from an aqueous medium. In another aspect, this invention relates to the recovery of NMP from an effluent of a process for preparing poly(arylene) sulfide.
The extraction of N-methyl-2-pyrrolidone (NMP) from aqueous solutions and/or slurries with polar organic solvents is known, and has been described in U.S. Pat. Nos. 3,687,907 and 3,697,487. Of particular importance is the extraction of NMP from effluents of a process for making poly(arylene sulfide), in particular poly(phenylene sulfide), also referred to as PPS. PPS process effluents generally are aqueous brines which comprise NaCl, NMP and other organic and inorganic compounds, as has been disclosed in the above-cited patents. A linear aliphatic alcohol, 1-hexanol, has been used as a extractant for NMP, as is disclosed in U.S. Pat. No. 3,687,907. However, there is an ever present need to discover more effective extractants for NMP than 1-hexanol.
SUMMARY OF THE INVENTION
It is an object of this invention to recover NMP from an aqueous medium by liquid-liquid extraction. It it another object of this invention to extract NMP from an effluent of a process for preparing poly(arylene sulfide). It is a further object of this invention to use an aliphatic alcohol as extractant for NMP. Other objects and aspects of this invention will be apparent from the detailed description and the appended claims.
In accordance with this invention, in a process for recovering N-methyl-2-pyrrolidone (NMP) from a liquid aqueous medium comprising liquid-liquid extraction with an organic extractant, the improvement comprises employing at least one branched aliphatic alcohol having 5-7 carbon atoms per molecule as extractant.
In one preferred embodiment, the extractant is 2-ethyl-1-butanol or 2-methyl-1-pentanol or a mixture thereof. In another preferred embodiment, the substantially liquid aqueous medium contains dissolved alkali metal halide and dispersed poly(arylene sulfide) particles. In a further preferred embodiment, the substantially liquid aqueous medium is an effluent from a process of preparing poly(arylene sulfide) by reaction of at least one polyhalo-substituted aromatic compound (in particular 1.4-dichlorobenzene) with an alkali metal hydrogen sulfide (in particular NaHS) in the presence of NMP.
DETAILED DESCRIPTION OF THE INVENTION
The extraction of NMP from an aquoeus medium with the extracting of this invention can be carried out in any suitable manner, substantially in accordance with the procedures described in U.S. Pat. Nos. 3,687,907 and 3,697,487, the disclosures of whichare herein incorporated by reference. Liquid-liquid extraction techniques are well known to those having ordinary skill in the art, and are not described in detail herein. Surveys of such liquid-liquid extraction techniques are provided in Kirk-Othmer Encyclopedia of Chemical Technology, Third Edition, Volume 9, 1980, John Wiley and Sons, Inc., pages 672-716; and in an article entitled "The Essentials of Extraction" by Jimmy L. Humphrey et al, Chemical Engineering, Sept. 27, 1984, pages 76 and 84-88.
In preferred embodiments of this invention, the NMP-containing aqueous medium is a brine and contains at least one dissolved alkali metal halide, in particular alkali metal chloride (more preferably NaCl), which can be present in any suitable concentration (e.g., 0.1-20 weight-%), preferably about 1-115 weight-% alkali metal halide. The aqueous medium can contain water at any suitable concentration, preferably about 20 to about 95 weight-% H 2 O. The aqueous medium can contain NMP at any suitable concentration, preferably about 2 to about 50, more preferably about 5 to about 40, weight-% NMP. The aqueous medium can contain other impurities, such as 1,4-dichlorobenzene, NaSH, Na 2 S, sodium acetate, and dispersed poly(phenylene) sulfide PPS particles, as has been described in the above-cited patent references.
The extraction process can be carried out at any suitable temperature (preferably at about 20° to about 100° C.), at any suitable pressure (preferably at about 1-20 atm., more preferably at about 1 atm.), and at any suitable weight ratio of alcohol extractant to NMP-containing aqueous medium (preferably at about 0.5:1 to about 2:1).
The extractant, which exhibits little solubility in water, can be any branched aliphatic alcohol having 5-7 carbon atoms per molecule, such as 2-methyl-1-butanol, 3-methyl-1-butanol, 3-methyl-2-butanol, 2-methyl-1-pentanol, 3-methyl-1-pentanol, 2-ethyl-1-butanol, 3-methyl-2-pentanol, 3-ethyl-1-pentanol, 2-methyl-1-hexanol, 3-methyl-1-hexanol, 4-methyl-1-hexanol, 4-methyl-2-hexanol, and the like, and mixtures thereof; preferably 2-ethyl-1-butanol or 2-methyl-1-pentanol.
After the extraction step, i.e., the step of intimately contacting (preferably with agitation) the aqueous medium with the extractant, two liquid phases (i.e., an aqueous raffinate phase from which at least a portion of the NMP has been removed, and a branched alcohol containing extract phase which contains the portion of NMP which has been removed from the aqueous medium) are formed. The two liquid phases are then separated from one another. This can be achieved by any suitable means, such as draining of the lower phase or of the upper phase or of both phases, or by any other conventional separation technique.
The subsequent separation of the alcohol extractant from NMP (both contained in the extract phase) can be achieved by any suitable means, such as fractional distillation. The alcohol can be recycled for reuse in the extraction step, and NMP can be recycled to the process from which the aqueous NMP-containing medium originated, e.g., to a poly(arylene sulfide) reactor.
The following example is presented to further illustrate the invention and is not to be construed as unduly limiting the scope of this invention.
EXAMPLE
An aqueous feed comprising water, NMP and NaCl was contacted with alcoholic extractants in a one-stage liquid-liquid glass extractor (capacity: about 300 cc; equipped with inside stirrer, internal heating means, thermometer and condenser) at about 80° C. and an extractant: feed weight ratio of about 0.9:1. After the feed and the extractant had been intimately contacted in the extractor, the two liquid phases which formed were allowed to separate and were then analyzed. Results of these tests are summarized in Table I.
TABLE I__________________________________________________________________________ Feed (g) Bottom Top NMP Extractant + Phase Phase Recovery RecoveryExtractant Extractant (g) (g) (g) (Wt %).sup.1 (Wt %).sup.2__________________________________________________________________________2-Ethyl- H2O 40.24 33.59 5.911-butanol NMP 13.89 3.86 10.64 72.2 99.2 NaCl 1.45 1.44 0.00 Extr. 50.00 0.42 48.342-Methyl- H2O 54.32 48.27 7.641-pentanol NMP 18.76 6.05 11.59 67.8 99.0 NaCl 1.95 1.95 0.00 Extr. 67.60 0.66 64.761-Hexanol H2O 54.32 46.42 9.42 NMP 18.76 6.39 12.28 65.9 99.4 NaCl 1.95 1.95 0.00 Extr. 67.60 0.43 64.75__________________________________________________________________________ .sup.1 NMP Recovery = (NMP in Feed - NMP in Bottom Phase) ÷ (NMP in Feed) × 100 .sup.2 Extractant Recovery = (Extractant in Feed - Extractant in Bottom Phase) ÷ (Extractant in Feed) × 100
Test results in Table I clearly show the greater effectiveness as NMP extractants of the two branched hexanols versus linear 1-hexanol.
Additional tests revealed that the NMP recovery by liquid-liquid extraction was greater at a higher NaCl concentration of the feed (up to 15 weight-% NaCl).
Reasonable variations and modifications, which will be apparent to those having ordinary skills in the art, can be made in this invention without departing from the spirit and scope thereof.
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In a process for recovery N-methyl-2-pyrrolidone from a liquid aqueous medium (preferably a brine) by liquid-liquid extraction, the improvement comprises using a branched aliphatic C5-C7 alcohol as extractant. In a particular embodiment, the liquid aqueous medium is an effluent from a poly(arylene sulfide) process.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a flow completion apparatus for producing oil or gas from a subsea well. More particularly, the invention relates to a flow completion apparatus which comprises a tubing hanger having an annulus bore which is adapted to communicate with a choke and kill line of a blowout preventer which is installed over the tubing hanger during installation and workover of the flow completion apparatus.
[0002] Flow completion assemblies for producing oil or gas from subsea wells may generally be categorized as either conventional or horizontal. A typical horizontal flow completion assembly is disclosed in U.S. Pat. No. 6,039,119, hereby incorporated herein by reference.
[0003] International Publication No. WO 01/73259 of International Application No. PCT/US01/09607 filed Mar. 22, 2001 and published Oct. 4, 2001, shows a tubing hanger with an annulus bore. International Publication No. WO 01/73259 is hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] The flow completion apparatus comprises a wellhead housing which is installed at the upper end of the wellbore; a tubing spool which is connected over the wellhead housing and which includes a central bore which extends axially therethrough, a production outlet which communicates with the central bore, and an annulus passageway which communicates with the tubing annulus; a tubing hanger which is supported in the central bore and is connected to an upper end of the tubing string, the tubing hanger including a production bore which extends axially therethrough and a production passageway which communicates between the production bore and the production outlet; a first closure member which is positioned in the production bore above the production passageway; production seals positioned between the tubing hanger and central bore above and below the production passageway; and a tubing annulus seal which is positioned between the tubing hanger and the central bore below the production passageway and production seals. Furthermore, the tubing spool also comprises a workover passageway which extends between the annulus passageway and a portion of the central bore that is located between the production seals and the tubing annulus seal, and the tubing hanger also comprises an annulus bore which extends between the workover passageway and the upper end of the tubing hanger. In this manner, fluid communication between the tubing annulus and the upper end of the tubing hanger may be established through the annulus passageway, the workover passageway, and the annulus bore.
[0005] The flow completion apparatus further comprises a blowout preventer which is removably connectable to the top of the tubing spool and which includes a BOP bore, at least one set of BOP rams, and at least one choke and kill line that communicates with a portion of the BOP bore which is located below the BOP rams; and a tubing hanger running tool which is removably connectable to the top of the tubing hanger and which includes a generally cylindrical outer diameter surface and a production port that communicates with the production bore in the tubing hanger. An annulus passageway extends between the annulus bore in the tubing hanger and the BOP choke and kill line. This passageway may either be the annular area around the tubing hanger running tool or may include an annulus port through the running tool that communicates between the annulus bore and an opening which is formed in the outer diameter surface of the tubing hanger running tool to communicate with the BOP choke and kill line. In this manner, fluid communication between the tubing annulus and the BOP choke and kill line may be established through the annulus passageway, the workover passageway, the annulus bore, either the annular area around the tubing hanger running tool or an annulus port in the tubing hanger running tool, and the portion of the BOP bore which is located below the closed BOP ram.
[0006] The annulus bore in the tubing hanger provides a convenient means for connecting the tubing annulus with the BOP choke and kill line. An annulus port in the tubing hanger running tool provides a closed path between the annulus bore in the tubing hanger and the BOP choke and kill line.
[0007] A first barrier between the wellbore and the environment is provided by both the first closure member in the production bore and the tubing annulus seal between the tubing hanger and the tubing spool. In addition, a second barrier between the wellbore and the environment is provided by both a second closure member that is positioned in the production bore above the first closure member and the production seals that are positioned between the tubing hanger and the tubing spool above the tubing annulus seal. In this manner, both the first and second barriers between the wellbore and the environment are mounted in or on the tubing hanger.
[0008] These and other objects and advantages of the present invention will be made apparent from the following detailed description, with reference to the accompanying drawings. In the drawings, the same reference numerals are used to denote similar components in the various embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a representation of one embodiment of the flow completion apparatus shown in the production mode of operation with the tubing hanger annulus bore extending between a first and second closure member;
[0010] [0010]FIG. 2 is a representation of the flow completion apparatus of FIG. 1 shown in the installation and workover mode of operation with an annulus passageway extending from the tubing hanger annulus bore to the choke and kill line;
[0011] [0011]FIG. 3 is a representation of another embodiment of the flow completion apparatus shown in the production mode of operation with an annulus bore extending from the workover passageway to that portion of the internal bore of the spool tree above the first and second closure members;
[0012] [0012]FIG. 4 is a representation of the flow completion apparatus of FIG. 3 shown in the installation workover mode of operation with an annulus passageway extending from the tubing hanger annulus bore to the choke and kill line;
[0013] [0013]FIG. 5 is a representation of a still another embodiment of the flow completion apparatus shown in the production mode of operation with an annulus bore extending to the top of the tubing hanger and sealed with a seal stab;
[0014] [0014]FIG. 6 is a representation of the flow completion apparatus of FIG. 5 shown in the installation and workover mode of operation with a passageway extending through the running tool between the tubing hanger annulus bore and the choke and kill line;
[0015] [0015]FIG. 7 is a representation of the flow completion apparatus of FIG. 5 shown in the installation and workover mode of operation with a passageway extending around the running tool between the tubing hanger annulus bore and the choke and kill line;
[0016] [0016]FIG. 8 is a representation of a further embodiment of the flow completion apparatus shown in the production mode of operation with an annulus bypass bore extending between the annulus bore and the production bore;
[0017] [0017]FIG. 9 is a cross section at plane 9 - 9 in FIG. 8; and
[0018] [0018]FIG. 10 is a still further embodiment of the flow completion apparatus shown in the production mode of operation with a tubing suspension conduit below the tubing hanger.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The present invention relates to methods and apparatus for flow completion and particularly for circulation in the borehole of a well during installation and workover. The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein.
[0020] In particular, various embodiments of the present invention provide a number of different constructions and methods of operation of the completion system. The embodiments of the present invention also provide a plurality of methods for circulation in the borehole of a well. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Reference to up or down will be made for purposes of description with up meaning away from the bottom of the well and down meaning toward the bottom of the well.
[0021] In the description which follows, the use of the same reference numerals throughout the specification and drawings indicates like parts. The drawing figures are not necessarily to scale. Certain features of the invention may be shown in exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness.
[0022] Referring initially to FIG. 1, one embodiment of a flow completion apparatus according to the present invention, is generally indicated by reference numeral 10 . The flow completion apparatus 10 comprises a wellhead 12 , a tubing spool 14 which is connected and sealed to the wellhead and which includes a central bore 16 extending axially therethrough, a generally annular tubing hanger 18 which is supported on a shoulder (not shown) located in the central bore, and a tree cap 20 which is installed in the central bore above the tubing hanger. The tubing hanger 18 is secured to the tubing spool 14 by a lockdown mechanism (not shown) and suspends a tubing string 22 that extends into the well bore and defines a tubing annulus 24 surrounding the tubing string. Tubing hanger 18 also includes a production bore 26 which communicates with the flowbore of the tubing string 22 and a lateral production passageway 28 which extends between the production bore 26 and the outer diameter of the tubing hanger. The tubing spool 14 includes a production outlet 30 which communicates with the production passageway 28 , an annulus passageway 32 which communicates with the tubing annulus 24 , and an annulus outlet 34 which is connected to the annulus passageway 32 and a workover passageway 36 which extends between the annulus passageway 32 and an area 86 of the central bore 16 above the tubing hanger 18 . In addition, the tubing hanger 18 is sealed to the tubing spool 14 by upper and lower, preferably metal, production seal rings 40 , 38 , each of which engages a corresponding annular sealing surface formed on the wall forming central bore 16 . The communication between the workover passageway 36 and the tubing annulus 24 is sealed by a tubing annulus seal ring 57 . Furthermore, the production bore 26 is sealed above the production passageway 28 by a suitable closure member 42 , such as a plug, which directs the flow of oil or gas from the tubing string 22 into the production passageway 30 .
[0023] The tubing hanger 18 also includes an annulus bore 80 which extends between the upper end and lower end of the tubing hanger 18 . In this manner, communication between the tubing annulus 24 and area 86 above the the upper end of tubing hanger 18 is provided by the annulus passageway 32 , the workover passageway 36 , and the annulus bore 80 . This arrangement permits communication between the tubing annulus 24 and area 86 and also a choke and kill line in a BOP with tree cap 20 removed as shown in FIG. 2.
[0024] The flow completion apparatus 10 may also comprise a production master valve 44 and a production wing valve 46 to control flow through the production outlet 30 , and an annulus master valve 48 , an annulus wing valve 50 and a workover valve 52 to control flow through the annulus passageway 32 , the annulus outlet 34 and the workover passageway 36 , respectively. While these valves may be any suitable closure members, they are preferably remotely operated gate valves. Moreover, some or all of the valves may be incorporated into the body of the tubing spool 14 , into separate valve blocks which are bolted onto the tubing spool, or into individual valve assemblies which are connected to their respective outlets or passageways in the tubing spool with separate lengths of conduit. Furthermore, the production outlet 30 and the annulus outlet 34 are preferably connected to respective flow loops which communicate with a surface vessel, either directly or via a manifold, in a manner that is well known in the art.
[0025] In the production mode of operation of the flow completion apparatus 10 , shown in FIG. 1, a first barrier between the well bore and the environment is provided by the closure member 42 production seals 38 , 40 , and the tubing annulus seal 57 , which together serve to isolate the fluid in the wellbore from the environment above the tubing hanger. The second barrier is provided by the tree cap 20 and by a typically metal seal ring 54 which is disposed between the tree cap 20 and the tubing spool 14 and a wireline plug 56 which is positioned in an axial bore 58 extending through the tree cap. Thus, in the completion assembly 10 , the first barrier is associated with the tubing hanger 18 while the second barrier is associated with the tree cap 20 . Although not shown in FIG. 1, the tree cap 20 also includes a lockdown mechanism to secure the tree cap to the tubing spool 14 .
[0026] Referring now to FIG. 2, the flow completion assembly 10 is shown in the installation or workover mode of operation. In either of these modes of operation, a blowout preventer 60 is connected to the top of the tubing spool 14 and a tubing hanger running tool 62 is attached to the top of the tubing hanger 18 . The BOP includes an internal BOP bore 64 , at least one set of rams 66 which is capable of sealing against the tubing hanger running tool 62 , and at least one choke and kill line 68 for providing communication between the BOP bore below the rams 66 and a surface vessel (not shown). In addition, the tubing hanger running tool 62 comprises an internal bore 70 , or production port, which connects to the production bore 26 via a production stab (not shown). Also, although the BOP rams are described herein as sealing against the tubing hanger running tool, it should be understood that the rams could instead seal against another member, such as an extension member or a work string, which comprises a production port that communicates with the production port of the tubing hanger running tool.
[0027] During both installation and workover of the flow completion assembly 10 , communication between the tubing annulus 24 and the surface vessel may be established through the annulus passageway 32 , the workover passageway 36 , the annulus bore 80 , the central bore 16 , the BOP bore 64 , and the choke and kill line 68 . For example, deep well circulation can be accomplished by pumping fluid down the tubing hanger running tool bore 70 , through the production bore 26 , through the flowbore of tubing string 22 , around or through the lower end of the tubing string 22 , up the tubing annulus 24 , through the annulus passageway 32 , through the workover passageway 36 , through the annulus bore 80 , into the central bore 16 above the tubing hanger 18 , into the BOP bore 64 and through the BOP choke and kill line 68 to the surface.
[0028] Referring now to FIGS. 3 and 4, there is shown an alternative embodiment of the flow completion assembly 10 of FIGS. 1 and 2. Annulus bore 80 may be made in flow communication with a secondary annulus bore 82 extending through tree cap 20 by including an annulus stab 84 that seals into the top of the annulus bore 80 and into the secondary annulus bore 82 in the bottom of tree cap 20 . This provides an annulus bore which extends from workover port 36 to that portion of the internal bore 16 of tubing spool 14 above both the first and second closure members, namely tree cap 20 and wire line plug 42 , respectively. Secondary annulus bore 82 may be closed and sealed by a seal stab (not shown) installed in the upper end of secondary annulus bore 82
[0029] Referring now to FIG. 5, another embodiment of a flow completion apparatus according to the present invention is generally indicated by reference numeral 110 . The flow completion apparatus comprises a wellhead 112 , tubing spool 114 which is mounted on the wellhead which includes a central bore 116 extending axially therethrough, and a generally annular tubing hanger 118 which is supported on a shoulder (not shown) located in the central bore and from which is suspended a tubing string 120 that extends into the well bore and defines a tubing annulus 122 surrounding the tubing string. The tubing hanger 118 is secured to the tubing spool 114 by a lockdown mechanism (not shown) and includes a production bore 124 which communicates with the flowbore of the tubing string 120 and a lateral production passageway 126 which extends between the production bore 124 and the outer diameter of the tubing hanger. Similarly, the tubing spool 114 includes a production outlet 128 which communicates with the production passageway 126 , an annulus passageway 130 which communicates with the tubing annulus 122 , and an annulus outlet 132 which is connected to the annulus passageway. In addition, the tubing hanger 118 is sealed to the tubing spool 114 by an upper and lower, preferably metal, production seal rings 134 , 136 , each of which engages a corresponding annular sealing surface formed on the wall of central bore 116 . Furthermore, the production bore 124 is sealed above the production passageway 126 by a suitable closure member 138 which directs the flow of oil or gas from the tubing string 120 into the production passageway 126 . Ring seals 156 , 157 , located above and below production port 128 and production seals 134 , 136 , sealingly engage a corresponding annular sealing surface formed by the wall of the central bore 116 .
[0030] The tubing hanger 118 also includes an annulus bore 140 which extends between the top and the lower outer diameter of the tubing hanger 118 , and the tubing spool 114 comprises a workover passageway 142 that extends between the annulus passageway 130 and the annulus bore 140 . The communication between the workover passageway 142 and the tubing annulus 122 is sealed by tubing annulus seal ring 157 . In this manner, communication between the tubing annulus 122 and the top of tubing hanger 118 is provided by the annulus passageway 130 , the workover passageway 142 , and the annulus bore 140 . This arrangement permits communication between the tubing annulus 122 and a BOP to be routed through a tubing hanger running tool, shown in FIG. 6, rather than in the area 186 of the central bore 116 above the tubing hanger 118 .
[0031] The flow completion apparatus 110 may also comprises a production master valve 144 and a production wing valve 146 to control flow through the production outlet 128 , and an annulus master valve 148 , an annulus wing valve 150 and a workover valve 152 to control flow through the annulus passageway 130 , the annulus outlet 132 and the workover passageway 142 , respectively. While these valves may be any suitable closure members, they are preferably remotely operated gate valves. Moreover, some or all of the valves may be incorporated into the body of the tubing spool 114 , into separate valve blocks which are bolted onto the tubing spool, or into individual valve assemblies which are connected to their respective outlets or passageways in the tubing spool with separate lengths of conduit. Furthermore, the production outlet 128 and the annulus outlet 132 are preferably connected to respective flow loops which communicate with a surface vessel, either directly or via a manifold, in a manner that is well known in the art.
[0032] In the production mode of operation of the flow completion apparatus 110 , shown in FIG. 5, production seal 134 and tubing annulus seal 157 together function as a double barrier to isolate the fluid in the production passageway 126 from the environment below the tubing hanger 118 and production seal 134 and secondary seal 156 together function as a double barrier to isolate the fluid in the production passageway 126 from the environment above the tubing hanger 118 .
[0033] In accordance with the present invention, a first barrier between the well bore and the environment is provided by the closure member 138 and the production seals 134 , 136 , which together serve to isolate the fluid in the production bore from the environment above and below the tubing hanger 118 . A second barrier between the well bore and the environment is provided by a suitable second closure member 154 , which is mounted in the production bore 124 above the closure member 138 , and secondary seal 156 and tubing annulus seal 157 , preferably a metal ring seals, which are mounted on the tubing hanger 118 above and below production passageway 126 . Thus, the necessary first and second barriers for isolating the production passageway 126 from the environment are provided by components which are mounted on or in the tubing hanger 118 .
[0034] The present invention also provides for isolating the tubing annulus 122 from the environment above the tubing hanger 118 during the production mode of operation. Provided the annular master valve 148 and the workover valve 152 are closed, the production seals 134 , 136 , the secondary seal 156 , and the tubing annulus seal 157 will provide the required first and second barriers between the tubing annulus and the environment. However, when pressure in the tubing annulus 122 needs to be bled off through the annulus passageway 130 and the annulus outlet 132 , or when gas is introduced into the tubing annulus through the annulus outlet and the annulus passageway during gas lift applications, the annulus master valve 148 must be opened.
[0035] Therefore, the flow completion apparatus preferably also comprises a tree cap 158 which includes an annulus stab 160 that seals into the top of the annulus bore 140 to provide a second barrier, in conjunction with the workover valve 152 , between the tubing annulus 122 and the environment when the environment master valve 148 is open. While the tree cap 158 may include an annular, preferably non-metallic seal (not shown) to seal against the tubing spool 114 and thereby prevent sea water from entering the central bore 116 , the tree cap is not intended to provide a barrier against well pressure in the production bore. The tree cap 158 is preferably landed on the tubing hanger 118 and locked to the tubing spool 114 with a convention lockdown mechanism 162 . This lockdown mechanism will provide a backup to the lockdown mechanism used to secure the tubing hanger to the running tool. It should be noted that, although the tree cap 158 is depicted as an internal tree cap, it could instead be configured as an external tree cap.
[0036] Referring now to FIG. 6, during installation and workover of the flow completion apparatus 110 , a BOP 164 is lowered on a riser (not shown) and connected and sealed to the top of the tubing spool 114 . The BOP 164 includes an internal BOP bore 166 , at least one choke and kill line 168 , and one or more sets of BOP rams 170 , 172 . In addition, a tubing hanger running tool 174 is connected to the top of the tubing hanger 118 . The tubing hanger running tool 174 is either connected to the tubing hanger at a surface vessel and used to lower the tubing hanger into the tubing spool during installation of the tubing hanger, or lowered through a riser and the BOP and connected to the tubing hanger in the tubing spool in anticipation of a workover operation. The tubing hanger running tool 174 is shown to comprise a generally cylindrical outer diameter surface, a production port 176 which is connected to a production bore 124 in the tubing hanger 118 by a suitable production seal stab 178 , and an annulus port 180 which extends from a portion of the outer diameter surface of tubing hanger running tool 174 to a suitable annulus seal stab 182 that engages the tubing hanger annulus bore 140 .
[0037] Thus, with the BOP rams 170 , 172 sealed against the tubing hanger running tool 174 , communication between the tubing annulus 122 and the BOP choke and kill line 168 may be established through the annulus passageway 130 , the workover passageway 142 , the annulus bore 140 , the annulus port 180 , and the portion 167 of the BOP bore 166 which is located between the BOP rams 170 , 172 . For example, with the annulus wing valve 150 closed, pressure can be transmitted from the surface vessel down the choke and kill line 168 , through the annulus portion 180 , through the tubing hanger annulus bore 140 , through the workover passageway 142 , through the annulus passageway 130 , and into the tubing annulus 122 . The well circulation may be accomplished by closing both the annulus wing valve 150 and the production master valve 144 and pumping fluid down the choke and kill line 168 through the annulus port 180 , through the annulus bore 140 , through the workover passageway 142 , through the annulus passageway 130 , down the tubing annulus 122 , past the downhole packer, up the tubing string 120 , through the production bore 124 , and up the production port 176 . Moreover, since the flow between the tubing hanger annulus bore 140 and the choke and kill line 168 is restricted by the tubing hanger running tool 174 , no possibility exists that the flow will foul the tubing hanger lockdown mechanism or erode the central bore 116 .
[0038] Referring now to FIG. 7, there is shown an alternative embodiment of the flow completion assembly 110 of FIG. 6. Annulus bore 140 communicates with the choke and kill line 168 through an annular passageway 187 between the tubing hanger running tool 174 and the internal bores of the BOP 166 and the tubing spool 114 .
[0039] Referring now to FIG. 8, an alternate embodiment of a flow completion apparatus according to the present invention as described in FIG. 5, is generally indicated by reference numeral 110 . The flow completion apparatus comprises a wellhead 112 , tubing spool 114 which is mounted on the wellhead which includes a central bore 116 extending axially therethrough, and a generally annular tubing hanger 118 which is supported on a shoulder (not shown) located in the central bore and from which is suspended a tubing string 120 that extends into the well bore and defines a tubing annulus 122 surrounding the tubing string. The tubing hanger 118 is secured to the tubing spool 114 by a lockdown mechanism (not shown) and includes a production bore 124 which communicates with the flowbore of the tubing string 120 and a lateral production passageway 126 which extends between the production bore and the outer diameter of the tubing hanger. Similarly, the tubing spool 114 includes a production outlet 128 which communicates with the production passageway 126 , an annulus passageway 130 which communicates with the tubing annulus 122 , and an annulus outlet 132 which is connected to the annulus passageway. In addition, the tubing hanger 118 is sealed to the tubing spool 114 by an upper and lower, preferably metal, production seal rings 134 , 136 , each of which engages a corresponding annular sealing surface formed by the wall of the central bore 116 . Furthermore, the production bore 124 is sealed above the production passageway 126 by a suitable closure member 138 which directs the flow of oil or gas from the tubing string 120 into the production passageway 126 . Ring seals 156 , 157 , located above and below production port 128 and production seals 134 , 136 , sealingly engage a corresponding annular sealing surface formed by the wall of the central bore 116 .
[0040] The tubing hanger 118 also includes an annulus bore 140 which extends between the top and the outer diameter of the tubing hanger 118 , and the tubing spool 114 comprises a workover passageway 142 that extends between the annulus passageway 130 and the annulus bore 140 . The communication between the workover passageway 142 and the tubing annulus 122 is sealed by an annular seal ring 157 . Tubing hanger 118 also includes an annulus bypass bore 141 extending from annulus bore 140 through valve 139 and continuing through bypass bore 143 to production bore 124 . In this manner fluid communication between the tubing annulus 122 and the production bore 124 above closure member 138 is provided.
[0041] Referring now to FIG. 9, a section view of FIG. 8 generally indicated a valve actuation member 147 and valve stem 149 for valve 139 . Valve actuation as indicated here is described in U.S. Pat. No. 5,992,527 which is hereby incorporated herein by reference.
[0042] Similar valve actuation member 151 and valve stem 153 are shown as an alternate for valve closure member 154 . The valve actuation member 151 attached to tubing spool 114 may be used outside or inside the necessary second barriers for isolating the production bore 124 from the environment as described earlier.
[0043] The flow completion apparatus 110 may also comprise a production master valve 144 and a production wing valve 146 to control flow through the production outlet 128 , and an annulus master valve 148 , an annulus wing valve 150 and a workover valve 152 to control flow through the annulus passageway 130 , the annulus outlet 132 and the workover passageway 142 , respectively. While these valves may be any suitable closure members, they are preferably remotely operated gate valves. Moreover, some or all of the valves may be incorporated into the body of the tubing spool 114 , into separate valve blocks which are bolted onto the tubing spool, or into individual valve assemblies which are connected to their respective outlets or passageways in the tubing spool with separate lengths of conduit. Furthermore, the production outlet 128 and the annulus outlet 132 are preferably connected to respective flow loops which communicate with a surface vessel, either directly or via a manifold, in a manner that is well known in the art.
[0044] In the production mode of operation of the flow completion apparatus 110 , shown in FIG. 8, production seal 136 and tubing annulus seal 157 together function as a double barrier to isolate the fluid in the production passageway 126 from the environment below the tubing hanger 118 and production seal 134 and secondary seal 156 together function as a double barrier to isolate the fluid in the production passageway 126 from the environment above the tubing hanger 118 .
[0045] In accordance with the present invention, a first barrier between the well bore and the environment is provided by the closure member 138 and the production seals 134 , 136 , which together serve to isolate the fluid in the production bore from the environment above and below the tubing hanger 118 . A second barrier between the well bore and the environment is provided by a suitable second closure member 154 , which is mounted in the production bore 124 above the closure member 138 , and secondary seal 156 and tubing annulus seal 157 , preferably a metal ring seals, which are mounted on the tubing hanger 118 above and below production passageway 126 . Thus, the necessary first and second barriers for isolating the production passageway 126 from the environment are provided by components which are mounted on or in the tubing hanger 118 .
[0046] The present invention also provides for isolating the tubing annulus 122 from the environment above the tubing hanger 118 during the production mode of operation. Provided the annular master valve 148 and the workover valve 152 are closed, the production seals 134 , 136 , the secondary seal 156 , and the tubing annulus seal 157 will provide the required first and second barriers between the tubing annulus and the environment. However, when pressure in the tubing annulus 122 needs to be bled off through the annulus passageway 130 and the annulus outlet 132 , or when gas is introduced into the tubing annulus through the annulus outlet and the annulus passageway during gas lift applications, the annulus master valve 148 must be opened.
[0047] Therefore, the flow completion apparatus preferably also comprises a tree cap 158 which includes an annulus stab 160 that seals into the top of the annulus bore 140 to provide a second barrier, in conjunction with the workover valve 152 , between the tubing annulus 122 and the environment when the environment master valve 148 is open. While the tree cap 158 may include an annular, preferably non-metallic seal (not shown) to seal against the tubing spool 114 and thereby prevent sea water from entering the central bore 116 , the tree cap is not intended to provide a barrier against well pressure in the production bore. The tree cap 158 is preferably landed on the tubing hanger 118 and locked to the tubing spool 114 with a convention lockdown mechanism 162 . This lockdown mechanism will provide a backup to the lockdown mechanism used to secure the tubing hanger to the running tool. It should be noted that, although the tree cap 158 is depicted as an internal tree cap, it could instead be configured as an external tree cap.
[0048] Referring now to FIG. 10, one embodiment of a flow completion apparatus according to the present invention, is generally indicated by reference numeral 210 . The flow completion apparatus 210 comprises a wellhead 212 , a tubing spool 214 which is connected and sealed to the wellhead and which includes a central bore 216 extending axially therethrough, a generally annular tubing hanger 218 which is supported on a shoulder (not shown) located in the central bore, and a tree cap 220 which is installed in the central bore above the tubing hanger. The tubing hanger 218 is secured to the tubing spool 214 by a lockdown mechanism (not shown) and is in communication with a tubing string 222 that extends into the well bore and defines a tubing annulus 224 surrounding the tubing string. Tubing hanger 218 also includes a production bore 226 which communicates with the flowbore of the tubing string 222 and a lateral production passageway 228 which extends between the production bore and the outer diameter of the tubing hanger. The tubing spool 214 includes a production outlet 230 which communicates with the production passageway 228 , an annulus passageway 232 which communicates with the tubing annulus 224 , and an annulus outlet 234 which is connected to the annulus passageway 232 and a workover passageway 236 which extends between the annulus passageway 232 and an area 286 of the central bore 216 above the tubing hanger 218 . In addition, the tubing hanger 218 is sealed to the tubing spool 214 by a lower, preferably metal production seal ring 238 and an upper, preferably metal production seal ring 240 , each of which engages a corresponding annular sealing surface formed by the wall of the central bore 216 . The communication between the workover passageway 236 and the tubing annulus 224 is sealed by tubing annulus seal ring 257 and by seal ring 259 in sealing relationship with tubing suspension conduit 219 . Furthermore, the production bore 226 is sealed above the production passageway 228 by a suitable closure member 242 , such as a plug, which directs the flow of oil or gas from the tubing string 222 into the production passageway 230 .
[0049] In a similar manner as described for FIG. 1, the tubing hanger 218 also includes an annulus bore 280 which extends between the upper end and lower end of the tubing hanger 218 . In this manner, communication between the tubing annulus 224 and the upper end of tubing hanger 218 is provided by the annulus passageway 32 , the workover passageway 36 , and the annulus bore 280 . This arrangement permits communication between tubing annulus 224 and area 286 and also a choke and kill line in a BOP with tree cap 220 removed.
[0050] The flow completion apparatus 210 may also comprise a production master valve 244 and a production wing valve 246 to control flow through the production outlet 230 , and an annulus master valve 248 , an annulus wing valve 250 and a workover valve 252 to control flow through the annulus passageway 232 , the annulus outlet 234 and the workover passageway 236 , respectively. While these valves may be any suitable closure members, they are preferably remotely operated gate valves. Moreover, some or all of the valves may be incorporated into the body of the tubing spool 214 , into separate valve blocks which are bolted onto the tubing spool, or into individual valve assemblies which are connected to their respective outlets or passageways in the tubing spool with separate lengths of conduit. Furthermore, the production outlet 230 and the annulus outlet 234 are preferably connected to respective flow loops which communicate with a surface vessel, either directly or via a manifold, in a manner that is well known in the art. See U.S. Pat. No. 5,372,199, hereby incorporated herein by reference.
[0051] In the production mode of operation of the flow completion apparatus 210 , shown in FIG. 10, a first barrier between the well bore and the environment is provided by the closure member 242 production seals 238 , 240 , and the tubing annulus seal 257 , which together serve to isolate the fluid in the wellbore from the environment above the tubing hanger. The second barrier is provided by the tree cap 220 and by a typically metal seal ring 254 which is disposed between the tree cap 220 and the tubing spool 214 and a wireline plug 256 which is positioned in an axial bore 258 extending through the tree cap. Thus, in the completion assembly 210 , the first barrier is associated with the tubing hanger 218 while the second barrier is associated with the tree cap 220 . This embodiment allows the removal of tubing hanger 218 while leaving tubing string and tubing suspension conduit 219 in tubing spool 214 .
[0052] The embodiments described above assume a requirement for double barriers. It should be appreciated that one of the barriers may be eliminated should only one barrier be required in a particular jurisdiction.
[0053] It should be recognized that, while the present invention has been described in relation to the preferred embodiments thereof, those skilled in the art may develop a wide variation of structural and operational details without departing from the principals of the invention. For example, the various elements shown in the different embodiments may be combined in a manner not illustrated above. Therefore, the appended claims are to be construed to cover all equivalents falling within the true scope and spirit of the invention.
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A completion system for a subsea well includes a tree having a generally cylindrical wall forming an internal bore therethrough and a production port extending laterally through the wall in communication with the internal bore. The internal wall has a landing arranged to support a tubing hanger having seals for sealing the production port between the tubing hanger and the internal wall, the production port being arranged to communicate with a lateral production fluid outlet port in the tubing hanger. A workover port extends laterally from an opening in the internal wall below the production port and the production port seals and a tubing annulus seal sealing the workover port from the tubing annulus. A tubing annulus port extends from an opening in the tree below the tubing annulus seal and the tubing annulus port and workover port being arranged to be in fluid communication externally of the internal bore.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for carrying out a highly exothermic reaction such as that between an olefin and an organic hydroperoxide using a solid catalyst to form an oxirane compound.
2. Description of the Prior Art
Substantial difficulties are encountered in carrying out highly exothermic reactions where reactants and/or products are temperature sensitive. For example, the liquid phase reaction of propylene and an organic hydroperoxide using a solid catalyst to produce propylene oxide is a highly exothermic reaction, and selectivity to the desired product is very temperature sensitive. Proper control of reaction temperature presents a serious problem.
Conventional reactors for exothermic reactions are usually of two types:
(1) Quench type which consist of multiple fixed beds with cold feed quench injected in between beds
(2) Tubular type in which the catalyst is placed in the tubes of vertical shell and tube heat exchanger.
If the heat of reaction is high, the first type does not provide sufficient heat removal and proper reaction temperature control may not be possible.
The tubular reactor cost becomes prohibitive when high heats of reaction have to be removed through heat exchanger surfaces operating with a low heat transfer coefficient. There is also a temperature gradient from the center of the tube which is often detrimental to a process which requires nearly isothermal conditions.
Epoxidation can be carried out using multiple fixed catalyst bed reactors. The fixed bed epoxidation process may be practiced with a fresh bed last or fresh bed first rotation plan. See U.S. Pat. No. 5,849,937. Fresh bed first is preferable, since the downstream, older beds can be run at a higher temperature. This obtains the maximum activity at the best selectivity and with a minimum heat input and capital expense. One problem with fresh bed first however, is that of temperature control. The temperature rise for an adiabatic bed is large, about 150° F. or more and this results in rapid catalyst deactivation of the downstream portion of the bed. It also means that the front part of the bed, where the temperature is much cooler, is not converting very much product. A second problem is that the fixed bed reactors are very difficult to operate with normal reactant concentrations. If one wishes to obtain 30% to 50% hydroperoxide conversion, this is essentially impossible in an adiabatic bed because the reactor exhibits multiple steady states. One can obtain 1 to 15% hydroperoxide conversion or 99.0 to 99.9% conversion, but obtaining 30 to 50% hydroperoxide conversion is not possible.
To illustrate this, reference is made to FIG. 1 which is a plot of reaction inlet temperature versus hydroperoxide conversion for a conventional reaction system for propylene oxide production by reaction of propylene and ethylbenzene hydroperoxide. As can be seen, there is a steady increase in hydroperoxide conversion with increasing inlet temperature until an inlet temperature is reached at which hydroperoxide conversion jumps from a relatively low level to nearly 100%. When inlet temperature is then reduced, hydroperoxide conversion remains near 100% until at a substantially lower temperature hydroperoxide conversion suddenly falls to a much lower level. Under normal conditions, control of conversion at an intermediate level e.g. 50%, is almost impossible to accomplish. This can be seen from FIG. 1 . When the inlet temperature is raised, the conversion suddenly jumps from 20 to 99%. Upon reducing the inlet temperature, the conversion suddenly drops from 99 to 2%.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, the exothermic reaction between an olefin such as propylene and an organic hydroperoxide such as ethylbenzene hydroperoxide using a solid catalyst is carried out while maintaining the concentration of hydroperoxide in the feed below 8 wt % by either diluting the feed with a process stream depleted in hydroperoxide or by using a plurality of epoxidation zones and feeding only a portion of the total hydroperoxide feed to each zone.
In accordance with one embodiment, the invention a reactor system is provided comprised of a series of reaction zones packed with solid catalyst. The reaction mixture from the first reaction zone is separated into two portions, one portion being recycled to the feed to the first zone, the remainder passing to the second zone. The recycled portion is admixed with cold feed thus both preheating and diluting the feed while moderating the temperature of the reaction mixture passing through the first reaction zone and permitting convenient control of reactant conversion at a desired intermediate level.
In accordance with another embodiment, again a series of reaction zones is used with a portion of the total hydroperoxide being fed to each zone.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative plot of ethylbenzene hydroperoxide conversion versus feed inlet temperature for a typical system involving reaction of propylene and ethylbenzene hydroperoxide to form propylene oxide using a solid catalyst.
FIG. 2 illustrates a practice of the invention,
FIG. 3 illustrates an alternative practice of the invention.
DETAILED DESCRIPTION
Practice of the invention is especially applicable to highly exothermic reactions such as those between an olefin, e.g. propylene, and an organic hydroperoxide, e.g. ethylbenzene hydroperoxide.
In order to illustrate the invention, reference is made to attached FIG. 2 in the context of the reaction of ethylbenzene hydroperoxide with propylene to form propylene oxide. There are provided reaction zones 1 and 2 , each packed with a bed of solid epoxidation catalyst. A cold feed stream of ethylbenzene hydroperoxide and propylene is fed via line 3 to reactor 1 . Also fed via lines 4 and 3 to reactor 1 is a portion of the effluent reaction stream recycled from reactor 1 which is admixed with the fresh cold feed in sufficient amount to reduce the hydroperoxide concentration in the total feed to reaction zone 1 from the normal 10-20 wt % to below 8 wt %.
In reactor 1 , the exothermic reaction of the hydroperoxide and propylene takes place with the formation of propylene oxide. The reaction mixture passes from reactor 1 via line 5 with the net equivalent of the feed passing to reactor 2 and a portion being recycled via lines 4 and 3 as above indicated to reactor 1 .
In reactor 2 the mixture introduced via line 5 reacts to form additional propylene oxide and the reaction effluent is removed from reactor 2 via line 6 and can be worked up in conventional fashion for propylene oxide recovery and recycle of unreacted materials.
Two separate reaction zones are illustrated in FIG. 2 but it will be understood additional reaction zones can be provided. Also, although separate reactors are illustrated it will be understood that other configurations such as a single reaction vessel containing multiple reaction sections can be employed.
It has been found that better catalyst life and selectivity is obtained in accordance with the invention by recycling effluent from the first reaction zone back to the feed in amount sufficient to reduce the hydroperoxide concentration to below 8 wt %. The temperature rise is reduced and this reduces the difference in the rates of catalyst deactivation. It also reduces the average temperature needed for a given conversion, thus increasing the selectivity. The reactor temperature is much easier to control since the rate of convective heat transfer through the bed is larger. In general, hydroperoxide conversion in the first reaction zone is regulated at about 20 to 99%. Sufficient recycle of the first reaction zone effluent to the first zone feed is provided to dilute the hydroperoxide concentration in the first zone feed from the normal 10 to 30 wt % to about 4 to 8 wt %.
An alternate embodiment of the invention is shown in FIG. 3, also in the context of the reaction of propylene with ethylbenzene hydroperoxide to form propylene oxide.
As shown in FIG. 3, there are provided reaction zones 101 , 102 and 103 , each packed with solid epoxidation catalyst. A propylene feed stream is fed to reactor 101 via line 104 . An ethylbenzene hydroperoxide stream, preferably an oxidate stream from ethylbenzene oxidation is fed to the reaction system via line 105 .
Normally in this reaction where all of the propylene and hydroperoxide are fed to the first reaction zone, the hydroperoxide concentration by weight is in excess of 10 wt %, usually 10 to 30 wt %. However, in accordance with the present invention as shown in FIG. 3, only a portion of the total hydroperoxide is fed to each of the reaction zones 101 , 102 and 103 by lines 106 , 107 and 108 respectively. The amount of hydroperoxide added via each of lines 106 , 107 and 108 is regulated to provide a hydroperoxide concentration in the feed to each of zones 101 , 102 and 103 of less than 8 wt %.
Propylene fed via line 104 and hydroperoxide fed via line 106 are reacted in zone 101 in contact with solid epoxidation catalyst to form propylene oxide.
The reaction mixture from zone 101 is removed via line 109 , admixed with additional ethylbenzene hydroperoxide from line 107 to provide a feed to zone 102 comprised of less than 8 wt % hydroperoxide; and reacted in zone 102 to form additional propylene oxide.
Reaction effluent from zone 102 is removed via line 110 and admixed with additional hydroperoxide from line 108 to provide a feed to zone 103 comprised of less than 8 wt % hydroperoxide.
The reaction mixture from zone 103 is removed via line 111 and components thereof separated by conventional techniques.
Although three reaction zones are shown in FIG. 3, it will be appreciated that a greater or lesser number, e.g. 2 to 10 zones can be used.
Practice of the invention as above described allows close control of reaction conditions with accompanying improvement in reaction selectivity and catalyst life.
While it would be possible to lower the hydroperoxide concentration while adding all olefin and hydroperoxide to the reaction zone, such a procedure would result in substantially increased costs and difficulties in separations and recycle.
The epoxidation reaction of the present invention is carried out in accordance with known procedures. See, for example, U.S. Pat. No. 3,351,635, the disclosure of which is incorporated herein by reference for ppropriate temperatures, pressures, and reactants.
Generally reaction temperatures are in the range of 100° F. to 300° F., usually 150° F. to 250° F., and pressures are sufficient to maintain the liquid phase in both reactors 1 and 2 , e.g. 500 to 1500 psia.
Known solid heterogeneous catalysts are employed. In this regard, reference is made to European patent publication 0 323 663, to UK 1,249,079, to U.S. Pat. Nos. 4,367,342, 3,829,392, 3,923,843 and 4,021,454 the disclosures of which are incorporated herein as well as to U.S. Pat. No. 5,760,253.
The invention is especially applicable to epoxidation of alpha olefins having 3-5 carbon atoms with aralkyl hydroperoxide.
The following examples illustrate an preferred practices of the invention.
EXAMPLE 1
Referring to Table 1 and FIG. 2, propylene and ethylbenzene hydroperoxide feed at about 110° C. and 1000 psia are introduced to zone 1 via line 3 at the rate of about 1.4×10 6 lbs/hr.
Also fed to zone 1 via lines 4 and 3 at the rate of 1.4×10 6 lbs/hr. is a portion of the first zone effluent as recycle.
The reaction mixture passes through the solid catalyst bed in reactor 1 and is removed therefrom via line 5 .
The liquid reaction mixture is separated into a recycle stream which returns to reactor 1 via lines 4 and 3 and a net reaction stream which passes to reactor zone 2 . Reaction zone 2 is also packed with the same titania on silica catalyst used in reactor 1 . In reactor 2 further exothermic reaction of propylene with ethylbenzene hydroperoxide takes place to form propylene oxide.
Reactor 1 is a conventional reactor which contains a packed bed of titania on silica catalyst prepared as described in Example VII of U.S. Pat. No. 3,923,843. During passage through the catalyst bed in reactor 1 the exothermic reaction of propylene with ethylbenzene hydroperoxide takes place with the formation of propylene oxide. Pressure entering zone 1 is 1000 psia.
As a result of the reaction exotherm in zone 1 , there is a rise in temperature of the reaction mixture of about 74° F.
The following Table 1 gives the weight percentage compositions for the various process streams. The Stream No. designation refers to the process stream in the corresponding line or zone in the attached FIG. 2 .
TABLE 1
Reactor with Recycle
Combined
Fresh Feed
Recycle
Net Product
Feed
Stream No.
3
4
6
3 + 4
Temp, F.
110
185
223
149
Pressure, psig
1000
1000
1000
1000
Composition, wt %
PO
0
5.9
5.9
5.9
EBHP
14.5
0.001
.001
7.25
C3 =
52.8
48.6
48.6
50.7
MBA
1.6
14.0
14.0
7.8
ACP
1.8
2.1
2.1
2.0
EB
23.5
23.5
23.5
23.5
Propane
5.8
5.8
5.8
5.8
Rate lb/hr
1.4 × 10 6
1.4 × 10 6
2.8 × 10 6
2.8 × 10 6
EXAMPLE 2
Referring to FIG. 3, propylene and ethylbenzene feed at about 50° C. and 1000 psia are employed as starting materials. The entire amount of the propylene feed it passed by means of line 104 into the reactor 102 which is a fixed bed reactor containing an appropriate solid epoxidation catalyst. The totality of the ethylbenzene hydroperoxide feed stream to the system passes line 105 and is distributed respectively via line 106 to reactor 101 via line 107 to reactor 102 and via line 108 to reactor 103 . The amount of ethylbenzene hydroperoxide introduced into each of the reaction zone feeds is controlled such that the concentration of hydroperoxide entering each of the three reactor zone is less that 8 wt % of the total feed to the respective zones.
In each of the reaction zones the feed mixture passes there through at reaction conditions with the formation of propylene oxide product. The reaction mixture from zone 101 passes via line 109 to zone 102 . The appropriate amount of hydroperoxide is introduced line 107 and passes to zone 102 in admixture with the reaction effluent from zone 101 . In zone 102 , likewise reaction between hydroperoxide and propylene takes place with the formation propylene oxide product. Reaction effluent from zone 102 passes via line 110 to zone 103 . Additional hydroperoxide is introduced via line 108 in admixture with the effluent from zone 102 such that the feed entering zone 103 likewise contains less than 8 wt % hydroperoxide. In zone 103 additional reaction between hydroperoxide and propylene takes place with the formation of propylene oxide.
Each of reaction zones 102 , 103 and 104 contains a packed bed of titania on silica catalyst prepared as described in Example VII of U.S. Pat. No. 3,923,843. The following Table 2 gives the composition for the various process streams as well as the flow rates and temperatures and pressures occurring throughout the reaction system.
TABLE 2
Reactor with Split Feed
Stream No.
104
105
106
109
107
110
108
111
Temp °, F.
120
98
98
177
98
226
98
257
Pressure, psig
1000
1000
1000
1000
1000
1000
1000
1000
Composition, wt %
PO
—
—
—
2.7
—
4.5
—
5.8
EBHP
—
35.0
35.0
0.1
35.0
0.1
35.0
0.2
C3═
90.1
—
—
71.0
—
58.0
—
48.6
MBA
—
3.7
3.7
6.4
3.7
10.7
3.7
13.8
ACP
—
4.4
4.4
1.0
4.4
1.8
4.4
2.1
EB
—
56.8
56.8
10.8
56.8
18.2
56.8
23.5
Propane
9.8
—
—
8.0
—
6.7
—
5.8
Rate lb/hr
841094
592887
197619
1.04 × 10 6
197619
1.24 × 10 6
197619
1.43 × 10 6
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A process is provided for the production of oxirane compounds by reaction of an olefin such as propylene with an organic hydroperoxide using a solid contact catalyst, characterized in that a series of separate reaction zones are used, each packed with epoxidation catalyst, and the concentration of hydroperoxide in the feed to each reaction zone is maintained below 8 wt %.
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RELATED APPLICATION
The present application claims priority to Chinese Application No. 200610097378.3 filed Nov. 2, 2006, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
Small hydrophobic molecules such as steroid hormones and activated vitamins A and D control various biological phenomena, including growth, development, metabolism, and homeostasis, by binding to an activating specific nuclear receptors. Retinoids are natural and synthetic analogues of retinoic acid, an active metabolite of vitamin A, and are specific modulators of cell proliferation, differentiation, and morphogenesis in vertebrates. Modern medicinal chemistry of retinoids started in the 1970s ( Journal of Medicinal Chemistry, 2005, 48:5875-5882 and references cited therein). One class of synthetic retinoids are derivatives of polyenecarboxylic acids or aromatic carboxylic acids which consists of three parts, that is, the hydrophobic aromatic ring, benzoic acid moiety, and the linking group between them. Retinoid therapy using synthetic retinoids has already been realized in the field of dermatology and oncology. The synthetic retinoids, such as adapalene (compound 1) has been proven to be clinically useful in the treatment of acne and psoriasis.
Similar to adapalene, a number of other active compounds such as compound 2 ( Journal of Medicinal Chemistry, 2003, 46:909-912 with 1-adamantyl radical in the molecules also have therapeutic activity, including cancer chemopreventive effect. The known synthetic methods capable of producing these compounds employ 1-adamantanol as the starting material. However, this process generates disubstituted (1,2 or 1,3) adamantane as byproduct. After fine tuning the process, the disubstituted adamantane becomes the major product.
DETAILED DESCRIPTION OF THE INVENTION
The present invention offers a process for the preparation of disubstituted adamantine derivatives, which subsequently produce retinoids with disubstituted adamantyl radical that may be of pharmaceutical importance.
The process according to the invention is more specifically intended for the adamantylation of aromatic compounds, and in this case the receptor compound can, for example, be anisole, phenol, toluene, naphthalene, thiophene, or furan and their substituted derivatives.
According to a preferred embodiment, the aromatic receptor compounds have the general structures of 3 and 4, while the disubstituted adamantine derivatives have the general structures of 5 and 6, wherein R and X represent the substituent groups shown below.
R═—OCH 3 X═Cl, Br, I, CN
—OH —O(CH 2 ) 5 CH 3 —CH 2 OH —(CH 2 ) 3 OH —CH 2 CH(OH)CH 2 OH —COOH
The receptor compound can also be a thiol, in which case the process according to this invention leads to the formation of an adamantyl thioether. Among the thiols, special mention is made of 4-methoxy or 4-bromo benzene thiol.
The receptor compound can also be a nitrile such as acetonitrile. In this case the process according to the invention leads to the formation of an amide which can then be transformed under conventional conditions into 1,2-diaminoadamantane.
The following specific examples lead to the synthesis of a retinoid, compound 13 having dual structure of adapalene.
EXAMPLES
Compound 9: 7 (3.05 g, 0.020 mol) and 8 (8.65 g, 0.050 mol) were dissolved in CH 2 Cl 2 (18 ml). Concentrated H 2 SO 4 (1.07 ml, 0.020 mol) was added slowly to the resulting solution with the internal temperature at around 25° C. The resulting mixture was stirred at 25-30° C. for 3 hours, poured into water (100 ml), neutralized to pH 6 with saturated sodium carbonate solution, extracted with CH 2 Cl 2 (3×100 ml). The organic phase was washed with water (2×100 ml), dried over anhydrous sodium sulfate, filtered. HPLC showed the solution contained about 30% compound 5, 70% compound 6. The solution was evaporated to dryness. The solid was purified by flash chromatography, eluted with the mixture of CH 2 Cl 2 and methanol (95:5) to give 6.2 g pure light yellow solid compound 9 (99.5% HPLC). Yield 65%. The compound also can be obtained by recrystallizing the crude solid in chloroform and isooctane. The recovery was lower. The similar reaction conducted in chloroform at 40° C. offered compound 9 in 40% percent yield. 1 H NMR(CDCl 3 , 400 MHz): 7.33(s, 1H), 7.18(d, 1H), 6.55(d, 1H), 4.81(s, 1H), 2.42(s, 1H), 2.30(s, 1H), 2.19(d, 2H), 2.05(d, 2H), 1.79(s, 1H).
Compound 10: Dimethyl sulfate (2.0 ml, 0.021 mol) was added to a suspension of compound 9 (4.78 g, 0.010 mol) and anhydrous potassium carbonate (6.61 g, 0.063 mol) in dry acetone (100 ml). The mixture was reflux overnight, poured into water (200 ml), extracted with CH 2 Cl 2 (2×100 ml). The organic layer was washed with 1M NaOH (2×100 ml) and brine (2×100 ml), dried over anhydrous sodium sulfate, filtered. To the filtrate was added heptane (200 ml) and concentrated. Off-white solid came out during concentration. The solid was filtered, washed with heptane to give 4.35 g compound 8 (98.5% HPLC). Yield 86%. 1 H NMR(DMSO-d6, 400 MHz): 7.35(d, 1H), 7.20(s, 1H), 6.95(d, 1H), 3.79(s, 3H), 2.27(s, 1H), 2.20(s, 1H), 2.15(d, 2H), 1.87(d, 2H), 1.70(s, 1H).
Compound 12: A solution of compound 8 (2.53 g, 0.0050 mol) in THF (25 ml) was added dropwise under nitrogen to a stirred mixture of Mg turnings (0.292 g, 0.012 mol) and a small crystal of iodine in THF (5 ml) at 40° C. in 45 minutes. After addition, the mixture was maintained at 40° C. for 30 minutes. The resulting Grignard solution was then added directly to a stirred solution of methyl 6-bromo-2-naphthoate (compound 11) (3.18 g, 0.012 mol), PdCl 2 (PPh 3 ) 2 (1.73 g, 0.0024 mol) and anhydrous ZnCl 2 (1.64 g, 0.012 mol) in dry THF (60 ml) at 50° C. in 10 minutes. The resulting mixture was stirred at 50-55° C. for 1 hour. The reaction was cooled in an ice bath and quenched by adding di-water (10 ml). The resulting paste was concentrated on a rotary evaporator and cooled in ice bath. 1 M HCl solution (100 ml) was added slowly. The suspension was extracted with CH 2 Cl 2 (3×100 ml). The combined organic phase was dried over anhydrous sodium sulfate, filtered. The filtrate was evaporated to dryness and purified by flash chromatography, eluted with the mixture of CH 2 Cl 2 and methanol (95:5) to give 2.45 g pure white solid compound 10 (99% HPLC). Yield 68%. 1 H NMR(CDCl3, 400 MHz): 8.61(s, 1H), 8.00(m, 3H), 7.91(d, 1H), 7.81(d, 1H), 7.67(s, 1H), 7.57(d, 1H), 7.00(d, 1H), 3.99(s, 3H), 3.91(s, 3H), 2.60(s, 1H), 2.36(d, 3H), 2.17(d, 2H), 1.85(s, 1H).
Compound 13. Compound 10 (1.2 g, 0.0017 mol) was suspended in methanol (120 ml). The NaOH powder (0.34 g, 0.0084 ml) was added. The mixture was heated under reflux for 2 hours and concentrated to give a residue. 1 M HCl solution (50 ml) was added slowly to the residue. The off-white solid was filtered, washed with water and dried. The solid was recrystallized from THF to give 0.95 g off-white solid compound 2 (99% HPLC). Yield 81%. M-: 688. 1 H NMR(DMSO-d6, 400 MHz): 12.82(b, 1H), 8.57(s, 1H), 8.19(s, 1H), 8.14(d, 1H), 8.05(d, 1H),7.97(d, 1H), 7.89(d, 1H), 7.66(m, 2H), 7.14(d, 1H), 3.89(s, 3H), 2.53(s, 1H),2.34(m, 3H), 2.09(d, 2H),1.82(s, 1H).
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A process for the preparation of disubstituted adamantine derivatives characterized by the factor that the aromatic receptors can be a series of halide anisole, phenol, toluene, naphthalene, thiophene, or furan and their substituted derivatives. The synthesized disubstituted adamantine derivatives were subsequently converted into a new class of synthetic retinoids of pharmaceutical importance.
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BACKGROUND OF THE INVENTION
The present invention relates to apparatus for removing cells and, more particularly,, to apparatus for physically removing cells in sterile manner from a disc stack on which cells are cultured in a mass cell culture apparatus.
Systems have been developed for the mass culture of cells such as, for example, the multi-plate system disclosed in U.S. Pat. No. 3,407,120 and the Biotech cylindrical rotating disc apparatus. A major difficulty associated with the use of such mass culture systems, however, is that of removing the cells from the discs on which they have been cultured. Prior art method of removing the cells involve the use of enzymes, such as trypsin which have the disadvantage of causing, to some extent at least, undesired chemical degradation of the cells.
It is, accordingly, an object of the present invention to provide apparatus and method for physically removing cells in a sterile manner from mass cell culture apparatus. Another object of the present invention is to provide an apparatus and method for physically removing cells in sterile manner from the discs of the multi-plate or multi-disc mass cell culture apparatus. These and other objects will be apparent from the following detailed description.
SUMMARY OF THE INVENTION
Apparatus for physically removing cells in sterile manner from a disc stack on which the cells have been cultured comprises a substantially shaft-like member having at least one rod-like member mounted at substantially a right angle to the axis of the shaft. The rod-like member may be provided with a flexible, substantially inert, impermeable material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a multi-plate cell culture apparatus fitted with a cell removing device of the present invention;
FIG. 2 is a plan view of the apparatus of FIG. 1;
FIGS. 3 and 4 are sectional views of various rod-like members.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 is a sectional view of a known rotating disc apparatus described in U.S. Pat. No. 3,839,155 whose disclosure is hereby incorporated by reference. The apparatus is equipped with a cell removing device according to the present invention preferably formed of a metal suitable for cell culture conditions, e.g., stainless steel or titanium. The apparatus comprises a cylindrical shell 10 having a central shaft 11 on which are mounted a plurality of discs 12 on whose surfaces the cells are cultured. Also fixedly mounted on the shaft is a magnetic couple (not shown) which is engaged by external magnetic drive means (not shown) in order to rotate the discs 12. The cell removing device consists of a substantially shaft-like member 13 having a turning handle 14 at its uppermost end and a plurality of rod-like members 15, each of which is attached at about a right angle to a portion of the shaft. The shaft is of such length that member 15 which is furthest from the handle can contact the disc 12 which is furthest from the handle. Members 15 are spaced apart from one another so as to fit between adjacent discs to contact the lower surface of a disc closer to the handle and the upper surface of the adjacent disc further from the handle, as well as to contact the upper surface of the disc closest to the handle and the bottom surface of the disc furthest from the handle. The shaft 13 passes through a circular opening 16 in the cover plate 17 which is secured to the top of the apparatus by bolts 18. The shaft 13 is hollow and thereby adapted to fit over guide rod 13a which is fixed to the bottom plate of the shell.
A recessed flange 19 in the upper surface of opening 16 is adapted to receive an O-ring 20 which is covered with a cap 21 which is fixed to plate 17 by screws 22 to seal opening 16.
The lower portion of shaft 13 has a flat surface 23 having a plurality of recesses 24, each recess adapted to receive a rod-like member 15. Members 15 may be secured in recesses 24 by soldering, or both the recesses 24 and the ends of the members 15 may be threaded so that the members 15 may be screwed into recesses 24, or by other suitable means. If attached by soldering, a solder fillet 25 is provided at the flat surface 23 to strengthen the attachment.
FIG. 2 is a plan view of the rotating disc apparatus with plate 17 removed and showing cylindrical shell 10, central shaft 11 and top disc 12, turning handle 14 and top rod-like member 15. By turning handle 14, shaft 13 is rotated thereby sweeping rod-like member 15 across the surface of disc 12 and displacing cells from the surface of disc 12 into the liquid medium in the apparatus from which liquid medium and cells are drawn off. Alternatively, shaft 13 may be turned to engage members 15 and disc 12 and shaft 11 rotated to turn discs 12.
FIG. 3 is a cross section of a rod-like member 15 having a coating 26 thereon of a flexible, substantially inert, impermeable material which is able to withstand steam sterilization such as polyfluorinated hydrocarbon, e.g., Teflon. The properties of Teflon are summarized in the 1953 edition of Handbook of Material Trade Names, p. 558.
FIG. 4 is a cross section of another rod-like member 15 surrounded by tubing 27 with the space between the tubing 27 and member 15 filled with a flexible adhesive 28 which is able to withstand steam sterilization such as a silicone rubber.
The plain rod-like member without coating or tubing is obvious and not shown in the drawings.
When used with a multi-plate cell culture apparatus, the cell removing apparatus of the present invention is positioned against the inside wall of shell 10 by turning handle 14. When the cell culture operation is completed, the handle 14 is turned causing shaft 13 to rotate and causing rod-like member 15 to sweep in arcuate manner across the surface of disc 12 displacing cells it meets and pushing off the edge of the disc into the liquid medium in the cell culture apparatus. The shaft 11 on which the disc is mounted is then partially rotated, e.g. about 90°, bringing another cell coated portion of disc 12 within the area swept by member 15. About 3 or 4 partial rotations of shaft 11 are sufficient to enable member 15 to displace substantially all of the cells on disc 12. Member 15 may then be turned against the inner wall of shell 10 and raised or lowered to contact another disc. Alternatively, the handle may be turned to bring the rod-like member 15 in contact with at least part of a surface of a disc and shaft 11 rotated by the magnetic drive means to displace cells.
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Apparatus for physically removing cells in sterile manner from a disc stack on which the cells have been cultured comprises a substantially shaft-like member having at least one rod-like member mounted at substantially a right angle to the axis of the shaft.
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CROSS-REFERENCE TO RELATED APPLICATIONS:
This application is a continuation-in-part of U.S. application Ser. No. 735,340 filed Oct. 26, 1976, now abandoned.
BACKGROUND OF THE INVENTION
A well known test for the determination of cardiac output involves the injection of a measured amount of cold injectate solution into the right heart proximal to the pulmonary artery in a predetermined time period of short duration, such as, on the order of two seconds. The temperature drop of the blood passing a thermistor positioned in the heart is then sensed and measured. The decrease in blood temperature in a given time resulting from the injectate solution, when integrated by a cardiac output computer, is a measure of the output capacity of the heart in liters per minute. This technique for determining cardiac output is well known and is of considerable importance in diagnosing and treating critically ill patients. The value of the technique of thermodilution cardiac output monitoring is directly related to the accuracy of the process. Many thermodilution cardiac output computers are commercially available for obtaining determinations of cardiac output from a blood temperature drop curve.
The reliability of the technique of thermodilution cardiac output monitoring depends on the accuracy and repeatability of the injection process. At the present time the greatest potential source of error is in the time period for the introduction of the injectate. In order for the output readings to be accurate, repeatable and reliable, the injectate must be delivered to the patient over a short predetermined time period, which time period must be the same for each injection. If the time period of injection varies, the rate of change of blood temperature over a given time will also vary, and the computer output readings will thus be rendered inaccurate and unreliable. Bearing in mind that injection should occur over a time period of approximately two seconds, the time it takes for 10 cc of O'dextrose to be injected manually, it can readily be seen that a variation of as little as a fraction of a second from injection to injection can lead to substantial errors in measurement.
In the present practice of the thermodilution injection technique, a doctor or medical technician manually operates a syringe to deliver the injectate into a catheter placed in the right heart proximal to the pulmonary artery. Manual introduction of the injectate has the potential for significant inaccuracies which in turn, lead to serious errors in the computer output. It is extremely difficult for a medical technician to deliver a steady flow of the injectate repeatably over the same time period, and it is even more difficult for different medical technicians to deliver the full amount of injectate in the identical time period repeatably. Thus, the delivery rate of the injectate usually varies, and the time period is usually somewhat greater or somewhat less than the time period for the previous injection. As a result large fluctuations of cardiac output are routinely observed in a series of determinations done on the same patient by different operators. The most probable cardiac output volume is arrived at by sampling several of the closest readings and rejecting the rest.
SUMMARY OF THE INVENTION
The problem of accuracy and repeatability of thermodilution injection is solved by the thermodilution injector of the present invention which accomplishes the delivery of an accurate amount of injectate at a predetermined rate and over a predetermined time period, with the rate and time period of injection being accurately determined and repeatable for all injections.
The present invention provides an accurate and reliable injector device to replace the manual injection technique heretofore used in the art. The injector device of the present invention includes a pneumatically powered piston which is connected to operate the plunger of a syringe. Fluid from a regulated pressure supply is delivered to the device to operate the piston in a stroke of repeatable time duration; the injection time being inversely proportional to secondary regulator pressure. The plunger of the syringe is thus depressed in an accurate time period so that the injectate in the syringe is delivered to the cardiac catheter in the desired time period.
Apparatus in accordance with the present invention may also include a detent control valve. The control valve causes retraction of the piston at a slower rate than the rate at which the piston was advanced, thereby providing for aspiration of the syringe for another injection.
Accordingly, one object of the present invention is to provide an accurate and reliable thermodilution injector for cardiac output monitoring.
Another object of the present invention is to provide a thermodilution injector for cardiac monitoring in which a measured amount of injectate is always delivered within an accurate predetermined time period.
Other objects and advantages of the present invention will be apparent to and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWING
Referring now to the drawings, wherein like elements are numbered alike in the several figures:
FIG. 1 is a top plan view of the thermodilution injector of the present invention.
FIG. 2 is a side elevation view of the thermodilution injector of the present invention.
FIG. 3 is a front elevation view of the thermodilution injector of the present invention.
FIG. 4 is a schematic showing of the pneumatic circuit of the thermodilution injector of the present invention.
FIG. 5 is a partial view of a modified version of the thermodilution injector.
FIG. 6 is a schematic diagram of the pneumatic circuit for the modified version of FIG. 5.
FIG. 7 shows a bolus injection set for use with an injector for purposes of isotope injection.
FIG. 8 is a schematic of a pneumatic circuit for isotope injection.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to a combined consideration of FIGS. 1, 2 and 3, the thermodilution injector, indicated generally at 10, has an upper enclosed body portion 12 of generally cylindrical shape which houses the actuating piston, a lower body portion 14 which serves as the handle, and a lower cylindrical projection made up of an upper section 16 and a lower section 18 removably fastened to section 16. The upper portion 16 of the cylindrical projection houses a flow regulator, and the lower section 18 houses a pressurized gas supply for the injector. An actuating trigger 20 projects from handle section 14, trigger 20 being the plunger of a double detent two position flow control valve. Upper body 12 serves as the cylinder for an actuating piston 22 (shown in phantom in FIG. 1) which has a rod 24 which projects outwardly toward the front of the injector. As will be described in more detail hereinafter, rod 24 actuates the plunger of a syringe for the delivery of injectate.
A pair of support arms 26 and 28 project from the front of upper body 12, the support arms being screw fastened to the front of upper body 12. A syringe holder 30 is mounted on the ends of support arms 26 and 28 by elongated screws 32 and 34. Syringe holder 30 has a centrally located retaining clip 36 which is generally U-shaped in configuration, with the legs of the U having arcuate sides to receive a syringe (see FIG. 3). Retaining clip 36 is of spring metal and it is sized to receive and grip a standard medical syringe. Slots 38 and 40 are formed in the sides of holder 30 to extend over each of the support arms 26 and 28, the slots 38 and 40 serving to receive the wings of a syringe body. Thus, it will be seen that a syringe can be securely held in holder 30 by inserting the syringe into the top of clip 36, the sides of clip 36 deflecting outward to receive the syringe and then returning to the unflexed position to hold the body of the syringe. At the same time, the wings normally present on a standard syringe are inserted in slots 38 and 40 so that the syringe is fixed against axial movement.
An adapter element 42 is fastened to the end of piston rod 24, the adapter element having a slotted head to receive the thumb button on the end of a syringe plunger so that the syringe plunger is connected to rod 24 and will be moved in and out of the syringe in accordance with the motion of rod 24.
When a syringe is appropriately located in holder 30 with the thumb button of the plunger in adapter 42, the plunger is moved forward to deliver injectate or withdrawn to aspirate a new load of injectate into the syringe in accordance with the movement of piston 22 and rod 24. The piston is powered by a pressurized gas supply, such as a CO 2 cartridge housed in projection 18, the delivery pressure being regulated by a pressure regulator in projection 16.
Referring to FIG. 4, a schematic diagram is shown of the pneumatic system. The pressurized gas from projection 18 passes through a pressure regulating valve 44 and is delivered to a manually operated two position valve 46 which is operated by a trigger 20. Valve 46 is a four-way two position valve which is detented to hold the valve in either of the two positions in which it is set by movement of trigger 20. Valve 46 may be Humphrey Model 41PPX obtainable from Humphrey Products, Division of General Gas Light Company, Kalamazoo, Michigan. In the position shown in FIG. 4, valve 46 would be delivering pressurized gas to the left side of piston 22, and the right side of piston 22 would be vented to atmosphere through a restriction 48. In this position of the valve, piston 22 would be moving rearwardly to withdraw the plunger from the syringe to aspirate the syringe. In the other position of valve 46, pressurized gas would be delivered to the right side of piston 22, and the left side of piston 22 would be vented directly to atmosphere so that piston 22 would move in the direction to push the plunger into the body of the syringe to deliver injectate. The presence of restriction 48 provides for a two speed operation of piston 22. The speed at which the piston will move rearwardly, and hence withdraw the plunger for aspiration, will be less than the forward motion of the piston and plunger because of the effect of restriction 48. Thus, piston 22, rod 24 and the plunger of the syringe will move forward at a first speed to deliver injectate and will move in the reverse direction at a second and slower speed appropriate for aspiration for another round of injection. It is extremely important to note that the forward motion of piston 22, rod 24 and the plunger of the syringe will always be at a constant speed, repeatable for each cycle of injection, because of the constant operating pressure which is always present on the right side of piston 22 when the piston is being driven forward. Thus, the injectate is always delivered at a constant flow rate and the elapsed time for injection will always be the same for each cycle of injection. Thus, the serious problems of inaccuracy heretofore present in delivering the injectate are totally eliminated in the present invention.
In the operation of the thermodilution injector of the present invention, trigger 20 would be first pulled outwardly relative to the body of the injector, this outward position being the aspiration position as shown in FIG. 4. Lower projection 18 would then be unscrewed from upper projection 16, and a CO 2 cartridge 50 (shown in phantom in FIG. 3) is inserted, neck up, in projection 18. Lower projection 18 is then rejoined to upper projection 16 so that the sealed end of the CO 2 cartridge is pierced by a pin extending downwardly from projection 16 in the known manner to permit flow of the pressurized gas supply of the CO 2 cartridge. If it is desired to test the device for pressure at this point, trigger 20 can be pushed inwardly to its inner detent position and then pulled outwardly to its outer detent position which will cause a cycling of piston 22 and rod 24. Next, a syringe is positioned in holder 30, with the body of the syringe being held by grip 36, the wings of the syringe being held in slots 38 and 40 and the head of the syringe being positioned in the slot of rod adapter 42. It should be noted that the capacity of various syringe models for a given stroke will vary, so a syringe should be selected to provide the desired volume of injectate for the stroke of the unit. Preferably, the syringe should be connected to the catheter before insertion in holder 30, and the syringe should be filled with the desired volume of injectate before being positioned in the holder. When the patient is ready and all of the other monitoring instruments have been prepared for measuring cardiac output, and the signal is given from the attending physician to inject the injectate, the operator of the unit of the present invention will then merely squeeze trigger 20 rapidly and firmly to move trigger 20 to its inner detent position. This movement of trigger 20 will switch valve 46 to the second position shown in FIG. 4 whereby piston 22, rod 24 and the plunger of the syringe will advance and inject the entire contents of the syringe in a predetermined period of time, such as on the order of two seconds. To refill the syringe, the syringe is merely connected to a reservoir of injectate in any known and desired manner, and trigger 20 is then pulled outwardly to its outer detent position. Valve 46 will then be switched to the position shown in FIG. 4 whereby piston 22 and rod 24 and the plunger of the syringe will be withdrawn (at a slower speed than the advance) to aspirate a constant volume of injectate in a desired time period, such as eight seconds. The syringe would then be disconnected from the reservoir and would be ready for another round of injection or injectate at the constant injection volume, injection rate and injection time of the present invention.
When CO 2 cartridge 50 is empty, the injection speed of the device will rapidly deteriorate. All that then needs to be done is to replace the empty CO 2 cartridge with a fully charged CO 2 cartridge, and operation of the system can continue.
If it is desired to inject less than the total capacity of the syringe, the syringe should be filled in each aspiration to the desired smaller volume and placed in holder 30 as previously described. However, the thumb button on the plunger should be connected into the retaining slot in rod adapter 42. In this configuration, the piston rod 24 will advance freely until it strikes the retracted syringe plunger, and the volume of injectate will then be delivered. Repeated operation in this mode requires manual aspiration of the syringe.
Referring now to FIGS. 5 and 6, a modified version of the thermodilution injector is shown which incorporates a first very important feature of variable injection rate and a second very important feature relating to safety which prevents inadvertent aspiration. FIG. 5 shows a modified version of the body portion of the injector of FIG. 1, and FIG. 6 shows the schematic of the pneumatic circuit for this modified version. In the modified version of FIG. 5, a four way control valve is housed in section 100 of the housing. The four way valve is indicated at 102 in FIG. 6, and it includes a push button 104 to operate the valve and a spring 106 to urge and return the valve to its unoperated or off position. Section 108 of the housing contains a variable pressure regulator valve 110 which is operated by a push button 112 against a return spring 114 to vary the pressure drop across the regulator depending on the amount of depression of button 112. As can best be seen in FIG. 6, the configuration of FIGS. 5 and 6 incorporates four way spring return valve 102 and variable pressure regulator 110 in the line between pressure regulator 44 and piston cylinder 12.
In the embodiment of FIGS. 5 and 6, pressure regulator 44 functions to maintain a constant level of gas pressure as in the FIG. 1 embodiment. However, variable pressure regulator 110 will vary the pressure level of the gas delivered from pressure regulator 44 to piston cylinder 12 to vary the rate of either forward or return motion of piston 12. Thus, the rate of movement of piston 12, either in the delivery or aspirating directions, can be selected and varied by the operator of the device by varying the depression of button 112.
Four way valve 102 determines the direction in which the piston 22 will move, i.e. to the left to deliver injectate, or to the right to aspirate. In the position shown in FIG. 6, which is the normal or unactuated position of valve 102, the valve is positioned to deliver pressurized fluid to the right of piston 22 and vent the left side of piston 22 which would drive the piston to the left to operate the syringe to deliver injectate. When button 104 is depressed to move valve 102 to its second position, the valve is positioned to deliver pressurized fluid to the left side of piston 22 while the right side of piston 22 is vented, which would drive piston 22 to the right to aspirate the syringe. However, no pressurized fluid is delivered to valve 102 until variable pressure regulator 110 is operated.
Spring 106 will retain valve 102 in the position shown in FIG. 6 unless the operator depresses button 104 to move the valve to the second position; and spring 106 will return valve 104 to the position shown in FIG. 6 whenever the operating force is removed from button 104. Thus, it will be seen that the position of valve 102 determines the direction of movement of piston 22 and determines whether the device will operate in the mode to deliver injectate or to aspirate, while the position of button 112 to vary the setting of variable regulator 110 will determine the rate of movement of piston 22 and hence the rate of movement of syringe plunger in either the injectate delivery direction or the aspiration direction. In addition, it will also be recognized that since the normal position of valve 102 is to effect delivery of injectate, aspiration can only be effected by deliberate depression of button 104 by the operator. Accordingly, inadvertent or accidental aspiration is avoided, since aspiration requires the deliberate depression of both buttons 104 and 112.
Referring now to FIGS. 7 and 8, still another modification is shown wherein the injection apparatus can be used as a bolus injector, particularly in the nuclear medicine field for isotope injection. FIG. 7 shows a bolus injection set, while FIG. 8 shows the schematic diagram of the pneumatic circuit for actuating the injector when used as a bolus injector. A standard syringe 116 is mounted in the injector apparatus as described above with respect to FIG. 1. Syringe 116 is fitted with a three way syringe set 118 which has one channel 120 communicating with the syringe, a second channel 124 which communicates with an output line 126 and a third conduit 128 which communicates with a fluid reservoir. Three way set 118 has an exterior handle 122 which positions an internal stop cock valve in three way set 118, the internal valve being configured to have three positions where (1) conduit 120 comunicates with conduit 124 to deliver the contents of the syringe to output line 126 while preventing any communication with conduit 128, (2) a second position in which conduit 120 is connected to conduit 128 to permit aspiration of fluid from a reservoir to load syringe 116 while preventing any communication with output conduit 124, and (3) a third position in which conduit 128 is connected to conduit 124 to flush the output line or administer intravenous fluids.
Output line 126 contains a "Y" type injection site 130 which receives a needle 132 from a syringe or other injection mechanism 134 to inject material from the syringe 134 to mix with the contents of line 126. In the preferred configuration of an isotope injector, syringe 116 and line 126 are filled with an injectate such as a saline solution, and injector 134 supplies a radioactive isotope to be carried in the saline solution in output line 126. The portion of output line 126 downstream of injection site 130 is encased in a lead or other suitable shield 134 to protect against radiation. Conduit 126 terminates in a adapter 136 which is connected to conduit 126 at the downstream end of shield 134, and an injection needle or a catheter would be positioned at the downstream end of adapter 136 for injection of the isotope into a patient for examination purposes.
In the operation of the device shown in FIG. 7, saline solution would be manually aspirated from the reservoir into syringe 116 and then delivered to output line 126 and needle adapter 136 to completely fill output line 126, adapter 136 and the injection needle or catheter attached to adapter 136, and a full charge of saline solution would be stored in syringe 116. After the syringe, output line and adapter (and needle or catheter) are charged with saline solution, a precisely measured volume of a radioactive isotope is injected at Y site 130. The volume of isotope injected may be any measured amount up to the total volume contained in that portion of output line 126 which is shielded by shield 134. Whatever selected amount of isotope is injected will, of course, displace and eject a corresponding volume of saline solution through adapter 136. The bolus injector set is then fully charged and ready for operation. Bearing in mind that syringe 116 is mounted in an injector 10, operation of the bolus isotope injection set is effected by cycling the injector to drive the plunger of syringe 116 forward to deliver the isotope and saline solution to the patient. It is most important to note that the entire isotope solution stored in the portion of line 126 shielded by shield 134 is delivered to the patient as a discrete bolus flushed with the solution in syringe 116 and line 126. To effect bolus injection, the aspirated volume of syringe 116 must be equal to or greater than the volume of line 126 encased in shield 134.
FIG. 8 shows a schematic of the pneumatic circuit for injector 10 when used as an isotope injector. A spring loaded two position four way valve 138 is positioned between pressure regulator 44 and cylinder 12. Valve 138 is urged to a first or non-operating position by a return spring 140, and the valve has a push button 142 to operate the valve. Valve 138 would be housed in the injector in the position such as valve 100, with actuating button 142 projecting similarly to actuating button 104. In the first or unactuated position of valve 138, both the right and left sides of piston 22 are vented to atmosphere, and the supply line from pressure regulator 144 is dead ended at the valve. That state of the valve is shown in FIG. 8. When button 142 is depressed to actuate the isotope injector, the valve moves to its second position where pressurized fluid is delivered to the right side of piston 22 while the left side of piston 22 is vented, thus causing piston 22 to move to the left to push the plunger of the syringe for injection. The operator of the injector retains control over injection during the entire injection stroke. If the operator releases the actuating pressure from button 142, spring 140 will automatically return the valve 138 to its unoperated position whereby both sides of piston 22 will be vented and the injection stroke will cease. Thus, an important safety feature is incorporated in the device in that the operator must consciously maintain the actuating force on button 142 to complete the injection, and the injection will be automatically terminated at any intermediate point upon removal of the operating force from button 142. Aspiration and return of piston 22 to the right are accomplished manually.
While a preferred embodiment has been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it will be understood that the present invention has been described by way of illustration and not limitation.
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A thermodilution injector is presented in which a pneumatically powered piston operates the plunger of a syringe to deliver a measured amount of injectate in an accurately predetermined time period.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Ser. No. 61/570,086, filed Dec. 13, 2011.
FIELD
[0002] The present disclosure relates to the field of hybrid electric vehicles (HEV) and battery electric vehicles (BEV), and more particularly to an electric power dissipation system and method for hybrid electric and battery electric vehicles.
BACKGROUND
[0003] Permanent magnet synchronous motors (PMSM) are widely used in hybrid electric vehicles and battery electric vehicles. Among the permanent magnet synchronous motors, interior permanent magnet (IPM) motors are the most commonly used motors for HEV/BEV applications due to their high power density, high efficiency and wide speed range.
[0004] When a hybrid electric vehicle or battery electric vehicle is in an electric mode (i.e., the mode when it is only running the electric motor without the assistance of an internal combustion engine), the vehicle needs to give the driver similar drive performance as compared to conventional vehicles that only use an internal combustion engine. One of the desired features for hybrid electric and battery electric vehicles is to have a coast-down performance similar to that of conventional vehicles. This requires the electric motor to provide certain brake torque to the vehicle when the accelerator pedal is released. In other words, the mechanical power is converted to electric power and fed back to the battery. This is also called coast-down regenerative braking. Regenerative braking is an energy recovery mechanism that slows down a vehicle by converting its kinetic energy into another form—in the case of hybrid electric and battery electric vehicles, the kinetic energy is converted into electrical energy. In conventional braking systems (i.e., for internal combustion engine vehicles), by contrast, excess kinetic energy is converted into heat by friction in the brake linings; therefore, the excess energy is wasted in these vehicles. For hybrid electric and battery electric vehicles, however, the excess energy can be stored in a battery or bank of capacitors for later use.
[0005] However, under certain conditions, (e.g., when the state of charge (SOC) of the battery is high or the battery temperature is hot/cold), regeneration current is not allowed back to the battery. Battery state of charge is the equivalent of a fuel gauge for the battery in a hybrid electric or battery electric vehicle, which measures how fully charged the battery is. Thus, when the state of charge of the battery is high or the battery temperature is hot/cold, the amount of power that can be accepted by the battery is met or exceeded. As such, there is the possibility of detrimental effects to the battery if more power is fed back to it.
[0006] Under certain conditions such as e.g., when the SOC is nearly full or the battery temperature is high, if coast-down regeneration is not allowed, the electric motor suddenly has to remove all of its braking torque to prevent the current (i.e., energy converted from kinetic energy) from charging the battery. This affects the smoothness of the driving experience as perceived and felt by the driver. This will give the driver inconsistent drive performance when the above conditions exist compared to when they do not. Thus, there is a need to allow regenerative braking in hybrid electric and battery electric vehicles under all circumstances even when the regeneration current cannot be fed back to the battery.
SUMMARY
[0007] In one form, the present disclosure provides a motor control apparatus for a hybrid electric vehicle comprising an electric motor. The apparatus comprises a battery control module coupled to a battery and configured to monitor and detect a state of the battery; and a motor control unit coupled to the battery and the battery control module, said motor control unit being configured to selects one of a normal motor control operation, a power dissipation motor control operation, or a discharge operation based on the state of the battery received from the battery control module. During the power dissipation motor control operation, power from brake torque is dissipated in stator windings of the electric motor.
[0008] The present disclosure also provides a method of operating an electric motor of a hybrid electric vehicle. The method comprises detecting, at a battery control module, a state of an electric battery within the vehicle; and selecting, at a mode control unit, one of a normal operation, power dissipation operation, or discharge operation of the electric motor based on the detected state of the battery. During the power dissipation operation, power from brake torque is dissipated in stator windings of the electric motor.
[0009] As disclosed herein, the state of the battery includes a state of charge of the battery, a battery temperature, and/or a fault condition. The motor control unit selects the normal motor control operation if the state of charge of the battery is below a predetermined value and selects the power dissipation motor control operation if the state of charge of the battery is above a predetermined value.
[0010] Further areas of applicability of the present disclosure will become apparent from the detailed description and claims provided hereinafter. It should be understood that the detailed description, including disclosed embodiments and drawings, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the invention, its application or use. Thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an interior permanent magnet operating plane;
[0012] FIG. 2 illustrates a schematic of the electrical system of a hybrid electric vehicle;
[0013] FIG. 3 illustrates a block diagram of the control process having the electric power dissipation process in accordance with the present disclosure; and
[0014] FIG. 4 illustrates a block diagram of the control process having the electric power dissipation process in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0015] Described herein is a mechanism to maintain consistent drive performance for hybrid electric and battery electric vehicles (as compared to conventional vehicles with internal combustion engines) under constrained conditions. The disclosed mechanism provides a path to dissipate power generated by braking torque without generating any power back to the battery. In addition, under certain conditions, the mechanism can even draw current from the battery while still producing the desired electric motor braking torque. In some instances, it is desirable to have current drawn from the battery to discharge it (to prevent a battery overcharge condition) or to warm it up (i.e., if the battery charge power limit is low because it is cold) so that the battery can provide full power more quickly.
[0016] Embodiments described herein dissipate the power generated by braking torque through the electric motor's stator windings, while the motor is providing the required electric motor braking torque and without charging the battery. In the synchronous frame, the steady-state voltage equation of an interior permanent magnet motor can be expressed as:
[0000] V ds =R s i ds −ω r L q i qs (1)
[0000] V qs =R s i qs +ω r ( L d i ds +λ PM □) (2)
[0000] Where v as , v qs , i ds and i qs are the motor currents and voltages in the d-q reference frame, w r is the rotor electrical frequency, L d and L q are the stator d- and q-axis inductances, R s is the stator resistance, and λ PM is the permanent-magnet flux linkage.
[0017] The motor torque output is given by:
[0000] T em =(3 P/ 2)(λ PM i q +( L d −L q ) i d i q ) (3)
[0000] Where P is the number of pairs of poles of the motor.
[0018] The motor current is limited by i max :
[0000] i ds 2 +i qs 2 <i max 2 (4)
[0019] With the motor model defined in equations (1) and (2) for a given torque, T em , the minimum current is the shortest distance from the torque curve to the origin, i=√{square root over (i ds 2 +i qs 2 )}. For a given torque T, the minimum current is the shortest distance from the torque curve to the origin in the current d-q coordinate and the Maximum Torque Per Ampere (MTPA) curve can be obtained as:
[0000]
i
d
=
I
PM
2
(
L
q
-
L
d
)
-
λ
PM
2
4
(
L
d
-
L
q
)
2
+
i
qs
2
(
5
)
[0020] Referring to FIG. 1 , the maximum torque per ampere (MTPA) curve, maximum torque per volt (MTPV) curve, current limit circle, I limit, and torque curves are plotted. The voltage ellipses for the motors (1) and (2) are also plotted. For any given torque, DC bus voltage, and motor speed, there exists a torque curve and a voltage ellipse curve as shown, for example, in FIG. 1 . The torque curve intercepts with the voltage ellipse and the boundaries such as the MTPA curve, MTPV curve and current limit circle. A unique set of optimal reference currents i d and i q within the optimal operational plane can be determined.
[0021] For a given torque command, the motor current i d and i q can be chosen at any point along the torque curve. However, the optimal (i.e., minimum) motor current is at the intersection between the MTPA and the torque curve as shown in FIG. 1 . To maintain the same motor torque output, it has been determined that more current will dissipate more power, or losses, in the motor stator windings. Thus, the present disclosure aims to maintain the same torque output with the more possible current (note: if maximum possible power needs to be dissipated, then the highest possible current i max on the same torque curve will be needed). The total power dissipation in the motor stator winding is:
[0000] P= 3 R s ( i ds 2 +i qs 2 ) (6)
[0022] And the power from the battery, or DC power supply is:
[0000] P=V dc I dc (7)
[0023] The maximum power dissipation is limited by the motor current limit, i max (i.e., the current limit circle radius). For a given torque command, the maximum power dissipation current command is at the intersection of the current limit circle and the torque curve as shown in FIG. 1 . The intersection point (i d — max , i q — max ) is determined by equations (3) and (4) set forth above.
[0024] FIG. 2 illustrates an electrical system overview of a hybrid electric vehicle. The electrical system includes a battery 10 , which is an electric battery, connected to a battery control module 20 and a power electronics and motor control unit 30 . The battery control module 20 monitors and controls the functions of the battery 10 . For example, the battery control module 20 can detect the state of charge of the battery and/or the battery's temperature. The power electronics and motor control unit 30 contains motor control process 40 (described below) and is also connected to an electric motor 50 , which can be for example, an interior permanent magnet motor.
[0025] FIG. 3 illustrates an example motor control process 40 having a power dissipation process 60 in accordance with the present disclosure. In a desired embodiment, the process 40 is implemented in software operated by control unit 30 or other processor. The power dissipation process 60 includes, among other processing, a current regulator process 62 and i q process 64 . The current regulator process 62 (which can be, for example, a proportional integral regulator) tries to regulate the DC current feedback to the current reference value. The DC bus voltage V dc and current feedbacks i ds are sensed and the DC power consumption P can be calculated by equation (7). Depending on the i dc — ref value, either zero or a positive value for more power consumption by the motor and other loads in the system, the DC current feedback is compared with the reference value and fed to the current regulator. The “other loads” could be, for example, a DC/DC converter (e.g., 300V to 12V), heater or cooler, and all other auxiliary loads that are connected to the high voltage DC bus. The auxiliary loads can be factored into the determination by use of load reference models or look-up tables for a more accurate calculation. The commanded i d is calculated by equation (6) and is compensated by the output of the current regulator process 62 . The commanded i d can also be obtained by using look-up tables that can take motor/vehicle parameter uncertainty and other vehicle power loads into consideration to get better accuracy of the power consumption.
[0026] The i d , i q calculation for normal motor torque control (i.e., when power dissipation mode is not needed) is performed in process 42 . It should be appreciated that the process 42 can also be implemented by using a look-up table 42 ′ (as shown in FIG. 4 ) with calibration entries to accommodate the uncertainty of the motor and other loads in the vehicle; this may allow for a more accurate calculation. The motor stator resistance value is also compensated for by stator temperature feedback. In other words, the motor stator resistance is compensated for by stator temperature feedback. Thus, for more accurate calculations, a sensor may be used to sense the temperature and calculate the resistance based on that temperature. For a given i d and commanded torque, the commanded i q is calculated by equation (3). I d and i q are limited by the intersection point of torque and current limit circle (i d — max , i q — max ). Depending on whether the drive system is in the power dissipation mode or not, a motor control process 44 will take input either the normal current command or the disclosed novel power dissipation current command.
[0027] According to the present disclosure, the battery control module 20 monitors the state of the battery 10 (e.g., SOC or temperature of the battery). Depending on the state of the battery, the motor control process 40 will switch the operation of the motor control process 44 to use either use normal motor control (i.e., under a normal battery condition) or the disclosed power dissipation motor control process in accordance with the disclosed principles (i.e., under a constrained battery condition). By dissipating the power in the motor stator windings, the vehicle can maintain the coast-down braking torque without charging the battery, which can improve vehicle drive performance when power limits are constrained. The motor control process can not only produce zero charging current to the battery, it can also follow a prescribed commanded DC discharge current to dissipate more power from the battery. This accelerates the warm-up process of the battery or prevent a battery overcharge condition.
[0028] The disclosed embodiments can also be used for transient driveline control when the battery charge power is constrained. For example, for active driveline damping control, the battery is often used as a buffer to sink and source electric motor power to damp driveline oscillations. If the battery charge power is compromised, the damping control cannot function properly. With the power dissipation control process disclosed herein, a portion of the damping control can be maintained even under adverse conditions.
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A method and apparatus for controlling an electric motor. An electric motor apparatus has an electric motor with motor stator windings, a battery, battery control module coupled to the battery and configured to monitor and detect a state of the battery, and a motor control unit coupled to the battery and the batter control module and being configured to select an operation of the electric motor based on a signal from the battery control module representing the state of the battery. The motor control unit selects a normal motor control operation, a power dissipation motor control operation, or a discharge operation. During the power dissipation motor control operation, power from brake torque is dissipated in the motor stator windings of the electric motor.
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BACKGROUND OF THE INVENTION
The seismic brace is an anti-movement brace used to prevent adverse sway or movement in the event of an earthquake. Seismic bracing is sometimes called earthquake bracing. In oder to keep the various independent elements of or whithin a building intact during an earthquake, adequate supports and seismic bracing must be installed. Without such seismic bracing the various independent elements of or within a building will be allowed to move independently. This independent movement can result in such elements breaking away from their installed position causing possible damage or inoperable conditions.
An object of the herein seismic bracing is to provide a structure which can be easily installed in selected positions and on various supports to prevent the swaying of the elements braced and to prevent excessive vibration of such elements as may be caused by earthquake or the like.
Another object of the invention is to provide a simple connector device which can be easily installed at each end of a brace member at various angles in which the brace member can be installed and which also reduces vibration and vibration noise of the bracing.
Another object of the invention is to provide a method whereby a connector device for bracings adjustable to a variety of angles is made so as to permit the efficient application of a suitable snubber between the relatively moveable pivot portions of the pivotted connector elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective developed view of a brace member and the connectors at its ends.
FIG. 2 is a front view of a support with the brace members and connectors.
FIG. 3 is a fragmental perspective view of a pipe hanger braced by the brace member and connectors.
FIG. 4 is a side view of another installation of a brace installation of a brace member and connectors.
FIG. 5 is a perspective view of the plates forming a connector.
FIG. 6 is a perspective view of the connector plates with the tongue bent.
FIG. 7 is a perspective view of the connectors with the tongue inserted and formed into a loop.
FIG. 8 shows part of the connectors dipped in cooling fluid during welding.
FIG. 9 is a perspective view of the completed connector after welding.
FIG. 10 is a partly sectional view of the connector.
DETAILED DESCRIPTION
Each brace 1 is a channel of substantially U-shaped cross-section with a nut 2 fixed near each end thereof within the cavity of the brace 1 facing toward the opening between the legs of the channel.
Each connector device 3 includes a pair of plates 4 and 5 with a loop 6 on the plate 4 moveable in an elongated slot 7 in plate 5. Each plate has therein a hole 8 near its end spaced from the loop 6, to accomodate a bolt 9 adapted to be screwed into the nut 2 within the U-shaped brace 1. When one plate 4 is secured to the nut 2 then the other plate 5 is secured to a support or base or hanging member to be braced.
The surfaces in and around the slot 7 is covered by an acoustical snubber 10. In one form this snubber 10 is formed by a coating on the plate 5 surrounding the slot 7 and also covering the interior walls on the slot 7. Selectively or in additon a snubber coating 11 may be also provided inside of the loop 6 to form a snubber bearing.
Various applications are illustrated herein for this seismic brace. For instance in FIG. 2 is shown so called clevis hanger 12 which is suspended from a threaded rod 13 anchored at the top in a ceiling 14. A seismic brace is extended from each side of the hanger 12 to the ceiling 14. The plate 4 of the seismic connector is secured to the usual yoke 15 of the hanger 12, and the other plate 5 is secured by the bolt 9 to the adjacent end of the brace 1 in the manner herein before described. Plate 4 of the connector at the other end of brace 1 is secured by a nut 16 to a bracket or plate 17 anchored in the ceiling 14. The plate 5 of each connector is mounted in the same manner at each end of the brace 1. In this manner the clevis hanger is braced against lateral vibration while the threaded rod 13 braces it against longitudinal movement.
In the form shown in FIG. 3 a channel bar 21 supports a plurality of pipes 22 which are strapped on the bar 21 by the usual pipe straps not shown. There is only a portion of one channel bar 21 shown but usually there are several along the length of the pipes. Each bar 21 is supported by one or more rods 23, each of which latter is anchored in a suitable bracket 24 on the ceiling or whatever support member there is on which the pipes are hung. The lateral brace 1 is secured by its connector 3 at each end thereof in the manner heretofore described at the one end by a bolt 9 to the hanging bar 21 and its other end in the manner heretofore described to a bracket 25 on the ceiling or surface from which the pipes are hung. Again the rods 23 inhibit longitudinal vibration, and lateral vibration is prevented, is inhibited and cushioned by the brace 1 and connectors 3 herein described.
In another form shown in FIG. 4 a hanging frame with vertical hangers 31 is hung from a supporting member such as a ceiling 32, and hanging on the lower end cross bars 33 on which rest pipes 34. The pipes are strapped on the cross bars 33 in the usual manner. To prevent collapse or lateral swinging of this frame the brace 1 is extended diagonally between opposite corners of the frame and the brace connections 3 are secured to the adjacent members of the corners in the same manner as heretofore described.
The brace connector herein is constructed and made by a novel method which prevents the softening or otherwise changing the characteristics of the snubber material and this method is illustrated in FIGS. 5 to 8 inclusive.
As shown in FIG. 5, a blank is cut and the hole 8 is formed through the blank which forms the hinge plate 4. Another blank is cut, in herein illustration with a slight offset at about the middle thereof, and the hole 8 is formed therein to form the plate 5. The elongated substantailly rectangular slot 7 is punched or otherwise formed in this plate 5.
The first plate 4 has a tongue from which the loop 6 is to be formed. As shown in FIG. 6 the tongue is reduced in width and is bent upward.
The end of plate 5 where the slot 7 is located is dipped into an acoustical material which is liquid in its initial stage and adheres to the outer surfaces as well as to the inside walls of the slot 7 so as to form the coating 10 heretofore described.
As shown in FIG. 7 the bent portion 6 is then extended through the slot 7 and is bent further upon itself into contact with the adjacent surface of the plate 4.
Then the plate 5 is dipped into a cooling substance such as in cold water to keep down the temperature of the coating while the end of the loop 6 is welded to the surface of the plate 4 as shown in cross-section in FIGS. 8 and 9. If desired, a suitable lining is also adhered to the inside surfaces of the loop 6 either before it is welded or thereafter.
The material of the coating in the herein illustration is an air hardened liquid plastisol which contains Trichlorephane, Methylene chloride and Toluene, sold under the tradename Plastic Dip made by Plasti-Dip International.
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Seismic or earthquake bracing includes brace members, in this form, a channel iron which at each end has an articulated connection respectively to a building element and to the item supported; each brace connector includes a pair of elements pivotally connected, and the hinged or pivot portions of at least one of the connector elements being provided with acoustical snubber which not only cushions the parts pivoted but also reduces noise of vibration which may be caused by earthquakes or the like.
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[0001] This invention is a continuation-in-part of co-pending U.S. patent application, Ser. No. 09/484,749, filed Jan. 18, 2000 by Qinyun Peng et al.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention involves a cured, siloxane containing, non-woven fiber mat containing a binder mixture which can be suitably employed as a roofing or other building composite requiring improved tear strength.
[0004] 2. Description of the Prior Art
[0005] Various methods to improve mat strength and stability of non-woven fibrous mats have been devised which are described in many patents and publications, representative of which are the following.
[0006] U.S. Pat. No. 4,335,186 discloses a chemically modified asphalt composition wherein the asphalt is reacted with a nitrogen-containing organic compound capable of introducing to the asphalt functional groups which can serve as reactive sites to establish a secure chemical bond between the asphalt and reinforcing fillers blended into the asphalt, such as glass fibers and siliceous aggregates.
[0007] U.S. Pat. No. 4,430,465 discloses an article of manufacture comprising a mat of fibers, such as glass fibers, coated with a composition comprising asphalt, an alkadiene-vinylarene copolymer, a petroleum hydrocarbon resin and an anti-stripping agent of a branched organic amine.
[0008] U.S. Pat. No. 5,518,586 discloses a method of making a glass fiber mat comprising dispersing glass fibers in an aqueous medium containing hydroxyethyl cellulose to form a slurry; passing the slurry through a mat forming screen to form a wet fiber glass mat; applying a binder comprising urea-formaldehyde resin and a water-insoluble anionic phosphate ester and a fatty alcohol to the wet glass fiber mat; and curing the binder.
[0009] U.S. Pat. No. 5,744,229 discloses a glass fiber mat made with polymer-reacted asphalt binder. The binder of the glass fiber mat comprises an aqueous emulsion of polymer modified asphalt produced by reaction of asphalt, a surfactant and a phenol-, resorcinol-, urea- or melamine-formaldehyde resin.
[0010] U.S. Pat. No. 5,851,933 describes a non-woven fibrous mat comprising glass fibers bonded with a cured mixture of urea/formaldehyde resin and a self crosslinkable vinyl acrylic/polyvinyl acetate copolymers and U.S. Patent No. 5,334,648 describes emulsion copolymers for use as a urea formaldehyde resin modifier.
[0011] U.S. Pat. No. 4,917,764 describes a glass fiber mat having improved strength featuring a carboxylated styrene-butadiene latex.
[0012] U.S. Pat. No. 5,804,254 describes a method for flexibilizing cured urea formaldehyde resin-bound glass fiber non-wovens.
[0013] U.S. Pat. No. 5,503,920 describes a process for improving parting strength of fiberglass insulation.
[0014] U.S. Pat. No. 5,032,431 describes a glass fiber insulation binder.
[0015] U.S. Pat. No. 4,931,318 describes silica as a blocking agent for fiberglass sizing.
[0016] U.S. Pat. No. 4,749,614 describes a fibrous substrate coated with a hydrolyzed amino silane useful for preparing polyepoxide substrates.
[0017] U.S. Pat. No. 4,596,737 describes a process for treating a glass fiber mat comprising contacting the surface of a cured mass of glass fibers with a latex polymer.
[0018] U.S. Pat. No. 4,500,600 describes glass fibers coated with a size composition comprising γ-aminopropyltriethoxysilane and an alkoxysilane.
[0019] PCT WO 99/13154 describes a structural mat matrix comprising a substrate of fiberglass fibers and wood pulp and a binder which consists of urea formaldehyde and acrylic copolymer.
[0020] BASF's April 1998 advertising brochure entitled NONWOVENS AND COATINGS DISPERSIONS discloses a crosslinked styrene/acrylic polymer (ACRONAL S 886S) useful as a binder for glass substrates.
[0021] Copending U.S. patent application, Ser. No. 09/484,749 discloses a fiber glass mat roofing composite, a urea/formaldehyde resin binder and a polysiloxane adhesion modifier.
SUMMARY OF THE INVENTION
[0022] In accordance with this invention there is provided a cured, polysiloxane containing, non-woven, fibrous mat comprising from about 60 to about 95 wt. % fibers containing from about 0.001 to about 15 wt. % polysiloxane; which fibers are fixedly distributed in from about 40 to about 5 wt. % of a formaldehyde type binder containing between about 0.1 and about 20 wt. % of a crosslinked styrene/acrylic or methacrylic, [designated herein as (meth)acrylic], copolymer as a binder modifier.
[0023] Although several methods of making non-woven fiber mats can be used to form the present mat, a wet laid process wherein the fibers are dispersed in white water to form a wet web derived from a slurry or mat is preferred. Optionally a dispersing agent, emulsifier, lubricant, defoamer, surfactant and/or other conventional excipients can be added to the fiber containing slurry of the present invention. In a mat forming machine such as a paper pulp apparatus, e.g. a Fourdrinier paper machine, excess water is removed from the fiber slurry to form the web and the modified binder of this invention, as a 5 to 40% aqueous solution, dispersion or emulsion is then applied to the wet web by use of a curtain coater or a dip and squeeze or knife edge applicator. Alternatively, the modified binder can be sprayed onto the wet web. Following binder saturation of the web, excess binder is removed and a web containing a siloxane polymer is then dried and cured at a temperature of between about 200°-400° C. for a period of from a few seconds to about 5 minutes. The siloxane can be introduced after or in admixture with the modified binder solution, or, if desired, a portion or all of the siloxane can be introduced into the fiber size or slurry before addition of binder. The siloxane component is employed in the form of a solution, suspension, emulsion or dispersion in water or in an organic solvent, such as isopropanol, cyclohexanol or other inert organic solvent. For the purposes of the present invention, a coating of polysiloxane or asphalt can be added as a top coat on the cured mat.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The preferred cured fiber mat of the present invention comprises by weight from about 68 to about 92% fiber containing from about 0.01 to about 10% polysiloxane and from about 8 to about 32% formaldehyde type binder containing between about 0.05 and about 15% of a 0.05 to about 10% crosslinked styrene/acrylic polymer modifier.
[0025] The formaldehyde type binder base is a thermosetting resin of formaldehyde in combination with urea, phenol, resorcinol, melamine or mixtures thereof. Of these, the formaldehyde/urea binder base is preferred. The binder base contains a binder modifying amount of a styrene/acrylic resin containing a polyfunctional component which crosslinks with the copolymer resin during curing of the mat. The styrene component of the resin can be unsubstituted or substituted on a ring carbon atom with lower alkyl, vinyl, allyl, chloro or phenyl; however, from the standpoint of economics; notwithstanding the reduced flammability and high thermal stability of some of these substituted types, unsubstituted styrene is most desired. The styrene/acrylic resin, which includes both acrylic and methacrylic moieties and mixtures thereof, contains a minor amount, e.g. between about 0.05 to 10 wt. %, preferably between about 0.1 and about 5 wt. %, of a crosslinking agent which may be a nitrogen containing crosslinking agent, such as a polyfunctional amine, amide or acrylonitrile, or may be any other polyfunctional crosslinking agent such as for example a di- or tri-olefinically unsaturated hydrocarbon or other conventional crosslinker reactive with the styrene/acrylic copolymer. Of the above polymer compositions, those providing self-crosslinkable characteristics are preferred. The (meth)acrylic polymer is generally a mixture of (meth)acrylates and additionally may contain (meth)acrylonitriles, (meth)acrylic acid and/or (meth)acrylamides as comonomers. One advantage of the present modified binder is that it allows for curing at a lower temperature than would otherwise be required for a mat containing siloxane/formaldehyde type binder alone. It is believed that this benefit is attributable to the crosslinking of the modifier. Another advantage is a degree of flexibility contributed by the styrene comonomer.
[0026] The fibers of the present mat can be fibers of glass, wood pulp or particles, polyethylene, polypropylene, polyester, Nylon®, Orlon® or mixtures of these fibers depending on the end use of the product. More specifically, for roofing shingles, acoustical boards, BUR and other asphaltic composites at least a major portion of glass fibers are employed and unmixed glass fibers are most desired. For facers or underlayment used in different articles of building construction, eg. divider panels, other synthetic fibers or wood chips fixed in a mat can be utilized.
[0027] The mat fibers generally have an average length of from about 3 to abut 140 mm and an average diameter of from about 5 to about 25 micrometers. Short and long fibers can be mixed to form a mat web of increased fiber entanglement.
[0028] The polysiloxane component of the mat is most preferably employed at a concentration of between about 0.05 and about 5% with respect to the modified binder and is a polysiloxane having repeating units of —[Si—O]—. The siloxane polymer can be modified with various substituents which include linear, branched or aromatic end-groups optionally containing oxygen, sulfur and/or nitrogen. Generally the present polysiloxanes are classified as polyalkyl-, polyaryl-, polyalkylaryl- and polyether-siloxanes. The polysiloxanes found to be most useful in the present invention are those having a weight average molecular weight of at least 600. The polysiloxanes listed in following Table 1 are representative.
TABLE 1 Polysiloxane Mol. Wt. Polyalkylene oxide-modified polydimethylsiloxane-dimethylsiloxane copolymer 13,000 Polyalkylene oxide-modified polydimethylsiloxane-dimethylsiloxane copolymer 3,000 Polyalkylene oxide-modified polydimethylsiloxane-dimethylsiloxane copolymer 4,000 (Carboxylatepropyl)methylsiloxane-dimethylsiloxane copolymer >1,000 Dimethylsiloxane-(60% PO-40% EO) block copolymer 20,000 (Hydroxyalkyl functional) methylsiloxane-dimethylsiloxane copolymer 5,000 Aminopropylmethylsiloxane-dimethylsiloxane copolymer 4,500 Aminoethylaminopropylmethoxysiloxane-dimethylsiloxane copolymer >1,000 Glycidoxy propyl dimethoxy silyl end blocked dimethyl siloxane polymer 5,000 Methacryloxy propyl dimethoxy silyl dimethyl siloxane polymer 40,000 Vinyl dimethoxy silyl end-blocked dimethyl siloxane polymer 6,500 Aminoethylaminopropyl dimethoxy silyl end blocked dimethyl siloxane polymer 3,800 Amine-alkyl modified methylalkylaryl silicone polymer 7,800 Epoxy functional dimethylpolysiloxane copolymer 8,300 Dimethylpolysiloxane 26,439 Dodecylmethylsiloxane-hydroxypolyalkyleneoxypropyl methylsiloxane copolymer 1,900 (Dodecylmethylsiloxane)-(2-phenylpropylmethylsiloxane) copolymer >1,000 Polyalkylene oxide-modified polydimethylsiloxane-dimethylsiloxane copolymer 600
[0029] The modified binder of the present invention alters the interfacial effect between the mat and a surface coating which promotes fiber “pull out” during force applied to prevent immediate fiber breaking or tearing which occurs during separation of portions of the coated mat when the modifier is omitted. It is believed that the increased tear strength of the composite is due to an interfacial interaction between the coating and the mat containing the present modified binder which dissipates the force applied for separation.
IN THE DRAWING
[0030] The accompanying drawing is a top plan view illustrating the separation of a composite which comprises a glass fiber mat having an asphalt coating which penetrates the mat. The portions of the coated mat being separated are indicated by 2 and 4 with fibers 11 bridging the separated area and resisting disunion before total separation occurs.
[0031] For the manufacture of roofing shingles or BUR, a polysiloxane containing fiberglass mat with a urea/formaldehyde binder and the present crosslinked polymer modifier is preferred. The dried, cured mat may be covered on one or both sides with a conventionally thick coating of a standard asphalt or asphalt compound to produce a composite roofing product which can be cut to any size or shape or used as undivided BUR sheeting and packaged in pallets or rolls for shipment and subsequent installation. In the case of BUR roofing, however, coating or mopping of the mat with a hot surface coating of asphalt is generally delayed until a course of sheeting is installed on the roof. The asphalt employed for coating may additionally contain an antifungal, antibacterial, UV inhibitor and/or coloring agent at the option user.
[0032] The roof covering herein disclosed is a product of conventional weight and somewhat increased flexibility which meets and exceeds the requirements of ASTM D-3462 testing. The significantly improved tear strength of the present product results in savings in packaging and transportation of the product as well as durability of the product when installed.
[0033] Having thus generally described the invention, reference is now had to the following examples which illustrate particular and preferred embodiments but which are not to be construed as limiting to the scope of the invention as set forth in the appended claims.
EXAMPLES 1-8
[0034] Testing Tear Strength of 3×2.5 inch Samples of Shingles Employing Glass Fiber Mats With Urea/Formaldehyde (UF) Modified Binder.
[0035] Tear test D-1922, as referenced in ASTM D-3462 (Jul. 10, 1997 version), was used to determine the tear strength of various glass fiber mats coated on both sides with a 25 mil coating of asphalt conventionally used in roofing materials. In summary, the test measures the force in grams required to tear apart the coated mat specimen using a pendulum device. Acting by gravity, the pendulum swings through an arc tearing the specimen from a precut slit. The test specimen is held at one end by the pendulum and on the opposite end by a stationary member. The loss in energy by the pendulum is indicated by a scale and pointer which registers in the force required to tear apart the specimen.
[0036] To a wet web of 25-100 mm long glass fibers, derived from drainage of a white water slurry, was added at room temperature, a standard urea/formaldehyde binder containing 1 wt. % styrene/acrylate/acrylonitrile polymer modifier (i.e. Acronal S 886 S, supplied by BASF) to provide a fiber to modified binder weight ratio of about 80:20. The web containing fibers and modified binder is then sprayed with an aqueous solution of poly(dimethylsiloxane), supplied by Chem-Trends as product RCTW B9296) to provide a polysiloxane concentration of from 0.25 to 5% with respect to UF, as noted in the following table. The resulting webs were then dried and cured at about 300° C. for a period of 10 seconds to produce cured, non-woven mats, after which the mats were coated on both sides at 215° C. with filled asphalt (comprising 32% w/w asphalt and 68% w/w limestone filler) using a two-roller coater.
[0037] The styrene/butadiene latex, employed in the examples was supplied Dow Chemical Co. and the urea/formaldehyde binder was obtained from Leste Co.
[0038] The results of these tests are as reported in following Table 2.
TABLE 2 UF SILOXANE Acronal S886 S STYRENE/BUTADIENE TEAR STRENGTH Ex. No. wt. % wt. % wt. % wt. % gram force (gf) 1 99 — 1 — 1241 2 98 1 1 — 2272 3 97 2 1 — 2415 4 96 3 1 — 3810 5 95 4 1 — 4418 6 97 5 1 — 4143 7 99 — — 1 1217 8 98 1 — 1 1455
[0039] It will be understood that many modifications in procedure and substitutions in the compositions of examples 2-6, including substitution of the polysiloxane, binder and binder modifier, as well as fibers or fiber mixtures, can be made without departing from the scope of the present invention and that these examples merely represent preferred embodiments of the invention.
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The invention relates to a coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating which comprises a cured, non-woven, fiber glass mat containing a polysiloxane wherein the fibers are fixedly distributed in a formaldehyde type binder containing a binder modifier which is a crosslinked styrene/acrylic polymer, and to a process for the preparation of the mat.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from a U.S. Provisional Application having Ser. No. 60/696,615 filed Jul. 5, 2005.
BACKGROUND OF THE INVENTION
[0002] With ever increasing environmental pressures being placed on the oil industry it has become necessary to develop and employ products and methods of well treatment which can perform in a timely fashion, be cost effective and conform to the stricter controls now in place.
[0003] It is known in the art that oil fields can become extremely viscous due to a heavy concentration of paraffin and asphaltene in the formation. These deposits can result in reduced oil production, fouling of flow lines and down hole tubing, under deposit corrosions, reductions in gas production, and increased pumping costs due to pumping a high viscosity fluid. Each of these conditions individually can result in lost revenue. The combination of two or more of these conditions will lead to a significant revenue loss to the well owner, as well as additional income spent due to clean up of oil spills caused by under deposit corrosion. Moreover, the differing oxygen concentrations in bulk oil with respect to the oxygen levels extant beneath the deposit result in localized, rapid corrosion of the piping and eventual oil leaks.
SUMMARY OF THE INVENTION
[0004] Applicant's invention comprises a formulation and method to enhance recovery from an oil well field. Applicant's method supplies a mixture of petroleum distillates and terpenoid compounds, and a salt extraction formulation comprising a mixture of humic acid and fulvic acid. The method discontinues the extraction of materials from the oil well, disposes the mixture of petroleum distillates and terpenoid compounds into the oil well, and disposes the salt extraction formulation into the oil well. The method recirculates the oil well, and then returns the oil well to service.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The invention will be better understood from a reading of the following detailed description taken in conjunction with the drawings in which like reference designators are used to designate like elements, and in which:
[0006] FIG. 1 is a perspective view of an oil well field;
[0007] FIG. 2 is a flow chart summarizing certain steps of Applicant's method;
[0008] FIG. 3 is a flow chart summarizing certain optional steps of Applicant's method;
[0009] FIG. 4 is a flow chart summarizing certain additional optional steps of Applicant's method;
[0010] FIG. 5 illustrates the apparatus used to dispose or inject Applicant's formulation into the oil well field of FIG. 1 ;
[0011] FIG. 6A illustrates the chemical formulation for certain asphaltene compounds;
[0012] FIG. 6B illustrates the physical shape of the asphaltene compounds of FIG. 6A ;
[0013] FIG. 7 comprises a UV absorption spectrum for Humic Acid and Fulvic Acid;
[0014] FIG. 8 comprises the 13 C nuclear magnetic resonance spectra of Humic Acid and Fulvic Acid;
[0015] FIG. 9 graphically depicts the Fourier Transform Infrared spectra of Humic Acid and Fulvic Acid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] This invention is described in preferred embodiments in the following description with reference to the Figures, in which like numbers represent the same or similar elements. Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0017] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are recited to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0018] Referring now to FIG. 1 , oil field 100 includes oil well 140 . Oil well 140 is disposed in near vicinity to a plurality of oil-containing fissures 110 . Oil well 140 typically comprises a first tubular assembly 160 disposed within a second tubular assembly 170 . The combination of tubular assemblies 160 and 170 define two separated lumens, namely lumen 165 and lumen 175 . Oil is removed from fissures 110 , and pumped upwardly through lumen 175 .
[0019] In the illustrated embodiment of FIG. 1 , blockage materials 120 are shown blocking oil-containing fissures 110 . In addition, blockage materials 130 are shown blocking portions of lumen 175 .
[0020] As a general matter, blockage materials 120 and 130 comprise a plurality of linear, branched, and/or cyclic hydrocarbons, sometimes referred to as paraffins or waxes, in combination with one or more higher molecular, polar, aromatic molecules sometimes referred to as “asphaltenes.”
[0021] Many of the paraffin compounds comprise more than 22 carbon atoms. Compounds such as botryococcane, a C 34 branched alkane, and β-carotene, a C 40 cycloalkane, have been identified in paraffin blockage materials. Moreover, deposits in pipelines can also comprise C 75 compounds, i.e. asphaltenes. As those skilled in the art will appreciate, asphaltenes comprise a plurality of compounds, some of which comprise fewer than 75 carbon atoms and some of which comprise more than 75 carbon atoms.
[0022] FIG. 6A illustrates two such asphaltene molecules. FIG. 6B graphically depicts an asphaltene having a molecular weight of about 7800 Daltons. Table I recites certain chemical differences between asphaltenes and paraffins.
TABLE I ASPHALTENE PARAFFIN Dissolves in heptane NO YES Crystalline NO YES Melting Point NO YES
[0023] A number of methods are known in the art to remove some or all of blockage materials 120 and/or 130 .
[0024] One of the most frequent methods of paraffin reduction utilized in down hole treatment is often referred to as “Hot Oiling”. Using this prior art method, heated refined oil (10-100 barrels) is pumped directly down the hole to re-liquefy the paraffin and clear the flow tube. Hopefully, some of the oil reaches the formation and also clears some of the fissures of paraffin theoretically resulting in increased production rates for a short period of time, generally from about 1 to about 7 days.
[0025] This prior art method may allow the corrosion inhibitor to actually protect the piping by contacting the steel piping. In actuality, much of the costly refined heated oil may not be recovered and the positive effects of this method may only be seen for a very short time with no guarantee of increased well performance.
[0026] The paraffin material that reforms typically comprises a much harder and tighter matrix than the original deposit, and is much more difficult to remove, particularly if calcium salts comprise part of the paraffin composition. Typically “Hot Oiling” applications will be performed one to two times per month. This method can be very expensive because the costs include heating, refining, trucking, manpower, and the cost of the lost down hole oil.
[0027] Other prior art methods utilize toluene and/or xylene to re-liquefy the paraffin and thick oil to a less viscous material. Typical applications of this product use from 20 barrels to 100 barrels down hole at a typical cost of $3.00 per gallon of product. This method re-liquefies the paraffin's using one or more volatile, very dangerous, cancer causing chemicals. These products potentially pollute the ground water and must be handled with extreme caution as indicated on each chemical's Material Safety Data Sheet. The paraffin and thick oil revert to their original state once these products have revolatilized causing deposits in flow lines or storage tank “dropout”.
[0028] “Hot watering” is probably the least expensive and potentially least effective prior art method of paraffin removal. Hot water is injected directly down hole to remove paraffin from the walls of the tubing. This method typically treats just the tubing and not much of the formation itself. Some short-term benefits can be seen but typically the results are seen for only a day or two.
[0029] Certain prior art methods utilize a 15% muratic acid solution to remove paraffin. This method may appear cost effective, however the muratic acid will attack the mild steel piping and greatly accelerate corrosion rates, reduce pipe wall thickness, and result in holes in the down hole tubing.
[0030] Applicant's composition and method comprises a total system treatment, which treats the source of the buildup resulting in cleaner flow lines, down hole pipes, and storage tanks. Applicant's method utilizes an environmentally friendly solvent system, in optional combination with other systems, to increase the time between treatments while maximizing production rates.
[0031] Applicant's composition, and method using that composition, re-liquefies both paraffins and asphaltenes, without utilizing known carcinogens. In addition, Applicant's method increases oil production, increases gas production, removes blockage materials for a longer period of time, removes paraffins and/or asphaltenes in the oil field formation, reduces oil viscosity, reduces piping corrosion rates, removes paraffins and/or asphaltenes from oil transfer lines, and reduces oil viscosity in the holding tank.
[0032] FIG. 2 summarizes the steps of Applicant's method. Referring now to FIG. 2 , in step 205 the method provides an oil field having an oil well disposed therein, such as for example oil field 100 , wherein the oil well, such as oil well 140 ( FIG. 1 ) exhibits diminished production capacity resulting from the presence of one or more blockage materials, such as blockage materials 120 ( FIG. 1 ) and/or blockage materials 130 ( FIG. 1 ).
[0033] In step 210 , Applicant's method determines if the compositions of the blockage materials will be analyzed. If the composition of the blockage materials will be analyzed, then the method transitions from step 210 to step 310 .
[0034] Referring now to FIG. 3 , in step 310 Applicant's method determines the relative concentrations of asphaltenes and paraffins in the blockage materials. As described above, paraffins are generally soluble in n-heptane while asphaltenes are not. In certain embodiments, step 310 comprises treating either isolated blockage materials, or a sample of crude oil from the subject well, with heptane to remove the soluble paraffins. ASTM Method D3279-90 is then utilized to analyze the asphaltene component of the heptane insoluble fraction. In certain embodiments, step 310 further comprises dissolving the heptane-insoluble components in Tetrahydrofuran (THF), and analyzing that THF solution using gel permeation chromatography (GPC).
[0035] In step 320 , Applicant's method determines, based upon the analysis of step 310 , if the blockage materials comprise a substantially higher percentage of asphaltenes than paraffins. In certain embodiments, by “substantially higher percentage” Applicant means that the weight of asphaltene compounds in the blockage material comprise at least 2 times the weight of paraffin compounds in that blockage material.
[0036] If Applicant's method determines in step 320 that the blockage materials comprise a substantially higher percentage of asphaltenes than paraffins, then the method transitions from step 320 to step 330 wherein the method selects and provides a solvent system comprising about 34 volume percent of a first hydrocarbon solvent, about 46 volume percent of a second hydrocarbon solvent, and about 20 volume percent of one or more terpenoid compounds. Applicant's method transitions from step 330 to step 230 ( FIG. 2 ).
[0037] In certain embodiments, Applicant's first hydrocarbon solvent comprises a hydrogenated, light petroleum distillate. In certain embodiments, Applicant's first hydrocarbon solvent comprises a mixture of hydrocarbon compounds, wherein that mixture is assigned Chemical Abstracts System (“CAS”) Number 64742-47-8. In certain embodiments, Applicant's first hydrocarbon solvent comprises a product sold in commerce under the tradename Drakesol 165. In certain embodiments, Applicant's first hydrocarbon solvent comprises a product sold in commerce under the tradename Drakesol 2251. In certain embodiments, Applicant's first solvent system comprises deodorized kerosene.
[0038] In certain embodiments, Applicant's second hydrocarbon solvent comprises a hydrogenated, medium petroleum distillate. In certain embodiments, Applicant's second hydrocarbon solvent comprises a mixture of hydrocarbon compounds, where that mixture is assigned CAS No. 64742-46-7. In certain embodiments, Applicant's first hydrocarbon solvent comprises a product sold in commerce under the tradename Drakesol 205. In certain embodiments, Applicant's first hydrocarbon solvent comprises a product sold in commerce under the tradename Drakesol 2257.
[0039] By “terpenoid compound,” Applicant means a hydrocarbon compound comprising between about 10 carbon atoms and about 15 carbon atoms, and further comprising an alkenyl moiety, and/or a cyclohexane moiety, and/or a cyclohexene moiety. For example, in certain embodiments Applicant's one or more terpenoid compounds comprise one or more of β-pinene (Compound I), menthene (Compound II), p-menthane (Compound III), limonene (Compound IV), and mixtures thereof. Embodiments of Applicant's composition which comprise limonene may comprise d-limonene, l-limonene, and/or mixtures thereof.
In certain embodiments, Applicant's terpenoid component comprises α-pinene, citrene, carvene, mixtures thereof, and the like.
[0040] Referring again to FIG. 3 , if Applicant's method determines in step 320 that the blockage materials do not comprise a higher percentage of asphaltenes than paraffins, then the method transitions from step 320 to step 340 wherein the method determines if the blockage materials comprise a substantially higher percentage of paraffin compounds than asphaltene compounds. If Applicant's method determines in step 340 that the blockage materials comprise a substantially higher percentage of paraffin compounds than asphaltene compounds, then the method transitions from step 340 to step 350 wherein the method selects and provides a third solvent system comprising about 46 volume percent of Applicant's first hydrocarbon solvent, about 34 weight percent of Applicant's second hydrocarbon solvent, and about 20 weight percent of Applicant's one or more terpenoid compounds. Applicant's method transitions from step 350 to step 230 ( FIG. 2 ).
[0041] If Applicant's method determines in step 340 that the blockage materials do not comprise a substantially higher percentage of paraffin compounds than asphaltene compounds, then the method transitions from step 340 to step 36 o wherein the method selects and provides a first solvent system comprising about 34 volume percent of Applicant's first hydrocarbon solvent, about 34 volume percent of Applicant's second hydrocarbon solvent, and about 32 volume percent of Applicant's one or more terpenoid compounds. Applicant's method transitions from step 360 to step 230 ( FIG. 2 ).
[0042] Referring once again to FIG. 2 , if Applicant's method determines that the composition of the blockage materials will not be determined, then the method transitions from step 210 to step 220 wherein the method provides Applicant's first solvent system described above.
[0043] In step 230 , Applicant's method provides a salt extraction system. In certain embodiments, Applicant's salt extraction system comprises a mixture of humic acid and fulvic acid. In certain embodiments, Applicant's humic/fulvic acid mixture comprises a weight ratio from about 95:5 humic acid/fulvic acid to about 5:95 humic acid/fulvic acid. In certain embodiments, Applicant's mixture of humic acid and fulvic acid are mixed in a formulation further comprising Urea, Potassium Hydroxide, mild Phosphoric Acid, mixtures thereof, and the like.
[0044] Humic acid comprises acidic materials extracted from Leonardite, where those acidic extracts are soluble in alkali, but insoluble in acid, methyl ethyl ketone, and methyl alcohol. Fulvic acid comprises acidic materials extracted from Leonardite, where those acidic extracts are soluble in alkali, acid, methyl ethyl ketone, and methyl alcohol. As those skilled in the art will appreciate, Leonardite comprises a soft, brown coal-like deposit found in conjunction with deposits of lignite.
[0045] FIG. 7 graphically depicts the UV/visible spectra for both humic acid (HA) and fulvic acid (FA). FIG. 8 graphically depicts the 13 C nuclear magnetic resonance spectra of HA and FA. FIG. 9 graphically depicts the Fourier Transform Infrared spectra of HA and FA.
[0046] In step 240 , Applicant's method discontinues operation of the oil well to be treated. By “discontinue operation,” Applicant means discontinuing the extraction of liquids and/or gases from the oil well.
[0047] Referring now to FIGS. 2, 3 , and 5 , in step 250 , Applicant's method disposes the selected solvent system of step 230 , or step 330 , or step 350 , or step 360 , into the oil well, such as well 140 ( FIG. 1 ). In certain embodiments, step 250 includes disposing between about 10 gallons to about 3 drums of the selected solvent system in vessel 510 , and pumping that solvent system from vessel 510 into well 140 using pump 520 and piping 530 .
[0048] Applicant's method transitions from step 250 to step 260 wherein the method pumps Applicant's salt extraction system into the oil well, such as for example well 140 , immediately after performing step 250 . By “immediately,” Applicant means within about 2 minutes. In certain embodiments, step 260 includes disposing between about 2 gallons to about 10 gallons of Applicant's salt extraction composition into vessel 410 and pumping that solvent system from vessel 410 into well 140 using pump 420 and piping 430 .
[0049] In step 270 , Applicant's method determines if Applicant's bio system will be utilized. If Applicant's bio system is not being utilized, then the method transitions from step 270 to step 285 . Alternatively, if Applicant's bio system is being utilized, then the method transitions from step 270 to step 275 wherein the method provides a bio system.
[0050] Applicant's bio system comprises paraffin eating bacteria. Applicant's bio system comprises a dry powder which is re-circulated and grown in an aerated tank for 24 hours while being fed a combination of organic nutrients, which enable a large colony count of paraffin eaters (4 billion cfu Iml).
[0051] Applicant's bio system is injected down hole, and mixed with the flush water, to provide long-term paraffin elimination in the formation. The greatly increased bacteria colony count, along with the “in situ” bacteria already existing in the formation, proliferate and thrive on paraffin, resulting in long term paraffin reduction in the formation and an increase in time between down hole treatments. Use of Applicant's bio system also results in a higher baseline of oil production and/or gas production for that well.
[0052] The prior art teaches that bacteria may cause corrosion. Prior art methods utilize anaerobic bacteria, such as for example IRB (Iron Reducing Bacteria) or SRB's (Sulfate Reducing Bacteria). These anaerobic bacteria could, and did, tend to cause corrosion of piping. In marked contrast, Applicant's bio system comprises aerobic bacteria which do not attack iron or other metals.
[0053] In certain embodiments, Applicant's bio system comprises Arthrobacter globiformis, Arthrobacter citreus, Nitrosomonas, Nitrobacter, Bacillus licheniformis, Bacillus amyloloquefaciens, Bacillus subtilis, Bacillus megaterium , and Bacillus pumilus. Arthrobacters comprise gram positive, aerobic rods that constitute a large portion of the aerobic chemoheterotrophic population of soil bacteria. In certain embodiments, Applicant's bio system further comprises sea weed cream, Leonardite extract, fish parts, and combinations thereof.
[0054] In certain embodiments, step 275 further comprises “growing” Applicant's bio system, wherein the components comprising Applicant's bio system, without the water, are mixed in a reaction vessel for about 24 hours, wherein that reaction vessel comprises the growing biosystem and a head space, wherein the oxygen level of that head space is maintained at about 2-3 ppm for the 24 hour growth period.
[0055] Applicant's method transitions from step 275 to step 280 wherein the method adds the water component to Applicant's bio system, and pumps that aqueous bio system into the well. In certain embodiments, step 280 comprises disposing between about 5 barrels and about 20 barrels of Applicant's aqueous bio system into the well. In certain embodiments, Applicant's aqueous bio system comprises about 10-30 weight percent aerobic bacteria, about 10-20 weight percent water, about 10-30 weight percent sea weed cream, about 20-30 weight percent Leonardite extract, and about 30-40 weight percent fish parts.
[0056] Applicant's method transitions from step 280 to step 285 wherein the well is recirculated for between about 6 hours to about 24 hours to allow contact between Applicant's solvent system, Applicant's salt extraction system, and optionally Applicant's bio-system, and the blockage materials disposed in oil field and oil well. In steps 250 , 260 , 280 , and 285 , the oil well and oil field are maintained at ambient pressure.
[0057] Applicant's method transitions from step 285 to step 290 wherein the method determines if a high pressure treatment protocol will be used. If Applicant's method elects not to use Applicant's high pressure protocol, then the method transitions from step 290 to step 295 wherein the oil well is placed back into service.
[0058] In certain embodiments, Applicant's method comprises the steps recited in FIG. 2 , in optional combination with the steps of FIG. 3 . In other embodiments, Applicant's method comprises the steps recited in FIG. 4 , in optional combination with the steps recited in FIG. 3 . In yet other embodiments, Applicant's method comprises the steps recited in FIGS. 2 and 4 , in optional combination with the steps recited in FIG. 3 .
[0059] Referring now to FIG. 4 , steps 410 , 430 , 440 , 470 , 475 , and 490 , comprise the elements of steps 205 , 230 , 240 , 270 , 275 , and 295 , respectively, as described hereinabove. In embodiments wherein Applicant's method comprises the steps recited in FIG. 4 without first utilizing the steps recited in FIG. 2 , step 420 comprises the elements of step 210 as described herein above, in optional combination with the elements of steps 310 , 320 , 330 , 340 , 350 , and 360 , as described hereinabove.
[0060] In embodiments wherein Applicant's method utilizes the steps of FIG. 2 , in optional combination with the steps of FIG. 3 , Applicant's method transitions from step 290 ( FIG. 2 ) to step 420 . In these embodiments, step 420 comprises using the solvent system previously selected in step 210 , or in step 330 , or in step 350 , or in step 360 , as described hereinabove.
[0061] In step 450 , Applicant's method injects the selected solvent system into the well under pressure. In certain embodiments, the pressure of step 450 is between about 200 psi and about 1000 psi. in excess of typical formation pressure. In step 460 , Applicant's method injects Applicant's salt extraction system into the well under pressure. In certain embodiments, the pressure of step 460 is between about 200 psi and about 1000 psi. in excess of typical formation pressure.
[0062] In step 480 , Applicant's method injects Applicant's bio system into the well under pressure. In certain embodiments, the pressure of step 480 is between about 200 psi and about 1000 psi. in excess of typical formation pressure. In step 485 , Applicant's method maintains a pressure of between about 200 psi and about 1000 psi in excess of typical formation pressure in the well for between about 24 to about 72 hours.
[0063] In certain embodiments, individual steps recited in FIGS. 2, 3 , and/or 4 , may be combined, eliminated, or reordered. For example, in certain embodiments Applicant's method includes the steps recited in FIG. 2 only. In other embodiments, Applicant's method includes the steps recited in FIGS. 2 and 3 .
[0064] In yet other embodiments, Applicant's method includes the steps recited in FIG. 4 only. In still other embodiments, Applicant's method includes the steps of FIGS. 3 and 4 . Finally in still other embodiments, Applicant's method includes the steps of FIGS. 2, 3 , and 4 .
[0065] While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention as set forth in the following claims.
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A formulation and method to enhance recovery from an oil well are disclosed. The method supplies a mixture of petroleum distillates and terpenoid compounds, and a salt extraction formulation comprising a mixture of humic acid and fulvic acid. The method discontinues the extraction of materials from the oil well, disposing the mixture of petroleum distillates and terpenoid compounds into the oil well, and disposes the salt extraction formulation into the oil well. The method recirculates the oil well, and then returns the oil well to service.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the drying of wet articles generally and, more particularly, to a novel dryer in the form of a portable rack upon which, for example, wet clothes can be hung for drying and which rack, although foldable to a very compact form, provides a total length of clothes hanging means which is on the order of almost 10 times the floor area taken by the rack, in terms of lineal feet per square foot.
2. Background Art
In many confined living quarters, such as apartments and boats, for example, outdoor drying lines or wash lines are limited or unavailable and, in many cases, are actually prohibited. For these reasons, residents of such living quarters have a need for a portable drying rack on which wet clothes are hung for drying. Such a rack may be used indoors within the apartment or boat or outdoors on a balcony, patio, or deck. The unit must be stable in use and portable so that it can be conveniently moved from one place to another and should fold conveniently for storage in a small area.
A number of indoor drying racks have been designed and are on the market but they all have one or another of various drawbacks. For example, many of them will not hold a full load of clothes taken from a clothes washer. Others are not conveniently foldable for storage and still others are unduly expensive or unstable in use. None is known which conveniently provides for the drying of sweaters the heavier ones of which typically drip water on whatever surface over which they are hung. Furthermore, none is known which provides for a high density of drying clothes in a relatively small floor area. Many require the loosening and/or tightening of fasteners to deploy them in their open positions.
Accordingly, it is a principal object of the present invention to provide a drying rack which is easily portable yet which provides for a high density of drying articles in a relatively small floor area.
It is another object of the invention to provide such a drying rack which is suitable for drying heavy articles such as sweaters without the heavy articles dripping water on the surface on which the dryer is placed.
An additional object of the invention is to provide such a drying rack which may be readily compactly folded.
Yet another object of the invention is to provide such a drying rack which may be deployed in its unfolded position without the need to loosen and/or tighten fasteners.
Other objects of the invention, as well as particular features and advantages thereof, will be elucidated in, or apparent from, the following description and the accompanying drawing figures.
SUMMARY OF THE INVENTION
The present invention accomplishes the above objects, among others, by providing a foldable drying rack having a rectangular midframe with side and end rails and hanging rails extending between the end rails. Hinged, foldable leg members extend downward from the ends of the midframe and provide support without having to loosen and tighten any fasteners. A shelf having hanging rails may be extended between the leg members below the midframe. Hinged, foldable rectangular wingframes, having hanging rails extending between the side rails may extend outward from the ends of the midframe and may also be deployed without having to loosen and tighten any fasteners. The wingframes may also be folded inward toward each other and joined to form a tent-like structure above the midframe. The drying rack may be deployed in its unfolded position without the need to loosen and/or tighten fasteners. In one embodiment, a ratio of almost 10:1 in terms of lineal feet of hanging rails per square foot of floor space is achieved.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the present invention with the wingframes thereof in their outwardly extended position.
FIG. 2 is a front side elevation view thereof showing the windframes in alternative outwardly or inwardly extended positions.
FIG. 3 is a top plan view thereof showing the wingframes in their inwardly extended positions.
FIG. 4 is a sectional view of FIG. 2 showing a shelf assembly extending between the leg members.
FIG. 5 is a detail showing a joint mechanism of the present invention.
FIG. 6 is a bottom plan view looking up of the present invention in its folded state, without the shelf assembly.
FIG. 7 is a front side elevation view of the present invention in its folded state, with the "folded" position of the shelf assembly indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the Drawing, reference should be had to FIGS. 1-4 together for an understanding of the elements and features of the drying rack of the present invention, generally indicated by the reference numeral 10. Rack 10 includes a midframe, generally indicated by the reference numeral 12, two windframes, generally indicated by the reference numerals 14 and 16, two leg members, generally indicated by the reference numerals 18 and 20, and a shelf assembly, generally indicated by the reference numeral 22.
Midframe 12 is rectilinear in form and includes side rails 30 and 32, end rails 34 and 36, the side and end rails comprising a continuous, unitary member, and hanging rails, as at 38, fixedly attached to and extending between the end rails. It will be understood that it is intended that hanging rails 38 are provided so that wet articles (not shown), such as articles of laundered clothing, may be placed thereover and hung therefrom to allow the articles to dry.
Since wingframes 14 and 16 are identical, except for orientation with respect to midframe 12, only the elements of wingframe 14 will be described. Wingframe 14 includes side rails 46 and 48, end rail 50, the side and end rails comprising a continuous, unitary member, and hanging rails, as at 54, fixedly attached to and extending between the side rails for the placement thereover of wet articles (not shown). (Wingframe 16 includes an end rail 52.)
Likewise, since leg members 18 and 20 are identical, only the elements of leg member 18 will be described. Leg member 18 includes vertical rails 60 and 62 and a horizontal rail 64 which rests on the surface (not shown) upon which rack 10 is placed, the vertical and horizontal rails comprising a continuous, unitary member. Non-skid members, as at 72, may be placed on horizontal rail 64 to prevent rack 10 from sliding on the surface upon which it is placed. Leg member 18 also includes transverse rails 68 and 70 fixedly attached to and extending between vertical rails 60 and 62.
Shelf assembly 22 includes first and second sections, generally indicated by the reference numerals 82 and 84, respectively. First section 82 includes side rails 86 and 88, end rail 90 with downward facing hooks 92 and 94 fixedly attached thereto, and hanging rails, as at 96, for the placement thereover of wet articles (not shown), fixedly attached to and extending between the side rails, the side and end rails comprising a continuous, unitary member. Formed as extensions of the ends of side rails 86 and 88 opposite the ends joined to end rail 90 are downward facing hooks 98 and 100. Second section 84 of shelf assembly 22 is identical to first section 82 except that the side rails of the second section do not terminate hooks. As is shown on FIGS. 2 and 4, shelf assembly 22 is formed by interleaving first and second sections 82 and 84 so that hooks 98 and 100 of the first section engage a selected one of the hanging rails of the second section.
FIGS. 6 and 7 show rack 10 in its folded state in which state it may be conveniently stored in a closet or other storage area or even under a piece of furniture. It will be understood that rack 10 is placed in its folded state by first removing shelf assembly 22. Then, wingframes 14 and 16 are rotated toward the top of midframe 12 and leg members 18 and 20 are rotated toward the bottom of midframe 12. As can be seen when rack 10 is folded, leg members 18 and 20 nest together so that they both lie flat against the underside of midframe 12. Although leg members 18 and 20 have identical elements, the dimensions thereof are somewhat different and it can be seen that vertical rails 60 and 62 of leg member 18 are spaced apart sufficiently that leg member 20 can nest therebetween. Wingframes 14 and 16 do not so nest, but, when folded, are closely parallel to midframe 12. First and second sections 82 and 84 of shelf 22 fold against each other and may be placed against folded leg members 18 and 20, as indicated on FIG. 7.
When rack 10 is placed in its unfolded state, as shown on FIGS. 1-4, leg members 18 and 20 and wingframes 14 and 16 are rotated relative to the ends of midframe 12. The means by which rotation is effected and by which those members are held in position can be understood by particular reference to FIG. 5 which shows the attachment of vertical rail 62 of leg member 18 and side rail 48 of wingframe 14 to midframe 12. The proximal end of side rail 48 terminates in a flattened portion 110 which is rotatably disposed on a shaft 112 which is fixedly attached to and extends orthogonally inwardly from side rail 32 of midframe 12. It can be seen that wingframe 14 is freely rotatable from its folded position (FIGS. 6 and 7) to its outwardly extended position (FIG. 2), but that, once the wingframe reaches its outwardly extended position, it is prevented from further such rotation by, and is supported in part by, the engagement of flattened portion 110 with the top of end rail 34 of midframe 12. A similar structural arrangement (not shown on FIG. 5) provides for the support of side rail 46.
Similarly, the proximal end of vertical rail 62 of leg member 18 terminates in a flattened portion 120 (See also FIGS. 1 and 2.) which is rotatably disposed on shaft 112 and which flattened portion includes an integral flange 122 extending outwardly therefrom. Vertical rail 62 is freely rotatable from its folded position (FIGS. 6 and 7) relative to midframe 12 until it reaches the position shown on FIG. 2 at which time further rotation is prevented by the engagement of flange 122 with the underside of end rail 34 of the midframe. A similar structural arrangement causes stopping engagement of vertical rail 60 with end rail 32. Thus, with leg member 20 similarly stoppingly engaged with midframe 12, rack 10 may be placed in and maintained in its open position without the need for loosening and/or tightening fasteners.
Flattened portions 110 and 120 are provided for greater strength at the ends of side rail 48 and vertical rail 62, respectively, where the greatest bending moment in those elements occurs.
Still referring to FIG. 5, shaft 112 further has disposed thereon a resilient spacer 140 disposed between side rail 32 and flattened portion 120. Shaft 112 also has disposed thereon a first resilient O-ring 142 which is disposed between flattened portions 110 and 120, a second resilient O-ring 143 which is disposed between flattend portion 110, and a locking wing-nut 144 which threadedly engages the end of the shaft and which selectively varies the force required to rotate wingframe 14 and leg member 18 by varying the frictional resistance between the resilient members and the other elements attached to the shaft.
Once leg members 18 and 20 have been placed in their unfolded positions, shelf assembly 22 may be set at an appropriate length and placed so that hooks 92 and 94 are supportingly engaged by transverse rail 70 of leg member 18, as shown in solid lines on FIGS. 2 and 4. The other end of shelf assembly 22 is similarly supported by leg member 20. If desired, shelf assembly 22 can be appropriately shortened and supported by leg members 18 and 20 in the position shown in dashed lines on FIG. 2. In addition to providing additional drying space, shelf assembly 22 also stabilizes rack 10.
Reference again to FIGS. 2 and 3 will aid in understanding how wingframes 14 and 16 are held in their inwardly extended positions. Here, wingframes 14 and 16 have been rotated away from the folded position shown on FIGS. 6 and 7 and then partially rotated toward the folded position such that end rails 50 and 52 are closely spaced apart. A removable, double-ended, resilient clamp 130 is grippingly slipped over the centers of the ends rails and maintains wingframes 14 and 16 in a tent-like form.
As indicated above, wet articles (not shown) may be placed over each of the various hanging rails of rack 10. If desired, wingframes 14 and 16 may be placed in their inwardly extended, or tent-like, positions and an article such as a heavy sweater, for example, may be placed thereon. A towel or other absorbent article may then be placed on mid frame 12 to prevent any water dripping from the sweater from falling on the floor or on other articles hanging from the midframe or shelf assembly 22.
In an embodiment of the present invention in its fully open position with shelf assembly 22 in its lower position, with the relative dimensions shown, and having a "footprint" measuring 22 inches by 76 inches, 110 linear feet of hanging rails are provided, thus giving a ratio of almost 10:1 in terms of linear feet per square foot. That rack, when in its folded position, as shown on FIGS. 6 and 7, occupies a volume measuring only 21/2 inches by 22 inches by 411/2 inches.
For the above embodiment, it has been found that the side and end rails of the midframe and the wingframes and the rails of the leg members can be satisfactorily manufactured from 10-mm diameter steel pipe and the other rails from 5/32-inch steel dowells, with welded points of attachment. Preferably, all rail members are dip-coated with PVC or painted by electrostatic painting with a suitable paint.
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 scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A foldable drying rack having a rectangular midframe with side and end rails and hanging rails extending between the end rails. Hinged, foldable legs members extend downward from the ends of the midframe and provide support without having to loosen and tighten any fasteners. A shelf having hanging rails may be extended between the leg members below the midframe. Hinged, foldable rectangular wingframes, having hanging rails extending between the side rails may extend outward from the ends of the midframe and may also be deployed without having to loosen and tighten any fasteners. The windframes may also be folded inward toward each other and joined to form a tent-like structure above the midframe. The drying rack may be deployed in its unfolded position without the need to loosen and/or tighten fasteners. In one embodiment, a ratio of almost 10:1 in terms of lineal feet of hanging rails per square foot of floor space is achieved.
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FIELD OF THE INVENTION
The invention relates generally to bird feeders. In particular, the invention relates to a selective nectar dispensing system for use with a bird feeder.
BACKGROUND OF THE INVENTION
Bird feeders are often used to attract various species of birds. It is oftentimes desirable to provide food only for one or more specific birds of interest. One way to attract a certain type of bird is to supply the bird feeder with the particular type of food the bird enjoys. For example, it is well known that certain birds, such as hummingbirds and orioles, prefer a nectar or nectar-type sweet liquid when feeding.
Prior art bird feeders have sought to prevent access from unwanted heavier birds and rodents such as squirrels. For example, Hornung U.S. Pat. No. 2,230,058 discloses a bird feeder designed for lighter birds. The weight of a heavier bird will lower a feeding platform to a tilted position, thus blocking the seed ports. Additionally, Dehls U.S. Pat. No 4,541,362 discloses a squirrel proof selective bird feeder which utilizes the weight of a squirrel to close off the feeding source by spring actuated means.
Although they target lighter birds, these prior art bird feeders are intended to eliminate heavier birds and rodents from feeding at the bird feeder. However, when the food source is a nectar or sweetened liquid, the biggest problem does not necessarily come from seed feeding birds. The problem often relates to insects, and in particular bees or wasps, which are also attracted to the nectar within the bird feeder. A particularly serious problem is the propensity for bees and other insects to enter and become trapped in the nectar feeder. The insects enter through the feeding ports and are unable to exit once inside the nectar reservoir. The aggregation of bees and other insects is a health hazard for birds, unsightly and a nuisance and, further, may plug or block the feeding ports to a point where it is prohibitive for birds to be able to feed on the nectar.
Brown U.S. Pat. No. 5,269,258 discloses a hummingbird and butterfly feeder which is designed to prevent bees from getting inside. However, certain birds such as orioles which also feed on nectar, lack the long proboscis that the hummingbirds have. The orioles require closer access to the actual nectar and larger feed port openings to get their larger beak into a feeder and in a position to feed. Therefore, bird feeders designed specifically for hummingbirds are problematic in that they tend to exclude large beaked birds.
BRIEF SUMMARY OF THE INVENTION
The present invention advantageously provides a bird feeder which selectively dispenses nectar and allows such birds as orioles to feed without allowing insects to have access to the nectar within the bird feeder. The feeder may be constructed to also permit hummingbirds to feed.
In one aspect of the invention, a selective nectar dispensing system for use with a bird feeder is provided. The bird feeder includes a base defining an interior side, a nectar reservoir, and at least one feeding port. The nectar dispensing system comprises a pivot assembly which is pivotally mounted to the interior side of the base. The pivot assembly has at one end a counterweight and at a second end a feeding port restriction portion. The pivot assembly is operable between a closed blocking position and an open feeding position. The counterweight normally biases the restricting portion to the closed blocking position. The counterweight has a mass selected to both permit a feeding bird to move the restricting portion towards the open feeding position, and to prevent movement of the restricting portion by an insect. The counterweight is connected to the feeding port restricting portion by a joint having a pair of arms extending therefrom. Each arm is integral with the joint and forms a fixed angle therebetween. One arm terminates at the counterweight and the other arm terminates at the feeding port restricting portion. Preferably, the counterweight provides an overbalance mass of approximately one gram and the pivot assembly arms are of a substantially equal length, and are selected such that the counterweight arm including the counterweight weighs one gram in excess of the weight of the feeding port restricting portion arm. The joint further includes mounting members extending therefrom and is attachably mounted to the interior of the base such that the mounting members pivot when the feeding port restricting portion is moved, as by a bird. The fixed angle between the arms extending from the joint is preferably greater than 90° but less than 180°.
In another aspect of the invention, the feeding port restricting portion is shaped to substantially fit within the feeding port in its closed blocking position, but without contacting the peripheral edge of the port. Preferably, the feeding port restricting portion has a spherical shape selected to facilitate the dropping of nectar from the feeding port restricting portion. The nectar dispensing system includes a joint member which is mounted to at least one pivot mount member located at the interior side of the base such that the joint member can be removably inserted into the pivot mount member. The joint member further includes a pin extending horizontally therethrough where the joint member is permitted to pivot with respect to the pin when inserted into the pivot mount member.
In yet another aspect of the invention, a bird feeder is provided which comprises a base defining an interior and exterior sides and having at least one feeding port, a nectar reservoir removably connected to the base, and a pivot assembly. The bird feeder further includes a bird support surface connected to the base. The bird support surface further includes a bird attracting portion which is removably attached to the base. The bird attracting portion has an aperture which provides access to the feeding port. The bird attracting portion is integrally formed with the bird support surface. The bird attracting portion includes mounting tab members for insertion into slots located in the base. Preferably, the bird attracting portion is a simulated citrus flower or the like representative, for example, of an orange blossom for attracting orioles.
The present invention also contemplates a method of selectively providing access to a bird feeder in accordance with the aforementioned aspects of the invention.
Various other features, objects, and advantages of the invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the presently preferred embodiment of a nectar feeder incorporating the subject invention.
FIG. 2 is an enlarged vertical section detail through one of the feeding ports of the feeder shown in FIG. 1.
FIG. 3 is a further enlarged detail of FIG. 2 showing operation of the selective dispensing device of the preferred embodiment.
FIG. 4 is an angular elevation detail of the feeding port taken on line 4--4 of FIG. 2.
FIGS. 5 and 6 are perspective details of two embodiments of the pivot mounting assembly for the nectar dispensing system.
FIG. 7 is an enlarged sectional detail similar to FIG. 2 showing an alternate embodiment of the invention in the closed blocking position.
FIG. 8 is a detail similar to FIG. 7 showing the nectar dispensing system in the open feeding position.
FIG. 9 is an angular elevation detail of the feed port taken on line 9--9 of FIG. 7.
FIG. 10 is a bottom plan detail of a portion of the pivot assembly taken on line 10--10 of FIG. 8.
FIG. 11 is a vertical sectional detail taken through the center of the feeder of FIG. 1.
FIGS. 12-15 are sectional details of the locking tab arrangement shown in FIGS. 2, 7, 8 and 11.
FIG. 16 is a horizontal sectional detail taken on line 16--16 of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The presently preferred embodiment of the nectar feeder 10 including the selective dispensing system of the present invention is shown in perspective in FIG. 1. As shown in FIG. 1 and in FIG. 11, the feeder 10 is shown mounted on the upper end 11 of a vertical post 12. The feeder 10 includes a lower base 13, enclosed at the bottom by a demountable nectar holding chamber 14 and at the top by a demountable nectar supply reservoir 15. The feeder 10 is preferably of all molded plastic construction and, as is well known in the art, the supply reservoir 15 is typically transparent to provide an additional attractant to feeding birds and to provide an indication of the level of nectar in the upper supply reservoir 15. Alternate mounting of the feeder 10 may be provided by suspending the feeder from a wire 16 attached to a mounting flange 17 seated in a grooved recess 18 in the top of the supply reservoir. The top of the reservoir 15 is preferably provided with flat surfaces 20, defining the edges of the recess 18, so the reservoir 15 may be free standing when inverted to facilitate filling with nectar. As may be best seen in FIG. 11, the lower end of the supply reservoir 15 has an externally threaded neck 21 which is adapted to threadably engaged an internally threaded sleeve 22 centered in the top of the base 13. Inside the base 13, the holding chamber 14 defines a shallow cylindrical dish 23 into which the nectar flows and is held when the feeder is inverted such that the nectar is held in the dish at a level generally indicated by the line L in FIG. 11.
Referring also to FIGS. 2-5 the selective nectar dispensing system of the present invention is intended to permit nectar-feeding birds such as orioles (and in the alternate embodiment hummingbirds as well) to feed, but blocking ingress to the interior of the base and holding chamber dish 23 by insects. The main outer wall 24 of the base 13 is generally frustoconical and, on the interior of the base wall 24 is mounted a pivot assembly 25. The pivot assembly includes a central hub 26 to which are integrally attached oppositely extending axially aligned stub shafts 27. Extending integrally and generally radially from the hub 26 are a counterweight arm 28 and a feeding port closing arm 30. The opposite end of the counterweight arm 28 is provided with an integral counterweight 31 and the opposite end of the closing arm 30 is provided with an integral spherical restricting portion 32. The stub shafts 27 are adapted to be snapped into downwardly opening slots 33 in a pair of mounting flanges 34 extending downwardly from the inside of the outer base wall 24. The upper ends of the slots 33 are provided with cylindrical bearing surfaces 35 which allow the stub shafts 27 to rotate freely therein.
Just below and aligned with the mounting flanges 34, the outer wall 24 is provided with a feeding port 36. In the embodiment shown in FIG. 1, the base 13 is provided with three feeding ports 36. In the normal at rest position, the pivot assembly 25, as best seen in FIGS. 2 and 3, is biased rotationally in a counterclockwise direction by the counterweight 31. The spherical restricting portion 32 on the end of arm 30 enters and substantially closes the feeding port 36. However, the spherical portion 32 does not contact the peripheral edge 37 of the feeding port, but instead, the closing arm 30 contacts the edge 37 to provide a rotational stop for the pivot assembly. In this manner, any liquid nectar which is picked up by the spherical end portion 32, will tend to run down and drop back into the nectar dish 23.
A bird perch 38 is attached to the outer wall 24 of the base 13. The perch includes an attachment base 40 and an integral T-shaped perching bar extending generally horizontally from the lower edge of the base 40. The attachment base 40 is generally circular in shape and is preferably designed to simulate a citrus flower, such as a blossom which is known to attract orioles. The center of the attachment base 40 has a conical depression 42 which defines a central access opening 43 which is aligned with the feeding port 36 when the perch is attached to the base. Attachment is facilitated by providing the upper edge of the attachment base 40 with an attachment lip 44 adapted to hook into a rectangular opening 45 in the base wall 24, and a lower spade-like tab 46 adapted to snap into a lower rectangular opening 47 in the base wall 24.
As best seen in FIG. 2, with the counterweight 31 holding the opposite spherical portion 32 in the feeding port blocking position (shown in dashed lines), the feeding port 36 is substantially closed but the spherical closing portion 32 does not contact the peripheral edge 37 of the port. A nectar feeding bird, such as an oriole, attracted to the perch 38 inserts its beak 48 through the access opening 43, pushes the spherical portion 32 rotationally out of the way, allowing the beak to continue through the feeding port 36 to reach the nectar (as shown in the full line position). When the beak 48 is retracted, the counterweight 31 causes the pivot assembly 25 to return to the blocking position, and any nectar which has accumulated on the spherical end portion 32 will run downwardly and drop back into the nectar reservoir dish 23.
The entire integral pivot assembly 25 is preferably molded of plastic and the arms 28 and 30, counterweight 31 and restricting portion 32 are selected to provide a counterweight overbalance of mass of approximately 1 gram. The 1 gram overbalance has been found sufficient to prevent as many as three marauding bees from moving spherical end portion 32 against the force of the counterweight. Further, spherical end portion 32 fits closely enough within the peripheral edge 37 of the feeding port 36 to prevent smaller insects, such as ants, from entering the reservoir. To accommodate the rotational movement just described, the pivot assembly arms 28 and 30 are mounted at an angle between 90° and 180°. The stop which is provided by engagement of the closing arm 30 with the peripheral edge 37 of the feeding port, in addition to positioning the restricting portion 32 in the feeding port, also prevents the counterweight from rotating downwardly into the nectar.
The alternate embodiment of the pivot assembly 50 shown in FIG. 6, is constructed substantially identically to the preferred FIG. 5 embodiment, except that the central hub 51 is provided with a through bore 52 to accept a single pivot shaft 53. The pivot shaft 53 may be made of plastic or metal, but is otherwise mounted in the slotted mounting flanges 34 in the same manner previously described.
Referring now to FIGS. 7-10 selective access to the feeder 10 is provided by an alternate pivot assembly 54 which is attached to the outside of the feeder. In this embodiment, the lower holding chamber 14 which encloses the base 13 (in a manner which will be described in greater detail below) is provided with a pair of downwardly depending mounting flanges 55 to which the pivot assembly 54 is attached. The pivot assembly includes a hub 56 which carries a pivot shaft 57 rotationally supported at its ends in the mounting flanges 55. A counterweight arm 58, carrying a counterweight 60 extends radially inwardly of the feeder base and, in the closed blocking position, at a slight downward angle as shown in FIG. 7. A perch arm 61 extends generally horizontally in the opposite direction from the pivot shaft 57 and is generally T-shaped as is the perch bar 41 of the previously described embodiment. An integral closing arm 62 extends at an angle back toward the feeder from approximately the center of the perch arm 61. The free end of the closing arm is provided with a semi spherical closure 63 which, in the at rest position of FIG. 7, is positioned in the conical depression 64 in the center of the attractor base 65. The base 65 may be identical to the attachment base 40 of the previously described embodiment and may be demountably attached to the outer wall 24 of the base in the same manner. As shown in FIG. 7, the rigid, closing arm 62 positions the spherical closure 63 within the conical depression 64, but without touching the walls thereof. This prevents the closure from becoming stuck in the depression with nectar deposited by feeding birds. However, the small annular space between the depression and the outside of the spherical closure is small enough to prevent the ingress of insects as small as ants.
Referring to FIG. 8, the counterweight 60 and the lengths of arms 58 and 61 are chosen such that a nectar-feeding bird, such as an oriole, landing on the end of the perch arm 61 will cause the same to pivot downwardly, carrying the closing arm and spherical closure 63 therewith. The rotational movement of the closing arm and spherical closure are such that contact is not made with any part of the attachment base 40.
Because hummingbirds are not heavy enough to cause the necessary pivotal movement of the pivot assembly 54, the spherical closure 63 may be provided with a small central feed hole 66 through which the beak and tongue of a hummingbird may be extended when the assembly is in the closed position of FIG. 7. Thus, large and small nectar-feeding birds may utilize the selective dispensing system of this embodiment, while the feeder remains protected against ingress of all insects of concern.
As indicated above, the lower holding chamber 14 portion of the feeder 10 is demountably attached to the lower edge of the base 13. The lower edge of the base includes a circular peripheral lower rim 67 which includes an outwardly offset lip 68. The holding chamber 14 includes a circular peripheral upper rim 70 which terminates in an inwardly offset lip 71. The lip 68 and 71 interfit with a friction fit which is normally sufficient to hold the base 13 and holding chamber 14 together. However, to provide a more secure attachment, the inside of the outer wall 24 of the base, just below each of the feeding ports 36, is provided with downwardly depending L-shaped locking tabs 72. In similar locations around the outer wall of the cylindrical dish portion 23 of the holding chamber, integral locking tabs 73 extend radially outwardly. With the locking tabs 72 and 73 offset rotationally from each other, the rims 67 and 70 of the base and holding chamber, respectively, may be pressed together and, with subsequent relative rotation between the respective rims, the locking tabs 73 are caused to override the horizontal lips 74 of the locking tabs 72, thereby preventing separation of the lower holding chamber from the base. Preferably, the locking tabs 73 and respective engaging horizontal lips 74 are provided with rib-like detents 75 to secure the tabs in a locked position. Conveniently, the outside surfaces of the base 13 and the holding chamber 14 immediately adjacent their respective interengaging rims 67 and 70 may be provided with alignment indicators 76 to indicate when the tabs are in the locked position. Conversely, the alignment indicators 76 are offset rotationally from one another when the interengaging rims are first brought together for connection.
Referring to FIGS. 11 and 16, the center of the underside of the holding chamber 14 is provided with a downwardly opening blind sleeve 77 for receipt of the upper end 11 of the mounting post 12. The walls of the sleeve 77 may be provided with axially extending ribs 78 to facilitate insertion of the post. It has been found that the previously described locking tabs 72 and 73 are particularly useful in holding the base and holding chamber of the feeder together when post-mounted in windy conditions.
It is recognized that other equivalents, alternatives, and modifications aside from those expressly stated, are possible and within the scope of the appended claims.
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A selective nectar dispensing system for use with a bird feeder. The nectar dispensing system includes a pivot assembly which has a counterweight at one end and a feeding port restricting portion at another end. The pivot assembly is operable between a closed blocking position and an open feeding position. The counterweight normally biases the restricting portion to the closed blocking position and has a mass selected to both permit a feeding bird to move the restricting portion towards the open feeding position and to prevent movement of the restricting portion by an insect, thus providing selective access to the feeding port. The feeding port restricting portion is urged away from the feeding port against the force of the counterweight. Access to the feeding port is provided only when the feeding port restricting portion is urged away from the feeding port by the beak of a feeding bird in one embodiment and by the weight of the bird in another embodiment.
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BACKGROUND OF THE INVENTION
Prior art repeatedly bears witness to the belief that increased use of metal parts, such as, necks, bodies, nuts, etc., improves sustain and tonal qualities, when used in the construction of electric guitars. Unitary metal construction of guitar parts or wholes increases the accuracy of electronic tone and improves the sustain of string vibrations. It is known that uses of denser woods in constructing electric guitars, improves the sustain qualities and tonal qualities of such instruments.
Along with the foregoing improvements in the electric guitar, explained above, have come a new set of problems. Using metal in construction of electric guitars, has caused a cold feel to the instrument, as well as an added cost to construct coverings where hands touch the instrument most. Guitar strings stretched acrossed long expanses of metal may experience difficulty staying at set tunings, with temperature changes. Denser woods used in electric guitar construction, to effect better sustain and tone qualities, adds more weight, while not achieving the same results as obtained by use of metal construction. Electric guitars in predominant use today, that are considered to have adequate sustain and tone qualities, commonly have profiles of up to nearly two inches of body thickness.
SUMMARY OF THE INVENTION
The object of the present invention is to alleviate the aforementioned problems that have arisen, in association with improving sustain and tone qualities in electric guitars. In achieving this desired object, the present invention will provide a novel electric guitar, unusually light in weight, with a small body thickness profile, that has a warm feel to the touch, and that has desirable sustain and tone qualities, equal to or greater than electric guitars in predominant use today. The present invention will further provide an electric guitar, with metal parts that does not have intolerable tuning problems.
The present invention operates by constructing an inertial environment on the surfaces where the strings are attached, to simulate an inertial environment that an all metal electric guitar might have at the surfaces where its strings are attached. The brief description of the construction of the present invention, which follows, will make its operation more clear. The guitar body, neck, and head are constructed from a solid material, such as wood, fiberglas, or other non-metallic material. The body may be reduced in thickness to the limit of its structural integrity. Practice shows that a body thickness profile of an inch or less may be used. A metal plate is firmly secured to the top surface of the guitar body at the bridge area, where the strings are to be attached to a bridge or tremolo system. A second metal plate, remote and separate from the first metal plate, is firmly secured to the top surface of the guitar head, where the strings are to be attached to the tuning machines. Both metal plates are subsequently overlayed with a material the same as, or similar to that of which the body is constructed of, in various fashion, to help in securing the plates, and for varied aesthetic effects. The strings are fixed at their proper points of attachment after the aforementioned constructions are completed. The sustain and tone redeeming characteristics gained by constructing an electric guitar in this manner, allows an overall lighter weight and thinner body profile than those weights or profiles that are possessed by electric guitars in predominant use today. No appreciable desirable benefit can be gained in sustain or tone quality characteristics, in the present invention, by increasing body weight, and furthermore, the weight may be reduced further by removing body sections that are not essential for the proper function of the instrument. This reduced weight benefit, in the present invention, does not diminish appreciably the superior sustain and tone quality characteristics of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1-A is a perspective view of an assembled embodiment of the present invention.
FIG. 1-B is an exploded perspective view of an embodiment of the present invention.
FIG. 2 is a section view as viewed at line II.--II. of FIG. 4.
FIG. 3 is a sectional view as viewed at line III.--III. of FIG. 4.
FIG. 4 is a top plan view of the guitar of FIG. 1-B after assembly.
FIGS. 5, 6, and 7 are top plan views of the guitar head for three different configurations of the present invention.
FIG. 8 is a sectional view as viewed at line 8--8 of FIG. 5.
FIG. 9 is a sectional view as viewed at line 9--9 of FIG. 6.
FIG. 10 is a sectional view as viewed at line 10--10 of FIG. 7.
FIG. 11 is an exploded prespective view of the present invention.
FIG. 12 is an isometric view of a guitar head with a metal plate installed.
FIG. 13 is a sectional view as viewed at line 13--13 of FIG. 12.
FIG. 14 is a fragmentary top plan view of a bridge/tailpiece combination incorporated in the present invention.
FIG. 15 is a sectional view as viewed at line 15--15 of FIG. 14.
FIG. 16 is an exploded fragmentary view of a tremolo system as incorporated in the present invention.
FIG. 17 is a sectional view as viewed at line 17--17 of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
First, looking at FIG. 1-B to comprehend the details of the assembly of the present invention, a body 1 is conventionally constructed of solid material, such as wood, fiberglas, or other non-metallic material. If a wood body 1 is chosen, a conventional fingerboard 5 is cemented to the top of the guitar neck 27 and frets 22 are installed in a conventional manner. Rectanglar receptacle areas 9 are routed on top of the body 1, for receiving conventional electric guitar pickups 2, as shown in FIG. 1-A. A cavity 12 is routed into the body 1 for housing electronic controls, which is conventional in electric guitar construction. Metal inserts 11 containing female threads are installed in the body 1 as is conventional for receiving bridge-holding stud bolts 23, as shown in FIG. 15.
A metal plate 8, preferably brass 3/32 of an inch thick, with a baked on enamel finish to prevent corrosion, is provided with an aperture 29 for receiving an electric guitar pickup 2, said pickup shown in FIG. 1-A. Said metal plate 8 is further provided with holes 14 for wood screw 10 fastening means and larger holes 15 for the bridge-holding stud bolts 23 to pass through without touching the metal plate 18. Said metal plate 8, thus provided is fastened to the site 26 on the body 1 by wood screw 10 means, and suitable cementing means.
The body overlays 3, which for purposes of example could be said to be constructed of solid maple, a quarter of an inch thick, are provided to be fixed to the body 1 by suitable cementing means. The body overlays 3 are routed on their undersides to form-fit over the metal plate 8, so as to allow the body overlays 3 to contact the body 1 surface that remains exposed around the metal plate 8, and be cemented thereto. The body overlays 3, further are allowed by their under-routings, to overlay at least one eighth of an inch of the metal plate's 8 adjacent periphery, so as to be pleasing aesthetically, as well as helping to secure the metal plate 8.
As an alternate method of installing the metal plate 8, observe FIG. 11. The metal plate 8 to be secured to the body 1, may be installed into a recessed area 24, routed into the body 1. The recessed area 24 supports the metal plate 8, to a depth that allows the top of the plate 8 to be even with the unrouted remainder to the top surface of the body 1. The plate 8 is secured into the recessed area 24 by wood screw 10 means, as well as, suitable cementing means. The top overlays 3 for the body 1, in this method, do not require under-routings to fit over the metal plate 8. These body overlays 3, lie flatly on, and are cemented to the top surface of the body 1, that remains unrouted around the metal plate 8. The body overlays 3, also overlay at least one eighth of an inch of the metal plate's 8 proximal periphery. The body overlays 3 need not be cemented to the metal plate 8, when a relatively small portion of the metal plate 8 is overlayed.
Now referring to FIG. 1-B and FIGS. 5,6,7,8,9, and 10, a second metal plate 18 is secured to the top surface of the guitar head 25 by wood screw 10 means, and suitable cementing means. The area not covered by the second metal plate 18 leaves some of the top surface of the guitar head 25 exposed. The head overlay 19, overlays at least one eighth of an inch of the second metal plate's 18 adjacent border and is routed to allow the head overlay 19 to contact and be cemented to the portion of the guitar head 25 surface that is not covered by the second metal plate 18.
The present invention, assembled in the aforementioned manner, will further be furnished with conventional fixtures for electric guitars. Ref. FIGS. 1-A and 1-B, the electric pickup 2, nearest the neck is installed into aperture 9. The electric pickup 2, nearest the bridge, is installed through the aperture 29 in the metal plate 8, and into the aperture 9 of the body 1. Bridge-holding stud bolts 23 are directed through the clearance holes 15 in the metal plate 8, into the threaded inserts 11, without touching the metal plate 8. This is to avoid temperature related expansional changes in the metal plate 8 that could be transferred to the bridge-holding stud bolts 23 causing tuning problems. The bridge/tailpiece combination 20, referring to FIGS. 14 and 15, is now installed on the bridge-holding stud bolts 23. Now referring to FIGS. 16 and 17, if a tremolo system 21 is used for string attachment on the body 1 end of the present invention, the tremolo-holding screws 31, should pass through the clearance holes 15 in the metal plate 8 and be anchored in the body 1, below the metal plate 8, without touching the metal plate 8. This also is to avoid temperature related expansional changes in the metal plate 8, that could be transferred to the tremolo-holding screws 31, causing tuning problems.
The strings 6 are attached to the bridge/tailpiece combination 29, or tremolo system 21, in a conventional manner, and are tensioned across the body 1, to the neck 27 and further along the neck 27 and attached, according to convention, to tuning machines 7, which are fixed in the holes 17 in the guitar head 25.
The weight of the present invention should be reduced further, in order to construct the invention in its best contemplated mode. This further weight reduction is to be accomplished by excluding a section from a conventional guitar shape that is a non-essential area 30 for the proper function of the guitar of the present invention. This non-essential area 30 includes all of the area beyond the bridge/tailpiece combination 20, at the body end remote from the guitar head 25, that may be excluded without threatening the structural integrity of the bridge/tailpiece combination 20, the cavity 12 that houses the electronic controls, or the player's right arm resting area 32.
The present invention, now described, obviously lends itself to further modifications and alterations by those skilled in the art, without the necessity of departing from the scope of the invention.
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An electric guitar has a lighter weight and a smaller body thickness profile than electric guitars in predominant use today, while maintaining superior sustain and tonal qualities. Favorable inertial environments are constructed to enhance the sustain and tonal qualities of the guitar, by firmly securing a metal plate on the top of the guitar body surface, on the area surrounding the string fastening means at the body end, then firmly securing a second metal plate on the top of the guitar head surface, on the area of the string fastening means at the head end.
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U.S. application Ser. No. 10/785,060
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a method for providing antimicrobial properties to composite yarns, composite fabrics or composite articles in a simple post-production process, and the antimicrobial composite yarns, fabrics or articles provided therefrom.
2. Discussion of the Background
There are currently many types of antimicrobial fiber based products on the market. There are two basic methods for providing antimicrobial properties: 1) a poisoning method and 2) a contact kill method. In the poisoning method, the products are conventionally prepared by the incorporation of silver ions (either in the form of salts or as silver ion containing ceramics) onto the surface of the product or, in the case of polymeric based products, into the interior of the polymer by addition to the polymer melt. The silver ions then infiltrate the microbes and prevent reproduction. The downside to this method, of course, is that it takes time and the silver ions are naturally depleted, as they must come off of the product and infiltrate the microbe in order to work.
In the contact kill method, an antimicrobial agent is applied to the external surface of individual fibers or yarns or dissolved in a polymer melt prior to formation of the fibers or yarns, which upon contacting the microbe causes its death. U.S. Pat. No. 5,567,372 discloses the use of a siloxane quaternary ammonium salt based antimicrobial agent by incorporation into the polymer melt prior to fiber formation. U.S. Patent Application Publication 2003/0064645 discloses the preparation of biocidal polyester fabrics, fibers and other materials using a process that requires treatment of the polyester to provide active functional groups to which a heterocyclic N-halamine is then covalently bonded to render the polyester antimicrobial. U.S. Pat. No. 6,596,657 discloses a method for providing antimicrobial properties particularly for polypropylene and nylon containing fabrics by initial phosphonylation of the polymer fiber surface, or for non-modified surfaces by using a non-volatile salt of an antimicrobial agent such as triclosan, or by complexing iodine with a polymer containing grafted amide-bearing chains. However, all of these methods have in common the need to create the antimicrobial properties at the polymer level, either during preparation of the polymer itself, or by surface modification of the polymer fibers by chemical reaction.
In the area of composite fibers, some effort has been expended to create antimicrobial products. Since composite fibers are often used to prepare cut-proof gloves and other articles often used in meat packaging and similar industries where there are potentially high levels of bacteria, an antimicrobial composite fiber product would be very useful. U.S. Pat. No. 6,351,932; WO 99/35315; and U.S. Pat. No. 6,266,951 each disclose antimicrobial properties in a composite fiber. However, in each case, these properties are generated by forming the composite fiber from a component that has been provided with antimicrobial properties prior to incorporation into the composite fiber. Thus, in each of these cases, it is necessary for the fiber manufacturer to either purchase the antimicrobial component for use in preparation of the composite fiber, or to prepare the individual antimicrobial component themselves, prior to incorporation into the composite fiber.
In each of U.S. Pat. Nos. 6,384,254 and 5,707,736 are described methods for treating fabrics with an antimicrobial composition. U.S. Pat. No. 6,384,254 discloses the use of a quaternary ammonium salt containing polysiloxane solution to treat a fabric by dipping, spraying or roll coating to give a controlled coating weight of the antimicrobial on the fabric, followed by drying with blowing hot air or in a heating furnace at 100-150 C. In U.S. Pat. No. 5,707,736 is described a continuous process for treating a fabric by immersion of the fabric in a tub of diluted antimicrobial agent, followed by pressing to partially dry, followed by drying in a hot air blowing chamber or hot drum chamber at a temperature of up to 120 C., followed by winding of the fabric, which is then used as a dressing or support. However, again each of these methods is used by the fabric manufacturer using equipment and conditions not readily available to the ordinary consumer and typically not involving articles of finished goods containing multiple types of fibers, yarns or other materials.
Accordingly, there is a need for a method for providing antimicrobial properties to yarns, fabrics and finished articles containing two or more different types of fibers or yarns (i.e. composite yarns, composite fabrics or composite articles, respectively), which can be readily performed by the consumer, or by the manufacturer after production of the finished product.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a process for providing antimicrobial properties to a composite yarn.
A further object of the present invention is to provide a process for providing antimicrobial properties to a composite fabric.
Another object of the present invention is to provide a process for providing antimicrobial properties to an composite article comprising a composite yarn or fabric.
Another object of the present invention is to provide a composite item selected from
These and other objects of the present invention have been satisfied by the discovery of a method for providing antimicrobial properties to a composite item, comprising:
immersing a composite item in an aqueous bath comprising an organic antimicrobial agent;
separating the immersed composite item from the bath; and
drying the separated composite item,
wherein the composite item is a member selected from the group consisting of composite yarns, composite fabrics and composite articles, and the antimicrobial composite items prepared therefrom.
DETAILED DESCRIPTION OF THE INVENTION
The term “fiber” as used herein refers to a fundamental component used in the assembly of yarns and fabrics. Generally, a fiber is a component which has a length dimension which is much greater than its diameter or width. This term includes ribbon, strip, staple, and other forms of chopped, cut or discontinuous fiber and the like having a regular or irregular cross section. “Fiber” also includes a plurality of any one of the above or a combination of the above.
As used herein, the term “high performance fiber” means that class of synthetic or natural non-glass fibers having high values of tenacity greater than 10 g/denier, such that they lend themselves for applications where high abrasion and/or cut resistance is important. Typically, high performance fibers have a very high degree of molecular orientation and crystallinity in the final fiber structure.
The term “filament” as used herein refers to a fiber of indefinite or extreme length such as found naturally in silk. This term also refers to manufactured fibers produced by, among other things, extrusion processes. Individual filaments making up a fiber may have any one of a variety of cross sections to include round, serrated or crenular, bean-shaped or others.
The term “yarn” as used herein refers to a continuous strand of textile fibers, filaments or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric. Yarn can occur in a variety of forms to include a spun yarn consisting of staple fibers usually bound together by twist; a multi filament yarn consisting of many continuous filaments or strands; or a mono filament yarn which consist of a single strand.
The term “air interlacing” as used herein refers to subjecting multiple strands of yarn to an air jet to combine the strands and thus form a single, intermittently commingled strand. This treatment is sometimes referred to as “air tacking.” This term is not used to refer to the process of “intermingling” or “entangling” which is understood in the art to refer to a method of air compacting a multifilament yarn to facilitate its further processing, particularly in weaving processes. A yarn strand that has been intermingled typically is not combined with another yarn. Rather, the individual multifilament strands are entangled with each other within the confines of the single strand. This air compacting is used as a substitute for yarn sizing and as a means to provide improved pick resistance. This term also does not refer to well known air texturizing performed to increase the bulk of single yarn or multiple yarn strands. Methods of air interlacing in composite yarns and suitable apparatus therefore are described in U.S. Pat. Nos. 6,349,531; 6,341,483; and 6,212,914, the contents of which are hereby incorporated by reference.
The term “composite yarn” refers to a yarn prepared from two or more yarns, which can be the same or different. Composite yarn can occur in a variety of forms wherein the two or more yarns are in differing orientations relative to one another. The two or more yarns can, for example, be parallel, wrapped one around the other(s), twisted together, or combinations of any or all of these, as well as other orientations, depending on the properties of the composite yarn desired. Examples of such composite yarns are provided in U.S. Pat. Nos. 4,777,789; 5,177,948; 5,628,172; 5,845,476; 6,351,932; 6,363,703 and 6,367,290, the contents of which are hereby incorporated by reference.
The term “composite fabric” is used herein to indicate a fabric prepared from two or more different types of yarn or composite yarn. The fabric construction can be any type, including but not limited to, woven, knitted, non-woven, etc. The two or more different types of yarn or composite yarn include, but are not limited to, those made from natural fibers, synthetic fibers and combinations thereof.
The term “composite article” is used herein to indicate a final article that comprises at least two different types of materials. The composite article can be prepared from a composite fabric, or can be prepared from a conventional fabric containing only one type of yarn, but is put together using a yarn or sewing thread made of a different material. Alternatively, the conventional fabric can be sewn together using a composite yarn as the sewing thread. Composite articles can be any form, including but not limited to, gloves, aprons, socks, filters, shirts, pants, undergarments, one-piece jumpsuits, etc. All of these types of articles, as well as other permutations that are readily evident to those of skill in the art, are included in the present invention definition of “composite article”.
The present invention relates to a method for providing antimicrobial properties to a composite yarn, composite fabric or composite article. The method comprises immersion of the composite yarn, fabric or article in an aqueous solution/emulsion/dispersion of an organic antimicrobial agent, draining excess water from the yarn, fabric or article, followed by drying the composite yarn, fabric or article using a heater, preferably at a temperature of from 50-100° C. Preferably the heater has forced blowing hot air at the desired temperature to assist in carrying off the moisture being liberated from the treated product. Alternatively, the heater can operate under reduced pressure if desired, to further lower the temperature and remove moisture being liberated.
As antimicrobial agent for use in the present invention, one can use any conventional organic (i.e. non-silver ion containing) antimicrobial agent. Preferably, the antimicrobial agent is a silicone based quaternary ammonium salt, more preferably a copolymer (which may or may not include partially or fully hydrolyzed forms) of a long chain (C 12 -C 20 ) alkyldimethylaminotrihydroxysilylpropyl ammonium halide and a chloroalkyltrihydroxysilane. Particularly preferred for use as the antimicrobial agent is a copolymer (which may or may not include partially or fully hydrolyzed forms) of octadecylaminodimethyltrihydroxysilylpropyl ammonium chloride and chloropropyltrihydroxysilane. Suitable such antimicrobials include, but are not limited to, the Bioshield line of antimicrobial agents available from NovaBioGenetics, Inc., antimicrobials such as those used to prepare the Biokryl products from Acordis, or the antimicrobial agents from Aegis Environments such as AEM 5700 Antimicrobial, AEM 5772 Antimicrobial and AEGIS Antimicrobial. The antimicrobial agent is used as an aqueous solution/emulsion/dispersion (depending on the solubility of the agent itself). When necessary for the creation of an emulsion or dispersion, any conventional emulsifier or dispersant can be used, so long as it can be readily washed away from the surface of the yarn, fabric or article using water and a detergent. Preferably the antimicrobial agent is present in the antimicrobial agent bath in an amount of from 0.1-2% by weight, more preferably from 0.1-1% by weight, most preferably from 0.3-0.7% by weight. If the antimicrobial agent is received from the supplier at a higher percentage that desired, the agent can be diluted as needed to provide the desired strength of solution/emulsion/dispersion.
For providing antimicrobial properties to a composite yarn, the present process can be used with the composite yarn at any stage after assembly of the yarn. If used in a continuous type process (within the context of the present invention a continuous type process includes both truly continuous processes and semi-continuous processes in which there are periodic stops for product type changes, other line modifications or for any other reason), the application of the antimicrobial liquid can be performed after assembly but prior to take up on a yarn package or bobbin. The application in such a continuous process can be done by immersion through a bath, followed by drying using an in-line dryer. Drying can alternatively be performed in such a continuous process by use of a heated drying roll around which the composite yarn is wrapped. Drying time can be adjusted based upon the size of the drying roll and the number of wraps of yarn around the roll. In a batch type process, the composite yarn is assembled, taken up on a bobbin, then the entire composite yarn package (yarn wound around the bobbin) is immersed in the antimicrobial agent bath. After immersion for a period of time sufficient to provide complete penetration of the antimicrobial agent liquid throughout the bobbin (preferably from 5-60 seconds), the package is removed from the bath, excess water drained, and the package placed in a heater at the drying temperature.
For providing antimicrobial properties to a composite fabric, the present process can likewise be used at any stage after formation of the fabric, either in a continuous type process or in a batch type process. As in the composite yarn case, the continuous type process for a composite fabric can be performed by applying the antimicrobial liquid after formation of the fabric (i.e. after weaving, knitting or forming the non-woven web), but prior to take up of the fabric on a roll. The application of the antimicrobial agent can be done by immersion through a bath, followed by drying the fabric using an in-line dryer. As in the composite yarn case, the composite fabric can also be rendered antimicrobial in a batch type process by immersion of an entire roll of the fabric, draining of the excess water, and placing the roll in a heater at the drying temperature.
In a preferred embodiment of the present process, the process is used on a composite article to provide antimicrobial properties. This embodiment is most preferred in that it can be readily accomplished by the consumer using a conventional household washer and dryer. In this embodiment, the antimicrobial agent is added to the washer before or during the wash cycle. After washing, the treated composite article is placed in the household dryer and dried at a temperature of approximately 70-90° C. The resulting composite article has antimicrobial properties which will last for at least 20 wash cycles, more preferably for at least 40 wash cycles, most preferably up to 50 wash cycles without the need for replenishment.
The present process can be used on any articles, including those made from synthetic fibers or yarns, those made from natural fibers or yarns, leather products, and articles that contain any or all of these. Suitable articles include any article of clothing or protective wear, such as shoes, socks, gloves, as well as filtering media.
A further preferred embodiment of the present invention provides for recycling of the spent liquid containing the antimicrobial agent, for use on other composite yarns, composite fabrics or composite articles. Conventionally, when manufacturers prepare antimicrobial products by immersion of a product (as opposed to incorporation into the internal structure of the product components themselves), the spent antimicrobial agent containing liquid is disposed of after a single use. Applicants have found that by recycling the spent antimicrobial agent containing liquid, multiple repetitions of the process can be performed without the need to replenish the level of antimicrobial agent. Even then, all that is needed is to add enough antimicrobial agent to the liquid to bring the amount of agent up to the desired level.
One major advantage in this method is the cost savings that result from the recycling of the antibacterial agent solution. This makes the treatment less expensive than most products used in the field today. Another advantage is that the treated products are washable with other basic wash items, towels and underwear etc. Normal bleach and detergents are also no problem and do not detract from the antibacterial properties of the product. Quite the contrary, the use of bleach can actually be advantageous as mentioned below. Once the present process has been performed on a composite yarn, fabric or article, the antimicrobial properties are robust and survive through multiple wash/dry cycles (as noted above). These properties can also be replenished or reactivated by washing or treating the used yarn, fabric or article in a hypochlorite containing bleach solution, such as the conventional sodium hypochlorite.
While the process of the present invention can be performed at any bath pH, it is preferred that the pH be slightly basic, more preferably ≧8, most preferably ≧9. At these higher pH's the resulting treated product has greater durability of the antimicrobial properties.
The present process provides the ability to readily treat yarns, fabrics and articles made from more than one type of material and impart antimicrobial properties to the entire product, regardless of its composition. Further, the present process does not require the use of pressurized equipment, as is often conventionally done when attempting to infiltrate an entire bobbin of yarn or roll of fabric. The present process is readily performed on finished articles by the consumer, or on assembled composite yarns or composite fabrics by the yarn or fabric manufacturer, with relative ease and with little added cost. Even better is the ability to recycle the antimicrobial agent bath used in the process for added cost savings. Further, by using organic antimicrobial agents (instead of silver ion based antimicrobials) and the lower drying temperatures of the present process, the resulting antimicrobial products do not experience the discoloration that occurs with silver based antimicrobials, or that can occur due to heat degradation of other antimicrobial agents.
Obviously, additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A process for providing antimicrobial properties to a composite item, such as a composite yarn, composite fabric or composite article, is provided involving the steps of immersing the composite item in a aqueous bath containing an organic antimicrobial agent, separating the immersed composite item from the bath and drying the separated composite item, and the antimicrobial composite items provided therefrom.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for manufacturing a filler neck for feeding fuel into a feeding pipe of a motor vehicle or the like.
[0003] 2. Description of the Related Art
[0004] From the viewpoint of efficiency in feeding fuel, reduction of manufacturing cost, or reduction of weight of the product, a pipe having a smaller diameter relative to the conventional pipe is often employed as a feeding pipe, recently. However, the legal regulations require a mouthpiece of the filler neck to have the diameter as large as that of the conventional one, so that it tends to become a larger diameter of the mouthpiece relative to that of the feeding pipe. In a case of a feeding pipe having a large diameter, it can be used as the filler neck as it is enlarged diameter of edge portion of the feeding pipe. To the contrary, a feeding pipe having a smaller diameter requires an additional step to joint a mouth piece manufactured separately to the feeding pipe to form a filler neck. (JP-A-H09-066747, JP-B-H06-020824, JP-U-H06-012987, U.S. Pat. Nos. 6,330,893, 6,588,459, etc.) Specifically, the conventional filler necks are formed by fitting a circumferential wall portion of the mouthpiece in the feeding pipe, and by jointing the overlapped circumferential wall portions. The conventional jointing methods are examplified by MAG welding, TIG welding and brazing. In general, the joint portion between the mouthpiece and the feeding pipe requires sufficient hermeticity. Thus, a presence of clearance for filling sub-welding materials or for brazing is required between the mouthpiece and the feeding pipe. That is, conventional joint methods are required an additional procedure for filling the clearance between the mouthpiece and the feeding pipe so as to be completely sealed after the junction process.
[0005] In addition, by the MAG welding or the TIG welding, it is hard to keep hermeticity of the joint portion because of burning through a peripheral edge of the feeding pipe. These welding methods also cause inevitably scattering of the welding spatters which bring the welding environment in danger. Moreover, both the methods increase manufacturing cost of the process of joint between a mouthpiece and a feeding pipe due to applying sub-materials for and welding at low-speed. In a case of manufacturing a filler neck in variety of sizes in small runs, variation in size of a mouthpiece and a feeding pipe causes a quality of welding finishing of the products in unstable. As a result, a joint strength and hermeticity of the products becomes unstable.
[0006] As for brazing, a condition of the clearance to obtain the products with sufficient welding strength and hermeticity becomes severer than that of the aforementioned welding methods. Generally, the brazing provides a relatively high joint strength with the clearance sized in a range of {fraction (3/100)} mm through {fraction (1/100)} mm. However, the joint strength significantly drops with the clearance of {fraction (1/100)} mm or less. Thus, the size management of the clearance is more delicate in brazing than in welding. Moreover, the brazing with silver-solder, for example, might bring deterioration to work environment due to generation of fluorine compounds or boron compounds during brazing.
[0007] Thus, in the conventional methods for manufacturing a filler neck by utilizing MAG welding, TIG welding or brazing, there have been existing problems of fuel evaporation due to insufficient hermeticity of a filler neck, or of low productivity. In response to the recent requests for solving these problems, the present inventors have conducted investigations to find a method for manufacturing a filler neck to joint a mouthpiece and a feeding pipe which were separately manufactured as individual members.
SUMMARY OF THE INVENTION
[0008] As a result, of the above investigation, the inventors have developed a method for manufacturing a filler neck comprising the following steps: forming a mouthpiece having a circumferential wall portion in a sectional circular shape, forming a feeding pipe having a circumferential wall portion in a sectional circular shape, fitting the circumferential wall portion of the mouthpiece in the circumferential wall portion of the feeding pipe closely in an overlapped condition, and welding the circumferential wall portions at a welding area W defined in a range of an overlapped area S defined by the overlapped circumferential wall portions; characterized by that: the welding is executed by a seam welding utilizing an internal welding electrode and an external welding electrode; the internal welding electrode is a cylinder having an outer diameter smaller than an inner diameter of the circumferential wall portion of mouthpiece, which has an electrode region on a side face of the cylinder and is inserted in the mouthpiece to press the electrode region against an inner face of the circumferential wall portion of the mouth piece at a predetermined pressure, the external welding electrode is a flat disk having a thickness equivalent to a width of the welding area W, which has an electrode region on a circumference face of the disk and presses the circumference face thereof against an outer face of the circumferential wall portion of the feeding pipe at a predetermined pressure, and both the welding electrodes together holding the overlapped circumferential wall portions of the mouthpiece and of the feeding pipe within the welding area W therebetween, allowing the mouthpiece and the feeding pipe, the internal welding electrode, and the external welding electrode to respectively rotate at synchronized peripheral speed, applying a predetermined electric current to the internal welding electrode and the external welding electrode, and thereby integrate the mouthpiece and the feeding pipe.
[0009] It is preferable that a pressure by the internal welding electrode and the external welding electrode is set in a range of 25 through 50 MPa, and a predetermined electric current applying to the internal welding electrode and the external welding electrode is in a range of 3,000 through 7,000 A. In addition, many recent mouthpieces and feeding pipes are made of stainless steel to which the electrodes become slippery. Therefore, the internal welding electrode may be employed a structure that it is rotated with a rotation axis thereof which a friction clutch is built in, so that the friction clutch slips to prevent a difference in peripheral speed between the internal welding electrode and the external welding electrode.
[0010] In the present invention, the circumferential wall portion of the mouthpiece and the circumferential wall portion of the feeding pipe are jointed by a seam welding in a press-fitted condition. Specifically, a welding area W established in a range of a width of the portion overlapped the circumferential wall portions of the mouthpiece and of the feeding pipe is welded apart from the overlapped peripheral edge of the feeding pipe by a seam welding. As a result, there is no melting drops of the weld at the overlapped peripheral edge portion of the feeding pipe, and thereby the high hermeticity of the filler neck can be obtained. In addition, there is no scattering of spatters in the seam welding which requires no clearances at the welding area W. In the same time, the seam welding as a high-speed welding operation brings enhancement of productivity of the filler neck. Moreover, the seam welding can also achieve a reliable welding result in spite of producing tight or loose tolerances, because of that nothing of sub-materials for welding is required, nor that the shapes of the peripheral edges of the mouthpiece and the feeding pipe influences to the result of the joint.
[0011] In order to perform the seam welding under the condition of which the welding area W is provided to the overlapped area S defined by press-fitting the circumferential wall portion of the feeding pipe over the circumferential wall portion of the mouthpiece, the circumferential wall portion of the mouthpiece is formed into a cylinder extending downwardly toward the feeding pipe, and the circumferential wall portion of the feeding pipe is formed into a cylinder having a shape substantially equal to the outer cross-sectional shape of the circumferential wall portion of the mouthpiece. Thereby, the circumferential wall portion of the feeding pipe can be fitted over the circumferential wall portion of the mouthpiece in a press-fitted condition free from occurrence of clearance therebetween. In general, the shape of the body of the mouthpiece excepting of the circumferential wall portion and the shape of the body of the feeding pipe excepting of the circumferential wall portion are in a sectional circular shape. Therefore, the circumferential wall portion of the mouthpiece is formed by reducing diameter of the body of the mouthpiece. In the same time, the circumferential wall portion of the feeding pipe is formed by enlarging diameter of the body of the feeding pipe. Since the circumferential wall portions of the mouthpiece and the feeding pipe are in an overlapped relation with each other, formation of each wall portion into a cylinder in a sectional circular shape provides flexibility in orientation of the mouthpiece relative to the feeding pipe and capability of assembly of both the circumferential wall portions at a fixed position. In addition to the above advantages, there is no deviation in strength between each circumferential wall portion as being of a cylinder in a sectional circular shape.
[0012] A fitting volume of the circumferential wall portion of the feeding pipe over the circumferential wall portion of the mouthpiece controls the region width of the overlapping area S between the circumferential wall portions of the mouthpiece and the feeding pipe in a press-fitted condition. Setting an extent of the fitting volume of the circumferential wall portions or the region width of the overlapping area S can be flexible, as far as a region width of the seam welding area W stays within the overlapping area S. However, the greater the fitting volume of the circumferential wall portions of the mouthpiece and the feeding pipe becomes, the harder the press-fitting becomes. Additionally, it is not preferable, from the viewpoint of uniformity of the product's quality, that the fitting volume varies in every products. Accordingly, the circumferential wall portion of the mouthpiece may be formed by reducing in diameter of the body of the mouthpiece through a tapered portion into a sectional circular shape, an upper end of the circumferential wall portion of the mouthpiece may be defined by a boundary portion between the tapered portion and the circumferential wall portion of the mouthpiece, and thereby the circumferential wall portion of the mouthpiece may be fitted in the circumferential wall portion of the feeding pipe in a manner that the peripheral edge of the feeding pipe abuts to the upper end of the circumferential wall portion of the mouthpiece. To press-fit the circumferential wall portions in the aforementioned manner can usually set the overlapping area S in a fixed range. This means that the mouthpiece and the feeding pipe can be positioned easily at the step of the assembling prior to the welding step. Moreover, a constant seam-welding area W can be provided in a range of the overlapped areas of the circumferential wall portions of the mouthpiece and the feeding pipe. As a result, an uniformity of the product's quality can be achieved.
[0013] An partition of the mouthpiece may be formed by radially and inwardly reducing a lower edge of the circumferential wall portion of the mouthpiece having a sectional circular shape as being of an orthogonal surface to the circumferential wall portion of the mouthpiece, An annular rib functioning as a gun guide may be formed to be downwardly projected from the partition. The internal welding electrode may be rotated while sliding an insulated nose face thereof contacting onto an inner face of the partition of the mouthpiece. A rigidity of the circumferential wall portion of the mouthpiece is enhanced by presence of the partition. A rigidity of the partition is also enhanced by presence of the annular rib. Accordingly, the shape of the circumferential wall portion of the mouthpiece can be retained by the enhanced rigidity at the step of press-fitting the circumferential wall portion of the mouthpiece in the circumferential wall portion of the feeding pipe. The annular rib functioning as a gun guide may be formed in a conical shape by gradually and successively reducing the circumferential wall portion of the mouthpiece. It is more preferable that the annular rib is integrally formed by folding the circumferential wall portion of the mouthpiece in order that the partition formed by folding the circumferential wall portion orthogonally and radially is folded vertically downward. Thus, the rotating position of the internal welding electrode during seam-welding becomes stable by the effect of the partition supports a nose face of the internal welding electrode in sliding contact, resulting in an optimized seam welding. Since the annular rib as a gun guide extending from the partition is arranged a part from the circumferential wall portion of the mouthpiece, the circumferential wall portion of the mouthpiece can be prevented from suffering damages occurred by a filler gun's insertion. Furthermore, the annular rib of the present invention is applicable to manufacture the various types of products with a common structure in a same production line, in accordance with difference of the fuel classifications, alteration of the gun guide's diameter adjusting to the individual national standard of the device, and alteration of the structure of the filler neck depending upon the individual legal requirements.
BRIEF DESCRIPTION OF THE DRAWING
[0014] [0014]FIG. 1 is a sectional view of a filler neck according to the present invention.
[0015] [0015]FIG. 2 is a sectional view showing a mouthpiece and a feeding pipe before assembling.
[0016] [0016]FIG. 3 is a sectional view showing a mouthpiece and a feeding pipe during operating in the seam welding after assembling.
[0017] [0017]FIG. 4 is a sectional view showing an another example of FIG. 2 with a different fuel pipe.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Preferred embodiments of the invention will now be described according to the drawings in the following.
[0019] A filler neck 1 of the present invention is characterized by a method for jointing a mouthpiece 2 and a feeding pipe 3 . As shown in FIG. 1, the mouthpiece 2 and the feeding pipe 3 do not have significant differences in appearance from conventional ones, which implies excellence in substitution of the filler neck 1 according to the present invention.
[0020] As shown in FIG. 2, the mouthpiece 2 made by an annular metal member is constructed by, in order from top in the drawing, a curled peripheral flange 4 , an internal thread 7 having a thread groove 6 for screwing a fuel cap□not shown in the drawing□thereto, and a body 8 of the mouthpiece which is an original raw pipe portion, wherein the body 8 of the mouthpiece is reduced in diameter radially and inwardly through a tapered potion 9 , so as to form a circumferential wall portion 12 of the mouthpiece in a sectional circular shape extending from an upper end 10 of the circumferential wall portion to a lower end 11 thereof. Further in the present embodiment, the lower end 11 of the circumferential wall portion 12 of the mouthpiece is reduced radially and inwardly to forma partition 13 , so that an annular rib 14 functioning as a gun guide 14 is formed with protruding from an eccentric position of the partition 13 toward the feeding pipe 3 . The partition 13 contributes as a strength portion to retain the shape of the lower end 11 of the circumferential wall portion of the mouthpiece 12 . And, the annular rib 14 contributes as a strength portion to retain the shape of the partition 13 .
[0021] The feeding pipe 3 is a metallic cylindrical tube., In the present embodiment, the feeding pipe 3 is constructed by an eccentric tapered portion 15 in which gradually enlarged in diameter thereof and by the circumferential wall portion 16 which is integrally formed extending from the end of the gradually enlarged eccentric tapered portion. Generally, an electric welded tube is used for a feeding pipe and remains bead weld on the inner face of the circumferential wall portion 16 of the feeding pipe, which impedes sufficient fitting of the welding area W required for a seam welding. In the present embodiment, however, the bead weld retained on the circumferential wall portion is spread to reduce its projection accompanying that the feeding pipe 3 is enlarged in diameter to form the circumferential wall portion 16 of the feeding pipe integrally through the eccentric tapered portion 15 . Accordingly, secure fitting of the inner face of the circumferential wall portion 16 of the feeding pipe over the outer face of the circumferential wall portion 12 of the mouthpiece can be achieved. In addition, the circumferential wall portion 16 of the feeding pipe provided to the enlarged feeding pipe 3 improves roundness thereof and then raises degrees of fitting of the inner face of the circumferential wall portion 16 of the feeding pipe over the outer face of the circumferential wall portion 12 of the mouthpiece. Thus, by the construction for fitting the circumferential wall portion 16 of the feeding pipe extending from the tapered portion 15 formed by enlarging the pipe gradually and radially over the circumferential wall portion 12 of the mouthpiece, it is suitable for performing a seam welding which brings excellent and stable hermeticity.
[0022] The present invention teaches that the circumferential wall portion 16 of the feeding pipe 3 is press-fitted in the circumferential wall portion 12 of the mouthpiece 2 and welded the outer face of the circumferential wall portion 12 of the mouthpiece and the inner face of the circumferential wall portion 16 of the feeding pipe by a seam welding. Since a seam welding requires a complete fitting at the welding area W without differential clearance, the outer diameter R1 of the circumferential wall portion 12 of the mouthpiece should be substantially equal to the inner diameter R2 of the circumferential wall portion 16 of the feeding pipe.
[0023] To be specific, the outer diameter R1 of the circumferential wall portion 12 of the mouthpiece having outer diameter R1 which is larger than the inner diameter R2 of the circumferential wall portion 16 of the feeding pipe in a range of 0.00 mm to 0.3 mm, preferably 0.00 mm to 0.2 mm, is press-fitted in the circumferential wall portion 16 of the feeding pipe so as to prevent from slipping the fitted circumferential wall portions 12 and 16 . In this case, in order to obtain an easiness of press-fitting the circumferential wall portion 12 of the mouthpiece into the circumferential wall portion 16 of the feeding pipe, as shown in FIG. 4, a guiding tapered portion 18 may be formed by enlarging a peripheral edge 17 of the feeding pipe till becoming larger diameter than the outer diameter of the circumferential wall portion of the mouthpiece. Since the welding area W to be seam-welded is set narrower than the overlapped area S, no affect is caused on the joint between the mouthpiece 2 and the feeding pipe 3 even if the guiding tapered portion 18 is formed at the peripheral edge 17 of the feeding pipe.
[0024] A fitting volume of the circumferential wall portion 16 of the feeding pipe relative to the circumferential wall portion 12 of the mouthpiece can be fixed by abutting the peripheral edge 17 of the feeding pipe to the upper end 10 of the circumferential wall portion 12 of the mouthpiece. Accordingly, the overlapped area S administrating the welding area W to be allowed a sufficient seam welding to provide can be obtained by an appropriate fitting volume set by which is press-fitted the peripheral edge 17 of the feeding pipe till abutting to the upper end 10 of the circumferential wall portion 12 .
[0025] Regarding to the cost performance while securing joint strength and hermeticity, a range of the welding area W may be set between 3 mm and 9 mm, preferably between 4 mm and 8 mm, further preferably between 5 mm and 7 mm. The overlapped area S having margins in front and back each of at lease 1 mm may be sufficient for the welding area W. This relationship between the welding area W and the overlapped area S facilitates assembly of the mouthpiece 2 and the feeding pipe 3 prior to a welding operation. Since the circumferential wall portion 12 of the mouthpiece is enhanced retaining in shape by presence of the partition 13 and the annular rib 14 , there is out of apprehension for deformation or damage on the mouthpiece 2 or the feeding pipe 3 when the circumferential wall portion 12 of the mouthpiece is fitted in the circumferential wall portion 16 of the feeding pipe.
[0026] The internal welding electrode 19 , as shown in FIG. 3, is a cylinder having an outer diameter smaller than an inner diameter of the circumferential wall portion 12 of the mouthpiece, which has an electrode region on a side face 20 with pressing against the inner face of the circumferential wall portion 12 of the mouthpiece. Although it is preferable for the internal welding electrode 19 to have a larger outer diameter in respect of rigidity thereof, the outer diameter of the internal welding electrode 19 is required to be set smaller than the inner diameter of the circumferential wall portion 12 of the mouthpiece. For example, if the inner diameter of the circumferential wall portion 12 of the mouthpiece is set in 38.8 mm, then the outer diameter of the internal welding electrode 19 falls in 35.0 mm.
[0027] In order to avoid contact with any other portions from the welding area W of the inner face of the circumferential wall portion 16 of the mouth piece, such as the peripheral flange 4 folded integrally from an opening 5 of the mouthpiece 2 , the external welding electrode 21 is formed into a flat disk having an electrode region on a circumference side thereof and presses the circumference side against the outer face of the circumferential wall portion 16 of the feeding pipe. The outer diameter of the external welding electrode 21 is a relative value determined by the size of the filler neck 1 . For example, if the inner face of the circumferential wall portion 12 of the mouthpiece has a diameter of 38.8 mm, then the relative value falls in 250 mm or more. That is, this relative value becomes at least 6 times greater than the diameter of the internal welding electrode 19 .
[0028] As seen in above, there is a large radius ratio between a pair of the inner welding electrode 19 and the external welding electrode 21 for a seam welding device (not shown in the drawing) in the present invention, and it appears the asymmetry shapes in that the internal welding electrode 19 has a cylindrical shape and the external welding electrode 21 has a disk shape.
[0029] The internal and external welding electrodes 19 and 21 are faced their electrode regions each other, to hold the circumferential wall portion 12 of the mouthpiece and the circumferential wall portion 16 of the feeding pipe within the welding area W therebetween, respectively rotating to seam-weld the welding area W in the circumferential direction.
[0030] In this case, for the purpose of facing the electrode regions in a fixed positional relation, the individual peripheral speed of the internal welding electrodes 19 and the external welding electrodes 21 should be equalized. Therefore, the individual rotating speed of the internal welding electrode 19 and the external welding electrode 21 are in relation of the inverse ratio to the aforementioned radius ratio, i.e., the internal welding electrode 19 has a relatively high rotating speed and the external welding electrode 21 has a relatively low rotating speed.
[0031] Further, the internal welding electrodes 19 and the external welding electrode 21 are abraded with age by the contact with each of the inner face of the circumferential wall portion 12 of the mouthpiece or the outer face of the circumferential wall portion 16 of the feeding pipe. There is a problem that, therefore, peripheral speed of the internal welding electrode 19 which rotating at higher speed with its smaller diameter becomes different from the predetermined speed. To solve this problem, the present embodiment suggests that a friction clutch is mounted to a rotation axis of the internal welding electrode 19 , and that the internal welding electrode 19 and the external welding electrodes 21 are allowed to respectively rotate mainly based on the external welding electrode 21 , and thereby corrects difference in peripheral speed between the electrodes 19 and 21 by slipping of the internal welding electrode 19 utilizing the friction clutch.
[0032] In this way, the internal welding electrode 19 and the external welding electrode 21 respectively rotate mainly based on the external welding electrode 21 . If the material of the mouthpiece 2 and the feeding pipe 5 generates a sufficient friction against the internal welding electrode 19 and the external welding electrode 21 , the mouthpiece 2 and the feeding pipe 3 are allowed to rotate accompanied with the internal and external welding electrodes 19 and 21 . However, in a case where the mouthpiece 2 or the feeding pipe 3 is made of stainless steel, an insufficient friction against the welding electrodes 19 and 21 , which likely causes idle rotations thereof. This problem may be solved by integrally rotating the mouthpiece 2 and the feeding pipe 3 in accordance with the synchronized rotation of the internal welding electrode 19 and the external welding electrode 21 . The rotation of the mouthpiece 2 and the feeding pipe 3 perform in the same direction of rotation of the internal welding electrode 19 . And a peripheral speed of the mouthpiece 2 and the feeding pipe 3 is synchronized with a peripheral speed of the internal welding electrode 19 and the external welding electrode 21 . This synchronization of the peripheral speed is automatically achieved by the friction clutch to allow the internal welding electrode 21 to slip.
[0033] While providing rotation to the mouthpiece 2 and the feeding pipe 3 , as described above, by rotating the inner welding electrode 19 which presses to the inner face of the circumferential wall portion 12 of the mouthpiece 2 and by rotating the outer welding electrode 21 which presses to the outer face of the circumferential wall portion 16 of the feeding pipe 3 , the seam welding of the present invention is carried out by applying a predetermined electric current intermittently between the internal welding electrode 19 and the external welding electrode 21 . Thus, the overlapped outer face of the circumferential wall portion of the mouthpiece and inner face of the circumferential wall portion of the feeding pipe is melt momentarily by electric heat, thereby completes to be welded.
[0034] In a case where stainless steel having a thickness of 1.2 mm is used for the circumferential wall portion 12 of the mouthpiece and the circumferential wall portion 16 of the feeding pipe, a pressure of the electrodes may be set in a range of 25 MPa through 50 MPa and an electric current value on the electrodes may be set in a range of 3,000 A through 7,000 A. Preferably, the pressure may be set in a little less than 40 MPa and the electric current value may be set in about 4,000 A respectively. These values are relatively smaller than typical values for a seam welding.
[0035] Application of the above-mentioned pressure and electric current, however, should be limited within the welding area W since distribution of the electric current out of the welding area W causes reduction of the electric current value to the welding area W, resulting in an insufficient seam welding. In the present invention, the contact of the external welding electrode 21 with the outer face of the circumferential wall portion 16 of feeding pipe is limited to the width of the circumference face of the disk 21 . At the same time, there is an apprehension that the nose face 22 of the internal welding electrode 19 contacts accidentally to the partition 13 integrally formed by extending radially and inwardly from the circumferential wall portion 12 of the mouthpiece. Therefore, the nose face 22 is insulated not only to prevent from the shunt current, but also to obtain a stable rotation of the internal welding electrode in sliding contact with the inner face of the partition. In the internal welding electrode 19 , the side face 20 thereof contacts in sliding with the inner face of the circumferential wall portion of the mouthpiece, and the nose face 22 thereof contacts also in sliding with the inner face of the partition 13 . As a result, the internal welding electrode 19 and the external welding electrode 21 contact to the mouthpiece 2 and the feeding pipe 3 in a stable attitude, thereby an excellent seam welding can be achieved.
[0036] A filler neck according to the manufacturing method in the present invention has an excellent hermeticity. This is resulted by that the circumferential wall portion of the mouthpiece is press-fitted in the circumferential wall portion of the feeding pipe to thereby carry out a seam welding thereon. By the seam welding, for example, there is an advantage that no clearances for welding in other method or brazing are required in a range of the welding area W. Accordingly, the outer face of the circumferential wall portion of the mouthpiece and the inner face of the circumferential wall portion of the feeding pipe can be overlapped closely. In the present invention, the circumferential wall portions of the mouthpiece and of the feeding pipe both having a diameter in a substantially equal to the other are press-fitted, thus to obtain the above closely overlapped condition.
[0037] Further, the seam welding according to the present invention is performed such that the internal and external welding electrodes together hold the mouthpiece and the feeding pipe therebetween. This welding method eliminates an additional requirement of jigs used in conventional methods for supporting the feeding pipe or the like. Thus, the improvement of productivity can be achieved in the present invention. In particular, the circumferential wall portions of the mouthpiece and of the feeding pipe overlapped in a press-fitted condition can prevent both the wall portions from slipping off until a seam-welding step. It allows an easier handling of the mouthpiece and the feeding pipe in welding operation.
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In response to the recent various requests, the present invention provides a method for manufacturing a filler neck to facilitate jointing a mouthpiece and a feeding pipe which were manufactured separately into an integrated filler neck having an excellent hermeticity. The method for manufacturing a filler neck 1 comprises the following steps: jointing an inner face of the circumferential wall portion 16 of a feeding pipe and an outer face of the circumferential wall portion 12 of the mouthpiece, and integrating with the mouthpiece 2 and the feeding pipe 3, wherein the outer face of the mouthpiece and the inner face of the feeding pipe are in relation to be fitted in a press-fitted condition, a seam welding is executed to the welding area W provided in a range of the overlapped area S defined by the width of the circumferential wall portions.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on European Patent Application No. 08169404.4, filed Nov. 19, 2008, which is hereby incorporated by reference in its entirety. Priority is not being claimed.
FIELD OF THE INVENTION
[0002] The invention relates to a jack-up offshore platform, on which is provided a lifting crane for lifting a load, which lifting crane comprises counterbalancing means for counterbalancing the load. The invention also relates to a jack-up offshore platform, a lifting crane and to a method of repositioning a load from a jack-up offshore platform.
BACKGROUND OF THE INVENTION
[0003] There is an increasing amount of large structures at sea that have to be serviced and repaired. A typical offshore wind turbine for instance comprises a nacelle supported by a tower of more than 100 meters high above sea level. A hub is connected to the nacelle for holding rotor blades, which can have a length of 70 meters and more. The nacelle alone typically accounts for 350 tons in weight. When assembling, servicing or repairing such large structures at sea, parts of the structure are generally transported to a jack-up offshore platform close to the structure, on which platform is provided a lifting crane for lifting the parts. The known platform comprises a lifting crane provided with a counterweight for counterbalancing the weight of the lifted parts. As structures become higher and larger, the required lifting cranes and counterweights become increasingly heavy, which consequentially also requires sturdier platforms. The counterweights moreover tend to take up more and more workspace from the jack-up offshore platform. Transporting large cranes and counterweights is also increasingly demanding and costly.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to provide a more effective jack-up offshore platform for assembling or servicing large and high structures at sea. It is a further object to provide a method for repositioning a load as well as a method for assembling and servicing a wind turbine.
[0005] According to the invention, this object is achieved by a jack-up offshore platform, on which is provided a lifting crane for lifting a load, which lifting crane comprises counterbalancing means for counterbalancing the load, whereby the counterbalancing means are connectable to the jack-up offshore platform. When lifting a load, the counterbalancing means are connected to the jack-up platform. As a result, at least a part of the force carried by the counterbalancing means is transferred to the jack-up offshore platform, and the counterweight needed to counterbalance the load can be reduced compared to the state of the art, or even deleted altogether. Alternatively, a larger load can be lifted relative to the state of the art platform and crane.
[0006] An additional advantage of the jack-up offshore platform according to the invention is that its lifting crane takes up less space of the jack-up offshore platform and makes assembling or servicing structures at sea less expensive and easier to perform. Providing counterbalancing means that are, in operation, connected to the jack-up offshore platform has not been attempted before since lifting cranes usually move, in particular rotate, when repositioning a load. Connected counterbalancing means may limit the movement of the lifting crane. The advantages provided by a decreased counterweight and increased workspace are such however that a more effective jack-up offshore platform is achieved by the invention. With a more effective platform is meant a platform that is able to operate faster, easier and at reduced cost.
[0007] In a preferred embodiment of the invention, the counterbalancing means comprise at least one counterbalancing cable attached to the lifting crane and connectable to the platform. When lifting a load, the at least one counterbalancing cable transfers the counterbalancing forces into the jack-up offshore platform. As a result, strong counterbalancing means are obtained, which take up minimal workspace.
[0008] In another preferred embodiment, the counterbalancing means are connectable to the platform by first connection means provided on the cable, and second connection means provided on the jack-up offshore platform. The first and second connection means cooperate to achieve the connection. This embodiment allows for easy connecting and disconnecting of the counterbalancing cable to and from the jack-up offshore platform.
[0009] In yet another preferred embodiment, the counterbalancing means are connectable to the jack-up offshore platform at least two spaced apart connection positions. This allows to use the lifting crane in at least two different positions. For example, with the lifting crane in a first position, a load can be lifted from a cargo ship onto a particular location of the platform, and, with the lifting crane in a second position, the load can be repositioned to the structure at sea. In a simple, yet adequate embodiment, the counterbalancing means are connectable to the platform at two spaced apart connection positions. When servicing or assembling a structure at sea, such as a wind turbine, the lifting crane usually lifts parts from a first location, for example from a cargo ship or from the jack-up offshore platform, and positions the load at the preferred location of the structure. When these locations are at a substantial distance from each other, two spaced apart connection positions allow for effective use of the counterbalancing cables, whereas even more limited workspace of the jack-up offshore platform is used.
[0010] The second connection means can be located at any position of choice of the jack-up offshore platform. Preferably, the counterbalancing means are connectable to the platform nearby edges of the jack-up offshore platform. This saves even more workspace, as edges are usually not part of the workspace, or at least not used extensively.
[0011] In still another preferred embodiment, the counterbalancing means are movably connectable to the jack-up offshore platform. To establish such a movable connection between the counterbalancing means and the platform, the jack-up offshore platform may for instance comprise a guide, such as a cable-guide or a bar-guide, fixed to the platform. The first connection means may for instance be provided in the form of a hook that is connected to the cable-guide or bar-guide and will slide along the cable-guide or bar-guide when moving the lifting crane. A person skilled in the art may envisage other solutions to such a movable connection. The present embodiment does not demand or demands less connecting and disconnecting of the counterbalancing means during the use of the lifting crane. When moving the lifting crane, the connection between the counterbalancing means and the jack-up offshore platform can move relative to the platform, whereby the counterbalancing means can be used over a wider range of positions of the lifting crane. In case the counterbalancing means comprise a counterbalancing cable, it is also possible to provide a connection that is able to vary the length of the counterbalancing cable, or that is movable in the direction of the counterbalancing cable. This allows to accommodate movements of the lifting crane and/or to vary the stress in the cable according to the needs.
[0012] Although the off-shore jack-up platform, and in particular the lifting crane according to the invention does not need a counterweight, a preferred embodiment of the lifting crane comprises, in addition to the counterbalancing means, a counterweight, supported by the lifting crane. Such a lifting crane is able to move and rotate in its unconnected state (when it is not connected to the platform) in a number of stable configurations, eventually carrying a relatively small load. The counterweight of the present embodiment will typically be smaller than the counterweight of the known lifting crane, and therefore still saves weight and workspace. Preferably, the distance between the counterweight and the lifted load is adjustable. This results in a more flexible lifting crane, as the counterbalancing couple exerted by the counterweight about lifted load can be adjusted, resulting in easy repositioning of loads.
[0013] The lifting crane of the jack-up platform according to the invention preferably comprises at least one sensor for detecting forces, and control means for counterbalancing the load such that the lifting crane remains in equilibrium on the basis of the outcome of the detected forces. The detected forces for a certain load can be influenced by changing the position of the lifting crane and/or by tightening or loosening the counteracting cable, and/or eventually also by tightening or loosening other cables provided between different parts of the lifting crane. The sensors and control means may also be used to find an equilibrium position of the crane in which the force in the counterbalancing means is about zero. If the detected force in the counterbalancing cable for instance is below a predetermined low value, the counterbalancing cable may be disconnected from the platform without the crane loosing its equilibrium. This allows to safely reposition the lifting crane to another position. On the other hand, the sensors and control means may also be used to limit the stress in the counteracting cable to below a certain yield stress, in order to prevent fracture of the cable. The control means may also provide a signal, for example a sound or a light signal, to inform the user when a certain predetermined stress level is exceeded.
[0014] The lifting crane of the jack-up platform according to the invention is able to lift loads higher than the known platform lifting crane. The lifting crane of the jack-up platform is particularly useful for lifting loads to a height between 50 and 150 meter, preferably between 60 and 130 meter and most preferably between 70 and 110 meter above the jack-up offshore platform. A jack-up offshore platform on which is provided such a lifting crane is particularly advantageous, as counterbalancing forces may be high. The lifting capacity of the lifting crane according to the invention may easily be enlarged, for instance by increasing the thickness of the counterbalancing cables and/or the number thereof. More or larger counteracting cables are still easier to transport, lighter and take up less workspace than when using more or larger counterweights, as is done in the state of the art.
[0015] In yet another embodiment, the lifting crane comprises a first boom, movably supported by the jack-up offshore platform at its lower end, and a second boom, hingedly connected to the first boom, for holding the load. This allows for a more flexible lifting crane, as loads can be lifted higher, without a longer first boom. As a result, transport of the lifting crane with higher capacity in terms of height to and from the platform is still easy to perform.
[0016] Even more preferably, the lifting crane comprises a first boom, movably supported by the jack-up offshore platform at its lower end, and a third boom, provided to space apart the counterbalancing cable and the first boom. Connecting the counterbalancing cable indirectly to the first boom by a third boom enlarges the effective arm of the counterbalancing force and thereby the couple exerted about the first boom. As a result, higher loads can be lifted and/or the at least one counterbalancing cable as well as the first and second connection means can be designed more lightweight, which results in cheaper transport of the lifting crane.
[0017] The invention also provides a jack-up offshore platform comprising connection means for part of the counterbalancing means of a lifting crane. The jack-up offshore platform according to the invention allows for supporting a lifting crane without a counterweight, and thus can be designed smaller or may provide an increased workspace of the jack-up offshore platform.
[0018] The invention also relates to a method for repositioning a load from a jack-up offshore platform by a lifting crane provided with counterbalancing means for counterbalancing the load. The method comprises connecting a part of the counterbalancing means to the platform in a first connection position; lifting the load whereby the counterbalancing means counterbalance the load, positioning the load such that the counterbalancing means are essentially unloaded; disconnecting the counterbalancing means from the first connection position; repositioning the load such that the lifting crane remains in equilibrium; connecting the counterbalancing means to a second connection position, and repositioning the load whereby the counterbalancing means counterbalance the load, and unloading the load. The advantages of the method have already been elucidated in the context of describing the jack-up offshore platform above, and will not be repeated here.
[0019] The invention finally relates to the use of a jack-up offshore platform according to the invention for assembling and servicing structures at sea. Especially when transport of a lifting crane is needed the invention is advantageous, as no or at least a smaller counterweight is needed. In particular assembling high structures, such as wind turbines, and/or heavy structures can be performed more easily with the jack-up offshore platform according to the invention.
[0020] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention will now be explained in more detail with reference to the drawings, without however being limited thereto and wherein:
[0022] FIG. 1 shows an embodiment of the jack-up offshore platform according to the invention in side view; and
[0023] FIG. 2 shows a schematic top view of another embodiment of a jack-up offshore platform according to the invention.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1 , a jack-up offshore platform 1 according to the invention is shown, located at sea nearby a semi-finished wind turbine 100 , which is fixed by foundations 103 to a base 4 . The jack-up offshore platform comprises supports 2 , fixed by foundations 3 to the base 4 , and a work deck 5 . A lifting crane 10 is positioned on the work deck 5 . The lifting crane 10 comprises a support 11 , which allows for rotation of the lifting crane 10 relative to the jack-up offshore platform 1 about a vertical axis 12 . The lifting crane furthermore comprises a frame 13 . The frame 13 hingedly supports a first boom 14 and a second boom 15 . A third boom 16 and a fourth boom 17 are hingedly supported nearby the top 14 a of the first boom 14 . A load 18 , supported by a cargo ship 19 , is connected to holding means 20 of the lifting crane 10 . A lifting cable 21 is at a first end 21 a connected to the third boom 16 , guided over pulleys 22 and connected to a winch 23 at a second end 21 b . The winch 23 is connected to the first boom 14 by a force sensor, which is not shown.
[0025] A counterbalancing cable 24 is at its first end 24 a connected to a first eyelet 25 a , which first eyelet 25 a is rigidly fixed to the jack-up offshore platform 1 , nearby an edge 1 a of the jack-up offshore platform 1 . The cable 24 is guided over a pulley 26 , fixed to the top 15 a of the second boom 15 and connected to a winch 27 at a second end 24 b . The winch 27 is connected to a force sensor 28 , which force sensor is fixed to the frame 13 of the lifting crane 10 , A first control cable 29 is at its first end 29 a connected to the second boom 15 by a winch, which is not shown, nearby the pulley 26 . At a second end 29 b the first control cable 29 is fixed to an end 17 a of the fourth boom 17 . A second control cable 30 is at its first end 30 a connected to the end 17 a of the fourth boom 17 by a winch 31 . At a second end 30 b the cable 30 is fixed to an end 16 b of the third boom 16 . In addition, the lifting crane 10 comprises a counterweight 32 , which is movably connected to the frame 13 by a support 33 . The support 33 allows displacement the counterweight 32 closer to and further away from the lower end 14 b of the first boom 14 . Preferably, the force sensor 28 is connected to a control system, which controls at least the winches 23 , 27 , 31 as a result of the level of the detected force.
[0026] When lifting the load 18 , the load will exert a couple about a lower end 14 b of the first boom 14 b . Both the counterbalancing cable 24 in cooperation with the first control cable 29 , as well as the counterweight 32 will exert a counterbalancing couple about the lower end 14 b of the first boom 14 . As a result the first boom 14 is in moment equilibrium. If the first boom 14 and the third boom 16 are oriented with higher inclination, the couple exerted about the lower end 14 b of the first boom 14 will decrease. As a result the counterbalancing force in the counterbalancing cable 24 and the first control cable 29 will decrease, and, if the inclination of the first boom 14 and the third boom 16 increase sufficiently, the counterbalancing cable 24 and/or the first control cable 29 may even become slack, as the counterweight 32 is able to counterbalance the decreased couple exerted by the lifted load 18 about the lower end 14 a of the first boom 14 . The counterbalancing cable 24 may now be disconnected from the first eyelet 25 a . With the first boom 14 and the third boom 16 in the inclined orientation, the lifting crane 10 may be rotated about the axis 12 , e.g. by 180°. After connecting the counterbalancing cable 24 to a second eyelet 25 b , the third boom 16 and/or the first boom 14 may be lowered to position the load 18 , e.g. a nacelle, on the semi-finished wind turbine 100 . During lowering the third boom 16 and/or the first boom 14 the counterbalancing force in the counterbalancing cable 24 and the first control cable 29 will increase.
[0027] In another embodiment, the first boom 14 of the lifting crane 10 does not comprise a third boom 16 or a fourth boom 17 . In that case, the first control cable 29 is connected to the top 14 a of the first 14 at its first end 29 a.
[0028] Now referring to FIG. 2 , a top view on another embodiment of the jack-up offshore platform 1 according to the invention is shown. The jack-up offshore platform 1 of FIG. 2 differs from the platform of FIG. 1 in that the first and second eyelets 25 a , 25 b are replaced by first and second bar-guides 25 a , 25 b . The counterbalancing cable 24 is connected to the second bar-guide 25 b at its first end 24 a by a hook 40 . The first boom 14 as well as the third boom 16 is in an almost upright position, wherein the load 18 is counterbalanced by the counterweight 32 . As the counterbalancing cable 24 is connected to the second bar-guide 25 b , both the first boom 14 as well as the third boom 16 may be lowered, wherein during lowering counterbalancing force in the counterbalancing cable 24 will increase. Rotation of the lifting crane 10 about the axis 12 , see also FIG. 1 , without the need of disconnecting and connecting the counterbalancing cable 24 , is made possible, as the curved second bar-guide 25 b allows for sliding of the hook 40 , depending on the orientation of the lifting crane 10 .
[0029] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments and those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
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A jack-up offshore platform, on which is provided a lifting crane for lifting a load, which lifting crane includes structure connectable to the platform for counterbalancing the load. The counterbalancing structure may include at least one counterbalancing cable for operably connecting to the platform. A lifting crane provided with counterbalancing structure connectable to a jack-up offshore platform, and to a method of repositioning a load from a platform.
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BACKGROUND OF THE INVENTION
The invention relates generally to mapping or survey apparatus and methods, and more particularly concerns efficient transmission of survey signals or data from depth level in a borehole or well to the will surface, for analysis, display or recordation; further it concerns efficient transmission of command data from a surface computer unit to the survey tool at depth level in a borehole or well for control of instrumentation operating modes, operating characteristics, or diagnostic purposes; and further it concerns supply of DC power downwardly to the instrumentation via a wireline by which such command signals and survey data or signals may be transmitted upwardly or downwardly respectively.
U.S. Pat. No. 4,459,760 discloses apparatus and methods to transmit sensor data as further disclosed in U.S. Pat. Nos. 3,753,296 and U.S. Pat. No. 4,199,869 that concern the use of angular rate sensors and acceleration sensors in boreholes to derive data usable in determination of borehole azimuth ψ and tilt φ. However, those patents only refer to data transmission in an upward direction in a borehole. U.S. Pat. No. 4,468,863 discloses a method for bidirectional transmission over the wireline so that survey tool operating modes and other characteristics may be altered from the surface when the survey tool is at depth in the well or borehole, however, that patent does not specifically disclose how such data can be communicated to and from the surface of a well, in usable form, and with the unusual advantages of the simple, effective and reliable communication system as disclosed herein.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide a data communication and method and system of simple, effective, reliable, and improved form, for use in a borehole environment, as will appear. Basically, the system includes:
(a) means for suspending said instrumentation in the borehole,
(b) said instrumentation operating to generate analog signals in the borehole,
(c) means responsive to reception of said signals for multiplexing said signals and converting same to digital signals, in the borehole,
(d) means responsive to reception of said digital signals for converting said digital signals to digital signal words,
(e) means in the borehole connected to receive said signal words and produce signal versions thereof for transmission to the surface,
(f) a transmission path operatively connected with said (e) means, for transmitting said signal versions upwardly in the borehole,
(g) means for stripping said signal versions off the transmission path at an upper elevation and processing said signal versions to a form usable in determination of borehole azimuth and/or tilt at the level of said instrumentation in the borehole,
(h) means to generate digital command words,
(i) means at an upper location connected to receive said digital command words and produce signal versions thereof for transmission ownwardly in the borehole, to said instrumentation,
(j) a transmission path for transmitting said command signals to the survey tool,
(k) means for stripping said command signal versions off the (j) transmission path and processing said signal versions to form usable command words for use by said instrumentation in the borehole to control operating modes and other operating characteristics of said instrumentation.
As will be seen, the wireline also transmits power (such as DC power) from a source at the well head to the instrumentation suspended in the borehole; and the instrumentation may include one or more of the following:
(i) angular rate sensor means and acceleration sensor means operated to produce the analog signals and useful in determination of borehole azimuth or tilt;
(ii) temperature sensor means operated to produce the analog signals;
(iii) tubing or pipe collar locater means operated to generate the analog signals as such means is raised or lowered in the borehole.
Typically, the survey method employs apparatus as referred to, with first means for measuring angular rate, and second means for sensing tilt, and a rotary drive for the first and second means, the basic steps of the method including:
(a) operating the drive and the first and second means at a first location in the borehole to determine the azimuthal direction of tilt of the borehole at such location,
(b) then traveling the first and second means and the drive lengthwise of the borehole away from that location, and operating the drive and at least one of the first and second means during such traveling to determine changes in borehole alignment during traveling,
(c) said (a) and (b) steps carried out while the signal versions are passed upwardly and downwardly in the borehole.
Apparatus embodying the survey tool may advantageously comprise:
(N 1 ) first sensor means for measuring angular rate about one or more axes,
(N 2 ) second sensor means for sensing tilt or acceleration along one or more axes,
(N 3 ) rotary drive mens for rotating and controlling said first and second means in the borehole, and
(N 4 ) circuit means operatively connected between said second means and rotary drive means for:
(i) allowing the drive to rotate the first and second means at a first location in the borehole to determine the azimuthal direction of tilt of the borehole at said location, and
(ii) causing the drive to maintain an axis defined by said second means at a predetermined orientation relative to horizontal during traveling of the apparatus in the borehole, whereby at least one of the first and second means may be operated during such traveling to determine changes in borehole alignment along the borehole length. These and other objects and advantage of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a circuit block drawing of a communications system, embodying the invention;
FIG. 2 is a circuit block drawing of the power supply--FSK receiver as shown in FIG. 1;
FIG. 3 is a circuit block drawing of the communications board as shown in FIG. 1;
FIGS. 4a and 4b show details of FSK receiver and modulator blocks employed in FIG. 1, and also an uphole power supply;
FIG. 5 shows details of FSK receiver power supply;
FIGS. 6a and 6b show details of a communications board block shown on FIG. 1;
FIG. 7 is an elevation taken in section to show one form of instrumentation employing the invention;
FIG. 7a is a circuit schematic for gimbal control;
FIG. 8 is an elevation showing use of the FIG. 7 instrumentation in multiple modes, in a borehole; and
FIG. 9 is a block diagram.
DETAILED DESCRIPTION
Referring to FIG. 7, a carrier such as elongated housing 10 is movable in a borehole indicated at 11, the hole being cased at 11a. Means such as a cable to travel the carrier lengthwise in the hole is indicated at 12. A motor or other manipulatory drive means 13 is carried by and within the carrier, and its rotary output shaft 14 is shown as connected at 15 to an angular rate sensor means 16. The shaft may be extended at 14a, 14b and 14c for connection to first acceleration sensor means 17, second acceleration sensor means 18, and a resolver 19. The accelerometers 17 and 18 can together be considered as means for sensing tilt. These devices have terminals 16a-19a connected via suitable slip rings with circuitry indicated at 29 carried within the carrier (or at the well surface, if desired).
Circuitry 29 typically may include a feed back arrangement as shown in FIG. 7a and incorporating a feed back amplifier 21, a switch 22 having arm 22a and contacts 22b and 22c, and switch actuator 23a. When the actuator closes arm 22a with contact 22c, the resolver 19 is connected in feed back relation with the drive motor 13 via leads 24, 25 and 26, and amplifier 21, and the apparatus operates for example as described in U.S. Pat. No. 3,753,296 to determine the azimuthal direction of tilt of the borehole at a first location in the borehole. See for example first location indicated at 27 in FIG. 8. Other U.S. Patents describing such operation are U.S. Pat. Nos. 4,199,869, 4,192,077 and 4,197,654. During such operation, the motor 13 rotates the sensor 16 and the accelerometers either continuously, or incrementally.
The angular rate sensor 16 may for example take the form of one or more of the following known devices, but is not limited to them:
1. Single degree of freedom rate gyroscope
2. Tuned rotor rate gyroscope
3. Two axis rate gyroscope
4. Nuclear spin rate gyroscope
5. Sonic rate gyroscope
6. Vibrating rate gyroscope
7. Jet stream rate gyroscope
8. Rotating angular accelerometer
9. Integrating angular accelerometer
10. Differential position gyroscopes and platforms
11. Laser gyroscope
12. Fiber Optic Gyroscope
13. Combination rate gyroscope and linear accelerometer
Each such device may be characterized as having a "sensitive" axis, which is the axis about which rotation occurs to produce an output which is a measure of rate-of-turn, or angular rate ω. That value may have components ω 1 , ω 2 and ω 3 in a three axis co-ordinate system. The sensitive axis may be generally normal to the axis 20 of instrument travel in the borehole, or it may be canted at some angle α relative to axis 20 (see canted sensitive axis 16b in FIG. 7).
The acceleration sensor means 17 may for example take the form of one or more of the following known devices; however, the term "acceleration sensor means" is not limited to such devices:
1. one or more single axis accelerometers
2. one or more dual axis accelerometers
3. one or more triple axis accelerometers
Examples of acceleration sensors include the accelerometers disclosed in U.S. Pat. Nos. 3,753,296 and 4,199,869, having the functions disclosed therein. Such sensors may be supported to be orthogonal or canted ast someangle relative to the carrier axis. They may be stationary or carouseled, or may be otherwise manipulated, to enhance accuracy and/or gain an added axis or axes of sensitivity. In this regard the sensor 17 typically has two input axes of sensitivity. A canted axis of sensitivity is seen at 17b in FIG. 7. The axis of sensitivity is the axis along which acceleration measurement occurs.
The second accelerometer 18 may be like accelerometer 17, excepting that its input axis 23 is typically orthogonal to the input axes of the sensor 16 and of the accelerometer 17. During travel mode, i.e., lifting or lowering of the carrier 10 in the borehole 11, indicated at 27' in FIG. 8, the output of the second accelerometer 18 is connected via lead 30 (in FIG. 7a, contact 22b, switch arm 22a, and servo amplifier 21 to the drive motor 13). The servo system causes the motor to rotate the shaft 14 until the input axis 23 of accelerometer is horizontal (assuming that the borehole has tilt as in FIG. 8). Typically, there are two such axis 23 horizontal positions, but logic circuitry in the servo-system may for example cause rotation until the output of acceleration sensor 18 is positive. Amplifier 21 typically includes signal conditioning circuits 21a, feedback compensation circuits 21b, and power amplifier 21c driving the motor M shown at 13.
If, for example, the borehole is tilted 45° due East at the equator, acclerometer 17 would register +0.707 g or 45°, and the angular rate sensor 16 would register no input resulting from the earth's rate of rotation. If, then, the apparatus is raised (or lowered) in the borehole, while input axis 23 of accelerometer 18 is maintained horizontal, the output from accelerometer 17 would remain constant, assuming the tilt of the borehole remains the same. If, however, the hole tilt changes direction (or its elevation axis changes direction) the accelerometer 17 senses such change, the amount of such change being recorded at circuitry 29, or at the surface. If the hole changes its azimuth direction during such instrument travel, the sensor 16 senses the change, and the sensor output can be integrated as shown by integrator circuit 31 in FIG. 7a (which may be incorporated in circuitry 29, or at the surface) to register the angles of azimuth change. The instrumentation can be traveled at high speed along the tilted borehole while recording such changes in tilt and azimuth, to a second position (see position 27" in FIG. 8. At that position, the instrumentation is again operated as at 27 (mode #1) to accurately determine borehole tilt and azimuth--essentially a re-calibration step. Thus, the apparatus can be traveled hundreds or thousands of feet, operating in mode #2 as described, and between calibration positions at which travel is arrested and the device is operated in mode #1.
The above modes of operation are typically useful in the tilted portion of a borehole; however, normally the main i.e. lower portion of the oil or gas well is tilted to some extent, and requires surveying. Further, this part of the hole is typically at relatively high temperature where it is desirable that the instrumentation be moved quickly to reduce exposure to heat, the invention lending itself to these objectives. In the vertical or near vertical (usually upper) portion of the hole, the instrumentation can revert to mode #1 operation, at selected positions, as for example at 100 or 200 feet intervals. In a near vertical hole, azimuth contributes very little to hole position computation, so that mode #1 positions can be spaced relatively far apart, and thus this portion of the hole can be mapped rapidly, as well.
The operation of the survey tool as described above requires that the link for communications provide as a minimum:
1. Transmission of command signals from surface equipment 300 to the tool to change the mode of operation from the periodic measurement mode to the travel mode. This transition is controlled by switch 22 shown in FIG. 7a. To command the periodic measurement mode, switch 22 closes the contact 22a to 22c so that wire 24 from resolver contact 19ais connected to wire 25 and the servo control amplifier 21. To command the travel mode, switch 22 closes contact 22a to 22b so that the signal from accelerometer A2, 18, available at contact 18a is connected through wires 30 and 25 to the servo amplifier 21.
2. Transmission of data signals from gyroscope G, 16, and accelerometer A1, 17 to the surface.
Other useful and desirable command signals that may be transmitted from the surface to the survey tool at the lower level in the borehole include:
1. Commands to change the electronics gains, frequency response and scaling of elements of the electronics, 29, associated with accelerometer A1 and gyroscope G.
2. Commands to change the timing and number or positions, used in the periodic measurement mode of operations such that survey time and accuracy can be optimized by using longer dwell times when disturbances are present and shorter times when there are no significant disturbances.
3. Commands to control power so that minimum power operation can be achieved. Such commands may control various heater operations and provide increased power capability to the gimbal control servo only when required for high load conditions. (See heater 105a in FIG. 1).
4. Commands to alter the selection and timing of data to be transmitted from the survey tool to the surface. Such commands can be used to require the survey tool to provide specific responses to diagnostic test requests, and to send auxiliary data.
Other useful and desirable data that may be transmitted to the surface from the survey tool in the borehole include:
1. The output of the resolver, 19, on the gimbal axis;
2. Multiple temperature signals from points within the survey tool; (see temperature sensor 299 in FIG. 1).
3. Diagnostic data such as various power supply voltages or control electronics responses to stimuli received in commands from the surface;
4. Mode response signals to assure that the survey tool has received commands from the surface and is operating in the mode commanded.
The required transmission paths for signals from the surface to the survey tool and from the survey tool to the surface can be provided by a variety of methods. Such methods include:
1. Multiconductor (more than 2) wirelines with separate paths for various signals and commands;
2. Two conductor wirelines in which the bi-directional paths are carried by the same pair of wires. In this case, as in the case of multiple conductor wirelines, power to operate the survey tool may also be supplied over the same conductors as those used for data and command transmission;
3. Electromagnetic transmission through the earth between the surface and the survey tool;
4. Transmission of acoustic pressure waves through the drilling fluids in the borehole. Such waves may be created by throttling valves of various design that modulate the fluid flow.
5. Tranmission by modulation of light waves carried by a fiber optic element in the borehole. Such a fiber optic element may, or may not, be associated with one of the wireline approaches described above.
For almost all of the transmission approaches described above, some means of multiplexing the transmission path is required to control the bi-directional transmission so that they do not interfere with each other. Methods which may be used include:
1. Frequency Division Multiplexing
2. Time Division Multiplexing
3. Pulse position Multiplexing
In addition to the problem of multiplexing the transmission path for the bi-directional transmissions, further multiplexing is generally required to accomodate the multiple commands or data required for transmission in each direction.
For purposes of illustrating one particular embodiment of a two-way communication system for a high speed survey tool, a system is described which selects from the above options:
1. A two conductor wireline also carrying DC power as the transmission path.
2. Time division multiplexing of the transmission path such that the surface equipment transmits one command word downwardly to the survey tool and the survey tool responds by transmitting the commanded data words upwardly to the surface equipment.
3. Both command and data words are transmitted as serial digital words in a bit-by-bit serial form using the standard RS232 format for serial digital data.
4. The serial digital bit stream is encoded onto the wireline by frequency shift keying (FSK) such that a digital one bit is represented by one carrier frequency and a digital zero bit is represented by another carrier frequency.
Referring now to FIG. 1, analog voltages from the tool sensors and electronics are supplied on leads 112 to the analog data converter board 103 for multiplexed analog to digital conversion. Also, the analog output signals of the angular rate sensor G, 16 and the first acceleration sensor A1, 17 are supplied on leads 113 to the V/F (Voltage-to-frequency) converter board, 104 for conversion to digital representations of the time integral of each signal. The integration and conversion of signals within board 104 are carried out by well-known means by using a voltage-to-frequency converter and a digital counter. Within board 103, the analog signals are multiplexed in time sequence and converted to digital output by a well-known successive approximation register parallel output analog-to-digital converter. The outputs at boards 103 and 104 are available to the digital tool data bus, 110, and are placed on the bus and presented to the communications board, 102, at the times that that board wishes to receive such data. Also, the communications board, 102, has a digital command bus, 111, by which it can transmit command data to tool modules such as diagnostic circuits, 105, the gimbal control servo, 106, the gyro loop board, 107, and the gyro wheel supply, 108. Any other module or board that is to receive command data can be connected to the same bus, 111. When the communication board, 102, has command data for any board or module, the communications board places the command data on the bus and addresses the proper module to read its command from the bus. Thus the communications board can transmit any command that it has received from the surface equipment to the proper module. See equipment 300 in FIG. 7.
The remainder of FIG. 1 shows the exchange of data and commands between the communications board 102, and the surface computer, 155. Since, as previously stated, this particular embodiment of a two-way communications system uses time division multiplexing to control the bi-directional transmission the process begins with a command generated by the computer, 155. Such command may be for example a request for data from the survey tool or a mode of operation command. Such computer command is sent to the uphole computer interface, 150, in a standard RS232 format over leads 156. Within the uphole computer interface, 150, the serial command is converted to a frequency-shift-keyed (FSK) modulation and placed on lead 141 which is connected to the inner conductor of a two-conductor wireline. The outer conductor, 144, of the wireline serves as a ground signal return path. Also connected to lead 141 through inductor L2, 150, and lead 157 is the uphole power supply 146 that provides a direct current power supply to the survey tool. Inductor L2 blocks the FSK signal from the power suppy so it must flow through the wireline to the survey tool. At the survey tool end of the wireline the combined FSK signal arrives at inductor L1, 109, and lead 158. The direct current power supply output goes through L1, 109 and lead 110a to the power supply--FSK receiver for use in generating secondary power supply levels. The FSK signal is blocked by inductor L1, 109, and thus enters the power supply--FSK receiver, 100 via lead 158. Within the power supply--FSK receiver module, the command signal is converted from FSK format to a serial digital signal at CMOS voltage levels for transmission of the command to the communications board, 102, by means of lead 101a. Since it was assumed that the command was a request for data, the communications board gates in the commanded data from the digital data bus, 110, and combines it in the desired serial form, converts it to FSK, and returns it to the power supply--FSK receiver, 100 by lead 101b. The FSK signal is used to modulate a current flowing in lead 158 which is connected to the wireline lead 141. Again, since inductor L1 and inductor L2, 109 and 150 respectively, block the FSK signal current, it must flow into the uphole computer interface, 150. Within 150 the FSK signal is converted to a standard RS232 serial interface signal and transmitted to the computer, 155, by means of lead 156. Since the computer, 155, initiated the total sequence by requesting data, the computer has been waiting for data to return, and therefore recognizes the data stream as the response to its requests and uses the data as the computer program specifies. When the returning data includes multiplexed A/D converter data, bits are included in the received message to identify which data is in each such word.
Another function for the uphole computer, 155, is to control or adjust the uphole power supply, 146. This is done by the computer generating a power control signal which is sent to the uphole computer interface, 150, by the RS232 digital interface connection 156. The uphole computer interface, 150, in turn converts the power control signal to the form required by the uphole power supply, 146. This control signal is transmitted by lead. The uphole power supply, 146, uses this input signal on lead 147 to adjust the output voltage or current at lead 157 to the desired valve.
FIG. 2 shows a block diagram of the power supply--FSK receiver, 100, and FIG. 5 shows a schematic of it. Block 114 is the tool power supply and is of conventional design. The FSK receiver, 115 is a type XR -2211 FSK Demodulator/Tone Decoder manufactured by EXAR, Inc., Sunnyvale, California. The current modulator 116 is a single high-voltage transistor controlled by the signal input on line 101b. FIG. 3 shows a block diagram of the communications board, 102, and FIG. 6 is a schematic of it. Control circuits, 117 generate the timing and control signals 118, 126, and 127 that control the communications process. The principal components other than the control circuitry are the UART, (Universal asynchronous receiver transmitter) 119, the command word latch, 122, and the voltage controlled oscillator, 120. The UART, of type 6402 manufactured by Harris Semiconductor Inc., Melbourne, Fla., can, under control of signals 126, accept a serial input at 128 from lead 125 to provide parallel outputs at 130 on bus 121 or accept parallel inputs at 131 on bus 110 and provide a serial output at 132 on lead 123. When serial inputs are to be accepted at 128, the gate, 118 is enabled so that the signal on lead 101a may be coupled to lead 125. When control circuits activate lead 127 to the command word latch , 122, the input data which has passed from serial input at 128 to parallel output at 130 and via bus 121 are coupled to the output digital command bus 111 and held there until a subsequent command is received.
When digital data is to be transmitted to the surface, the control circuits, 117, initiate actions that cause successive parallel digital data words to be presented on the digital tool data bus, 110, which are in turn inputted to the UART at 131 and then outputted from the UART in serial form at 132 for transmission by lead 123 to the voltage controlled oscillator, 120. The voltage controlled oscillator may be an XR -2207 manufactured by EXAR, Inc., of Sunnyvale, Calif. The voltage controlled oscillator provides a frequency-shift-keyed, FSK, output at 101b which is modulated onto the wireline current by the power supply--FSK receiver, 100 and outputted on lead 158 as previously described to the wireline, 141, and the uphole computer interface, 150.
FIG. 4 is a schematic of the uphole computer interface 150. It contains an XR -2207 and and XR -2211 to perform the same functions as they do in the power supply--FSK receiver, 100, and the communications board, 102.
Note also, in FIG. 1, the computer peripherals, indicated at 159.
FIG. 9 indicates, the provision of alternate or auxiliary transmission paths, both up and down, between surface equipment 300, as described, and down-hole equipment 301, as described. See for example equipments depicted in FIG. 1. The alternate transmission paths, indicated generally at 302, may take one of the following forms:
(a) means to propagate electromagnetic wave modulations (signals) through the earth between 300 and 301 (and using appropriate couplers or transducers 303 and 304 between 302 and 15, and between 302 and 100),
(b) means to propagate light wave modulations (signals) along a fiber optics path 302 in the borehole between 300 and 301 (and using appropriate couplers or transducers 303 and 304 between 302 and 150, and between 302 and 100),
(c) means to propagate acoustic pressure modulations through a drilling fluid path (indicated at 302) in the borehole between 300 and 301 (and using appropriate couplers or transducers 303 and 304 between 302 and 150, and between 302 and 150).
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The invention relates generally to mapping or survey apparatus and methods, and more particularly concerns efficient transmission of survey signals or data from depth level in a borehole or well to the well surface, for analysis, display or recordation; further it concerns efficient transmission of command data from a surface computer unit to the survey tool at depth level in a borehole or well for control of instrumentation operating modes, operating characteristics, or diagnostic purposes; and further it concerns supply of DC power downwardly to the instrumentation via a wireline by which such command signal and survey data or signals may be transmitted upwardly or downwardly respectively.
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This is a divisional of application Ser. No. 07/782,518, filed Oct. 25, 1991.
BACKGROUND OF THE INVENTION
The present invention relates to the field of angioplasty. In particular, the present invention relates to a balloon catheter which permits prolonged inflation of the balloon within a blood vessel, such as a coronary artery, without blocking blood flow by utilizing passive perfusion.
Angioplasty has gained wide acceptance as an efficient, effective and alternative method of treating constrictions caused by undesirous tissue growth or lesions on the inner walls of the blood vessels. Such tissue growth or lesions cause a narrowing of the blood vessels called a "stenosis" which severely restricts or limits the flow of blood. In the most widely used form of angioplasty, a dilatation catheter, which has an inflatable balloon at its distal end, is guided through the vascular system. With the aid of fluoroscopy, a physician is able to position the balloon across the stenosis. The balloon is then inflated by applying fluid pressure through an inflation lumen of the catheter to the balloon. Inflation of the balloon stretches the artery and presses the stenosis-causing lesion into the artery wall to remove the constriction and re-establish acceptable blood flow through the artery.
One disadvantage of many balloon catheters of the prior art is the complete occlusion of the blood vessel that results while the balloon is inflated. Prolonged complete blockage of a blood vessel poses serious risk of damage to the tissue, downstream from the occlusion, which is deprived of oxygenated blood. This consequence poses a severe limitation on the length of time the balloon can remain expanded within an artery to effectively treat the stenosis. Longer inflation times increase the probability that the artery will remain open after the catheter is removed.
Various methods for providing passive perfusion of blood through or past the inflated balloon are found in the following prior art references: Guiset U.S. Pat. No. 4,183,102; Baran et al. U.S. Pat. No. 4,423,725; Sahota U.S. Pat. No. 4,581,017; Hershenson U.S. Pat. No. 4,585,000; Horzewski et al. U.S. Pat. No. 4,771,777; Mueller et al. U.S. Pat. No. 4,790,315; Songer et al. U.S. Pat. No. 4,892,519; Goldberger U.S. Pat. No. 4,909,252; Sogard et al. U.S. Pat. No. 4,944,745; Sahota U.S. Pat. No. 4,983,167 and European Patent Application 0 246 998; Boussignac et al. U.S. Pat. No. 5,000,734; Patel U.S. Pat. No. 5,000,743; and Bonzel U.S. Pat. No. 5,002,531.
A disadvantage of prior tubular-shaped, perfusion balloon catheters is the additional manufacturing steps necessary to connect outer and inner skins of the balloon to create a perfusion passage between the up-stream side of the balloon and the down-stream side of the balloon. Another disadvantage is the risk of interrupted integrity of the balloon at the seams created by the connection of outer and inner skins. Additionally, tubular-shaped balloons of the prior art are relatively stiff due to the seams and internal support structures. There is still a need in the field, therefore, for a balloon catheter with good flexibility and a perfusion cavity which, when inflated within an artery, permits good arterial blood flow, and yet is capable of being manufactured with relative ease and minimal cost.
SUMMARY OF THE INVENTION
The present invention is a perfusion balloon catheter which includes a shaft with a shaft lumen, a support structure which extends distally from a distal end of the shaft, and a balloon formed by a flexible, inflatable tube carried by the support structure. The perfusion balloon catheter of the present invention uses a coiled support member, as the support structure, to hold a series of adjacent loops of the flexible tube and thereby form a composite balloon having a tubular shape. A distal end of the coiled, flexible tube is sealed, and a proximal end of the flexible tube is in fluid communication with the shaft lumen.
The balloon formed by the tube loops, when inflated, has an outer surface which interacts with the wall of the artery, and an inner surface which defines a passive perfusion passage. The present invention permits prolonged inflation of the balloon during a dilatation procedure while reducing the risk of tissue damage distal to the balloon location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a first embodiment of the perfusion balloon catheter of the present invention.
FIG. 2 is a side view, partially in section, of the distal end of the catheter of FIG. 1.
FIG. 3 is a longitudinal sectional view of the balloon assembly.
FIG. 4 is a sectional view of the balloon assembly taken along line 4--4 of FIG. 2.
FIG. 5 is a cross sectional view of the balloon assembly taken along line 5--5 of FIG. 3.
FIG. 6 is a cross sectional view of the balloon assembly taken along line 6--6 of FIG. 3.
FIG. 6A is a view of the balloon assembly of FIG. 6 shown with a dilatation balloon.
FIG. 7 is an enlarged side view, partially in section, of a second embodiment of the present invention.
FIG. 8 is a longitudinal sectional view of the balloon assembly of FIG. 7.
FIG. 9 is an end view of the balloon assembly taken from line 9--9 of FIG. 7.
FIG. 10 is a side view, partially in section, of a third embodiment of the present invention.
FIG. 11 is a longitudinal sectional view of the balloon assembly shown in FIG. 10.
FIG. 12 is an end view of the balloon assembly taken from line 12--12 of FIG. 10.
FIG. 13 is an enlarged side view, partially in section, of a fourth embodiment of the present invention.
FIG. 14 is a longitudinal sectional view of the balloon assembly of FIG. 13.
FIG. 15 is an end view of the balloon assembly taken along line 15--15 of FIG. 13.
FIG. 16 is an enlarged side view, partially in section, of a fifth embodiment of the present invention.
FIG. 17 is a longitudinal sectional view of the balloon assembly of FIG. 16.
FIG. 18 is a side view of the coiled support member of the balloon assembly.
FIG. 19 is an enlarged side view of the coiled support member, mandril and initial position of the flexible tube.
FIG. 20 is a side view of the coiled support member, mandril, and flexible tube looped once around the coiled support member and mandril.
FIG. 21 is a side view of the coiled support member, mandril, and series of loops of the flexible tube around the coiled support member and mandril.
FIG. 22 is a side view of the coiled support member, mandril, and tube loops with the flexible tube inflated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. The First Embodiment (FIGS. 1-6)
FIG. 1 shows a side view of perfusion balloon catheter 10, which includes manifold 12, elongated tubular shaft 14, balloon assembly 16, and guide wire 18.
Manifold 12 is located at the proximal end of catheter 10. Manifold 12 includes inflation port 20, through which inflation fluid is provided to and withdrawn from inflatable multiple-loop composite balloon 22 of balloon assembly 16.
Elongated tubular shaft 14 of catheter 10 is a single lumen tube having its proximal end 24 connected to manifold 12 and its distal end 26 connected to balloon 22 of balloon assembly 16. Shaft lumen 27 (shown in FIG. 2), which extends through shaft 14 from proximal end 24 to distal end 26, is in fluid communication with inflation fluid port 20 of manifold 12, and also with balloon 22 of balloon assembly 16.
In preferred embodiments, shaft 14 possesses the qualities of compression rigidity along the longitudinal axis, which facilitates advancement of catheter 10 through the vascular system, and good distal flexibility, which enhances maneuverability of catheter 10 through directional changes of the vascular system. These qualities are achievable in a variety of ways. In one embodiment, the proximal region of shaft 14 is a stainless steel hypo tube, and the distal region is a polyethylene tube which is connected to the proximal region. In another embodiment, shaft 14 is formed from a single piece of polymer tubing with a proximal region that has an outer and inner diameter larger than an outer and inner diameter of a distal region.
Guide wire 18 is external to and proximate to shaft 14 and runs the entire length of catheter 10. Guide wire 18 ends, at its distal end, with guide wire spring tip 18A. Catheter 10 is movable longitudinally over guide wire 18.
In FIG. 2, an enlarged side view of distal end 26 of shaft 14 and balloon assembly 16 is shown. Balloon assembly 16 includes coiled support member 28, inflatable tube 30 (which forms balloon 22) and retainer 32.
Coiled support member 28 has its proximal end mounted within flared distal end 26 of shaft 14 and extends distally from distal end 26. Adjacent coils of coiled support member 28 are spaced apart to hold tube 30 in a looped configuration along coiled support member 28. The distal end of coiled support member 28 terminates in a series of reduced diameter tight coils which form spring tip 34 of catheter 10. Coiled support member 28 is made of any flexible material capable of being formed into a coil, such as a metal wire or ribbon. Alternatively, other open support structures, such as an open-braided/strand-woven tube, can also hold tube 30 in a looped configuration.
Flexible tube 30 is a flexible, inflatable polyolefin copolymer material, such as Surlyn 8527 from Dupont, and cooperates with coiled support member 28 to form balloon 22. As shown in FIGS. 2-4, proximal end 36 of flexible tube 30 is located within flared distal end 26 of shaft 14. Distal end 38 of flexible tube 30 is sealed and is located near the distal end of coiled support member 28. Tube lumen 40 extends through tube 30 from proximal end 36 to distal end 38.
Proximal neck region 42 of flexible tube 30 is located within flared distal end 26, and has a smaller outer diameter and larger wall thickness than the remainder of tube 30. Tube 30 extends through the longitudinal interior of coiled support member 28 until tube 30 passes out of flared distal end 26 of shaft 14. Adhesive 44 fills a portion of the cavity within flared distal end 26 to attach the proximal portions of coiled support member 28, tube 30 and retainer 32 to shaft 14.
In the embodiment shown in FIGS. 2-6, the portion of tube 30 which extends distally out of flared distal end 26 is threaded between every other coil of coiled support member 28 and passes under upper extent 28A of every other coil of coiled support member 28 to form a series of inflatable, side-by-side loops 46. When inflation fluid from shaft lumen 27 is supplied to tube lumen 40, loops 46 inflate and cooperate to form balloon 22 (as illustrated in FIGS. 2-6).
Loops 46 are captured within coiled support member 28 by retainer 32. Retainer 32 is preferably a wire which extends from shaft 14 through coiled support member 28 and spring tip 34. Proximal end 32A of retainer 32 lies within shaft 14 and extends proximal to flared distal end 26 to shaft 14. Distal end 32B of retainer 32 is attached to distal end 34A of spring tip 34. Retainer 32 is positioned between the bottom of each loop 46 and lower extents 28B of the coils of coiled support member 28. Loops 46, therefore, are captured between retainer 32 and upper extents 28A of the coils. Retainer 32 thus serves to retain each tube loop 46 in a fixed position along coiled support member 28 while providing structural support to balloon assembly 16 at the distal end of catheter 10.
In order to ensure that loops 46 act as a unit, the tops of loops 46 are connected together by adhesive 48. Alternatively, loops 46 can be fixed together by applying a flexible coating over loops 46. The plurality of tube loops 46 define a generally tubular shaped balloon 22 having a composite outer surface 50 and a composite inner surface 52. Outer surface 50 applies a radially outward force to an artery wall when balloon 22 is inflated. Inner surface 52 defines perfusion passage 54 which extends through the length of balloon 22.
As shown in FIG. 6A, dilatation balloon D is coincidentally disposed at distal end 26 of shaft 14, within the perfusion passage 54 to enhance the radial outward force of outer surface 50. Dilatation balloon D (which is similar to a balloon of a dilatation balloon catheter shown in U.S. Pat. No. 4,943,278) has outer surface O, core wire w and inner cavity C which is in fluid communication with lumen 27 of shaft 14. Alternatively, dilatation balloon D can be disposed at a distal end of a catheter shaft which has separate inflation lumens, or at a distal end of a second catheter shaft. Dilatation balloon D is inflated with balloon 22 such that outer surface O of dilatation balloon D contacts inner surface 52 of perfusion passage 54, causing an outward radial force of dilatation balloon D to be transmitted to composite outer surface 50 of balloon 22. With the artery wall expanded by the composite outward radial force of balloon 22 and dilatation balloon D, dilatation balloon D is deflated to permit the flow of blood through perfusion passage 54 while balloon 22 remains inflated within the artery. Alternatively, dilatation balloon D may be moved proximal to balloon 22 to permit the flow of blood through perfusion passage 54.
The cross-sectional area of perfusion passage 54, which ranges from about 16 to about 44 percent of the cross-sectional area of composite outer surface 50, permits a flow of blood through balloon 22 while balloon 22 is inflated within the artery. Perfusion passage 54 is large enough to coincidentally serve as a guide passage for guide wire 18. Because balloon 22 is very short compared to the total lengths of catheter 10 and guide wire 18, the use of perfusion passage 54 as a guide passage permits rapid exchange of catheter 10 over guide wire 18 while guide wire 18 remains in place in the artery with the distal end of guide wire 18 in position across the stenosis.
FIG. 5 shows a cross-sectional view of a proximal portion of balloon assembly 16. For purposes of illustration, adhesive 44 is not shown in FIG. 5. Coiled support member 28 is shown within flared distal end 26. Flexible tube 30 is positioned within coiled support member 28. Retainer 32 is positioned below tube 30 and between coiled support member 28 and tube 30.
As illustrated in both FIGS. 5 and 6, inner surface 52 of loop 46 defines perfusion passage 54, which also serves as a guide passage for guide wire 18. Guide wire 18 has an unrestricted range of motion within the entire perfusion passage 54. Perfusion passage 54 readily provides an avenue for blood flow during a dilatation procedure while coincidentally serving as a passage for guide wire 18.
Catheter 10 shown in FIGS. 1-6A is capable of being used with guide wire 18 (over-the-wire rapid exchange use) or without guide wire 18 (stand-alone use as a fixed wire catheter) . Without guide wire 18, spring tip 34 permits use of catheter 10 as a fixed wire catheter.
2. The Second Embodiment (FIGS. 7-9)
FIGS. 7-9 show a second embodiment of the present invention which is generally similar to the first embodiment shown in FIGS. 1-6. Similar reference characters are used to designate similar elements.
This second embodiment differs from the first embodiment in that distal region 70 of flexible tube 30 transitions back within coiled support member 28 at the distal end of balloon 22. Coiled support member 28 extends distally beyond balloon 22, as shown in FIGS. 7 and 8. Distal region 70 of tube 30 extends distally through the longitudinal interior of several coils of coiled support member 28, and then extends out coiled support member 28 to form guide loop 72 at the distal end of coiled support member 28. Distal end 38 of tube 30 is bound to a distal-most coil of coiled support member 28 to seal the distal end of tube lumen 40.
Guide loop 72 has inner and outer diameters which are smaller than the inner and outer diameters of loops 46 of balloon 22. Guide loop 72 defines distal guide passage 74 for guide wire 18.
Distal guide passage 74 is generally aligned with perfusion passage 54 of balloon 22. Guide wire 18 extends through perfusion passage 54 and distal guide passage 74 and out the distal end of guide loop 72. The reduced dimensions of guide loop 72 relative to loops 46 restricts the range of transverse movement of guide wire 18 and directs guide wire 18 closer to catheter spring tip 34.
3. The Third Embodiment (FIGS. 10-12)
FIGS. 10-12 show a third embodiment of the present invention. This third embodiment is similar to the embodiment shown in FIGS. 1-6 except that catheter spring tip 34 is extended and guide wire support sleeve 100 is mounted on spring tip 34. In FIGS. 10-12, reference characters similar to those used in FIGS. 1-6 are used to designate similar elements.
Guide wire support sleeve 100 is positioned over spring tip 34 with the distal end of guide wire support sleeve 100 generally aligned with distal end 34A of spring tip 34. An inner surface of guide wire support sleeve 100 is bonded by adhesive 102 to spring tip 34. Guide passage 104 of sleeve 100 is located distally of perfusion passage 54. Guide wire 18 extends through perfusion passage 54 and guide passage 104 and out the distal end of guide wire support sleeve 100.
4. The Fourth Embodiment (FIGS. 13-15)
FIGS. 13-15 show a fourth embodiment of the present invention. This embodiment differs from previous embodiments primarily by virtue of guide wire tube 120, which extends from distal end 26 of shaft 14 through coiled support member 28'. Coiled support member 28', therefore, is larger in diameter than coiled support member 28 of the previous embodiments.
Flexible tube 30 is made of a flexible tubular material and cooperates with coiled support member 28' to form balloon 22. Flexible tube 30 includes proximal neck region 42, which is bonded within distal end 26 of shaft 14 by adhesive 44. Tube lumen 40 of flexible tube 30 is in fluid communication with shaft lumen 27.
Flexible tube 30 extends out of distal end 26 and into coiled support member 28'. Tube 30 forms a plurality of inflatable loops 46 which are held in place between coiled support member 28' and retainer 32. Loops 46 cooperate to form inflatable balloon 22.
Guide wire tube 120 has a length approximately equal to the length of coiled support member 28', and is positioned within coiled support member 28' below tube 30 and adjacent to retainer 32. The lower outer surface of guide wire support tube 120 contacts the lower inner surface of coiled support member 28'. Guide wire tube 120 and retainer 32 are maintained within coiled support member 28' by a bonding material, such as epoxy. The inner diameter of guide wire tube 120 defines guide wire lumen 122 for passage of guide wire 18.
The proximal end of coiled support member 28' is adjacent to flared distal end 26 of catheter shaft 14. The proximal end of guide wire tube 120 generally abuts flared distal end 26, with an upper internal surface 124 of guide wire tube 120 generally aligned with a lower external surface 126 of flared distal end 26. The proximal end of guide wire tube 120 therefore provides access for guide wire 18 external to catheter shaft 14. The location of guide wire tube 120 distal and external to catheter shaft 14 permits a physician performing a dilatation procedure to make a rapid catheter exchange of one size perfusion balloon catheter for another.
In this particular embodiment, a separate catheter spring tip (like tips 34 of the first three embodiments) is not used. The catheter of FIGS. 13-15 is intended for over-the-wire use, and a separate spring tip is not required.
5. The Fifth Embodiment (FIGS. 16 and 17)
FIGS. 16 and 17 show a fifth embodiment of the present invention. This embodiment differs from the other embodiments primarily by virtue of guide wire tube 150, and distal end adhesive 152.
As shown in FIGS. 16 and 17, guide wire tube 150 is positioned primarily within coiled support member 28". Proximal end 150A of tube 150 is located adjacent distal end 26 of shaft 14 and proximal to the proximal end of coiled support member 28". Tube 150 extends distally beyond the distal end of coiled support member 28". Tube 150 defines guide lumen 154 for guide wire 18.
Loops 46 of tube 30, which form balloon 22, are captured at their lower extremes between tube 150 and retainer 32. Retainer 32 extends from within shaft 14, through coiled support member 28" and into distal end guide 152. Retainer 32 is positioned adjacent to and above lower extents 28B of each coil of coiled support member 28".
Distal end adhesive 152 is disposed on distal end 150B of guide wire tube 150, distal end 32B of retainer 32 and the distal end of coiled support member 28" to secure tube 150, retainer 32 and coiled support member 28" at the distal end of catheter 10. The distal end of adhesive 152 is aligned with distal end 150B and is generally tapered from its proximal to its distal end to provide a streamlined profile of the distal end of catheter 10.
The balloon assembly shown in FIGS. 16 and 17 is bonded within distal end 26 of shaft 14. Proximal neck region 42 of tube 30 and proximal end 32A of retainer 32 are inserted within shaft lumen 27 at distal end 26 of shaft 14 with the proximal end of coiled support member 28" generally abutting distal end 26 of shaft 14. Retainer 32 extends into shaft lumen 27 of shaft 14 a distance greater than tube 30 and serves to support balloon assembly 16 and provide distal shaft pushability. Proximal neck region 42 and proximal end 32A of retainer 32 are bonded within distal end 26 of shaft 14 by adhesive 44. Lumen 40 of flexible tube 30 is in fluid communication with shaft lumen 27 and provides a means for inflating and deflating loops 46 of balloon 22.
Proximal end 150A of guide wire tube 150 is positioned adjacent to and above distal end 26 of shaft 26 upon installation of the balloon assembly 16 onto shaft 26. In a preferred embodiment, proximal end 150A and distal end 26 are bonded together (e.g., by an adhesive) in the piggyback configuration shown in FIGS. 16 and 17.
6. The Method of Manufacture (FIGS. 18-22)
FIGS. 18-22 show the components and the steps necessary to manufacture balloon assembly 16 of the embodiments shown in FIGS. 1-12. For purposes of this description, the method of manufacture will be described as proceeding from the proximal to the distal end of coiled support member 28.
As shown in FIGS. 18-22, an uninflated length of flexible tube 30 is inserted at the proximal end of coiled support member 28. Mandril 170 is positioned above and adjacent to the outer surface of coiled support member 28. Tube 30 is threaded through a side of coiled support member 28 as shown in FIG. 19. Tube 30 is wrapped in a distal direction around mandril 170 and coiled support member 28, and threaded between adjacent coils of coiled support member 28. Slight tension is then applied to tube 30 to secure tube 30 under upper extent 28A of a coil of coiled support member 28. Tube 30 is repeatedly looped in the fashion just described to form a series of inflatable, side-by-side loops 46. While FIG. 21 shows tube 30 passing between every other coil of coiled support member 28, spacings of tube 30 may vary depending on the size of the tubing or the coiled support member used. The distal end of tube 30 is then secured to the distal end of coiled support member 28 to seal distal end 38 of tube 30. Retainer 32 is then threaded through the length of coiled support member 28 between the bottom side of each tube loop 46 and lower extents 28B to lock tube loops 46 within coiled support member 28.
With mandril 170 in place,, tube 30 is heated to about 80° Celsius for about thirty seconds. Air pressure is applied to the open proximal end 36 of tube 30 to cause tube 30 and loops 46 to inflate and expand the outer diameter of tube 30. Tube 30 is then cooled in a room-temperature water bath, the air pressure is removed, and the support mandril 170 is removed. Balloon assembly 16 is then disposed at the distal end of catheter shaft 14 (not shown) according to the methods shown for the various embodiments in FIGS. 1-17.
Balloon assembly 16 of the embodiment shown in FIGS. 13-15 is manufactured similar to the embodiments shown in FIGS. 1-12 with one exception: the placement and location of guide wire tube 120 within coiled support member 28' succeeds placement of retainer 32.
Balloon assembly 16 of the embodiment shown in FIGS. 16-17 is also manufactured similar to the embodiments shown in FIGS. 1-12, except the location and placement of guide wire tube 150 within coiled support member 28" precedes the wrapping of tube 30 around mandril 170 and coiled support member 28". Loops 46 of tube 30 are therefore secured beneath guide wire tube 150.
7. Conclusion
The perfusion balloon of the present invention is simply constructed at an efficient manufacturing cost. The helical tube creates a generally tubular-shaped perfusion balloon which, unlike prior art tubular-shaped perfusion balloons, requires no additional intracavity structural support to create and maintain the perfusion passage during balloon inflation. In addition, the perfusion balloon of the present invention has fewer seams than previous tubular-shaped perfusion balloons which increases flexibility of the distal end of the catheter. Finally, the perfusion balloon of the present invention possesses a perfusion passage with a cross-sectional area which is between about 16 to 44 percent of the cross-sectional area of the inflated balloon. This permits the perfusion balloon of the present invention to remain inflated within the artery while allowing good blood flow through the perfusion passage.
While use of a dilatation balloon with a perfusion balloon catheter of the present invention has been described only with reference to the first embodiment, such use is incorporated by reference to embodiments 2 through 5. Additionally, as well known in the art, radiopaque material is incorporated into each embodiment of the present invention as a marker to permit a physician to monitor the advancement and positioning of the catheter.
Although the present invention has been described with reference to preferred 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.
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A perfusion balloon catheter includes an inflatable balloon formed by a series of loops of a flexible, inflatable tube in a generally cooperative tubular shape. The loops are supported by a coiled support member and are locked within the coiled support member by a wire retainer. The cooperative tubular shape of the individual loops perform to provide an inflatable cooperative outer surface of the balloon and a perfusion passage within the balloon.
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BACKGROUND OF THE INVENTION
The present invention relates generally to operations involving tools, such as safety valves, etc., installed in subterranean wells and, in an embodiment described herein, more particularly provides apparatus and methods for achieving secondary lock-out of such safety valves.
It is sometimes desired to lock-out a safety valve, that is, to prevent closure of the safety valve, after it has been installed in a subterranean well. Among the reasons for locking-out the safety valve may be that the safety valve has ceased to function properly, or operations are to be performed through the safety valve and its closure during those operations is to be prohibited. If the safety valve is malfunctioning, the lock-out operation may also establish fluid communication between a control line attached to the safety valve and extending to the earth's surface, and a second, typically wireline-conveyed, safety valve subsequently landed in the malfunctioning safety valve. This operation, in which a safety valve is prevented from closing and fluid communication is established with the safety valve's control line, is sometimes referred to as a "primary" lock-out.
In another type of lock-out, a second control line-operated safety valve is not to be installed, so it is not necessary or desired to establish fluid communication with a control line. This operation, in which a safety valve is prevented from closing, but fluid communication is not established with the safety valve's control line, is sometimes referred to as a "secondary" lock-out. Another safety valve which does not use control line pressure in its operation, such as a tubing-pressure or velocity-type safety valve, may or may not be subsequently installed to replace the locked-out safety valve. In any event, such secondary lock-out operation permits remedial operations to be performed in the well, without the danger of the safety valve inadvertently closing on a wireline, coiled tubing, or during an acidizing treatment, etc.
Some safety valves, such as the SP-1™ safety valve manufactured by, and available from, Halliburton Energy Services of Duncan, Okla., are initially equipped with built-in features that facilitate convenient lock-out operations. However, other safety valves, such as Halliburton Energy Services' WELLSTAR® safety valve, do not include such features and, thus, a lock-out operation for these safety valves typically involves use of a specially designed tool. The tool is usually positioned within the safety valve and a mechanism of the tool is actuated to prevent closure of the safety valve.
One type of specially designed tool used for secondary lock-out of a safety valve deposits an expandable ring within the safety valve, in order to maintain a flapper of the safety valve in an open position. The expandable ring is deposited within the safety valve so that the ring contacts the flapper and overcomes the biasing force of a spring acting to close the flapper. Unfortunately, due to design restrictions of the tool, the ring is very thin in cross-section and, thus, potentially weak and unreliable, the ring may extend inwardly into an axial flow passage of the tool and interfere with subsequent operations therein, and the ring is susceptible to damage and dislodgement if the safety valve is inadvertently operated by applying fluid pressure to its control line.
Another type of specially designed tool used for secondary lock-out of a safety valve deposits an expandable ring within the safety valve between an opening prong of the valve and an internal shoulder to thereby prevent the opening prong from displacing to a position in which the valve will be permitted to close. The tool is latched into the opening prong and tubing pressure is applied to a tubing string attached above the safety valve in order to displace the opening prong to a position in which the valve is open, and then to deposit the expandable ring. Unfortunately, it is possible for the ring to be deposited in the wrong location since it is latched to the movable opening prong and a shear pin which determines the pressure at which the ring is deposited may shear before the opening prong has been fully displaced to the open position. Additionally, due to design restrictions, the ring is very thin in cross-section and weak.
From the foregoing, it can be seen that it would be quite desirable to provide an apparatus for achieving lock-out of a safety valve which does not utilize a thin or weak expandable ring and which is not located relative to a moveable point of reference during its operation, but which prevents closure of the safety valve by depositing an expandable ring within the valve. Additionally, it would be desirable to provide an expandable ring for use with the apparatus that is structurally sound in axial compression, but that is capable of significant radial expansion and contraction. Furthermore, it would be desirable to provide the apparatus with features that prevent deposition of the ring when the apparatus is not actuated properly, enable the ring to be safely retrieved with the apparatus in the event that the apparatus has been only partially, or improperly, actuated, and which indicate upon retrieval to the earth's surface whether the apparatus has been properly actuated. Methods of achieving lock-out of a safety valve which ensure convenient and reliable operations in preventing closure of the safety valve would also be desirable.
Still further, it would be desirable to provide an apparatus which is capable of depositing a radially displaceable ring with respect to any of a variety of downhole tools. For example, tools such as packers, sliding side doors, plugs, etc. may have one or more members disposed therein which are displaceable to set or unset, open or close, or otherwise operate the tools. Such an apparatus may be used to limit displacement of these members. Alternatively, the deposition of a radially displaceable ring relative to a downhole tool may be used for other purposes, for example, to centralize a packer, plug, etc. within a wellbore prior to setting it therein.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with a described embodiment thereof, an apparatus is provided which is capable of accurately and reliably depositing a structurally sound radially displaceable ring within a safety valve or other downhole tool. The expandable ring has structural capabilities which are far superior to any previous expandable rings utilized in lock-out mechanisms. Methods of achieving lock-out of a safety valve are also provided.
In broad terms, an apparatus is provided which locates and locks relative to a fixed reference, such as a profile formed in a portion of a body of a safety valve. The apparatus also includes a set of dogs which extend radially outward and engage an opening prong of the valve upon application of an axial force to the apparatus. Thereafter, fluid pressure applied to the apparatus causes the opening prong to displace and open the safety valve. Further application of fluid pressure releases a radially compressed expandable ring, so that it is deposited in a recess between the opening prong and an internal shoulder of the safety valve.
After the ring is deposited, an indication of proper actuation of the apparatus is provided by an equalization of fluid pressure across the apparatus, which may be detected at the earth's surface. In the event that the apparatus has not been actuated properly, the expandable ring is not deposited. In order to ensure that the ring is not deposited improperly, a mechanism of the apparatus which deposits the ring is directly tied to a mechanism of the apparatus which displaces the opening prong.
The ring depositing mechanism retains the expandable ring therein during transport to the earth's surface, in the event that the apparatus has partially, or improperly, actuated. Additionally, the ring depositing mechanism provides a positive indication of proper actuation of the apparatus.
A disclosed and described embodiment of the expandable ring includes a series of circumferentially spaced apart cantilevers. The cantilevers are joined to each other at opposite ends of the ring, with the ring being continuous. When the ring is radially compressed, the cantilevers are deflected circumferentially, thereby decreasing the ring's circumference. In this manner, significant radial compression of the ring is achieved, while maintaining significant ability to resist axially compressive loads applied thereto.
These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of a representative embodiment of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a radially deflectable ring embodying principles of the present invention;
FIGS. 2A-2D are quarter-sectional views of successive axial sections of a lock-out tool embodying principles of the present invention, the lock-out tool being shown in a configuration in which it is initially run into a subterranean well in an operation to lock-out a safety valve installed therein;
FIGS. 3A-3D are cross-sectional views of successive axial sections of the lock-out tool of FIGS. 2A-2D, the lock-out tool being shown in a configuration in which it has been secured to, and sealingly engaged with, the safety valve, and initial fluid pressure has been applied to cause the lock-out tool to engage an actuator member of the safety valve;
FIGS. 4A-4D are cross-sectional views of successive axial sections of the lock-out tool of FIGS. 2A-2D, the lock-out tool being shown in a configuration in which additional fluid pressure has been applied to cause the lock-out tool to displace the actuator member and open the safety valve;
FIGS. 5A-5D are cross-sectional views of successive axial sections of the lock-out tool of FIGS. 2A-2D, the lock-out tool being shown in a configuration in which further fluid pressure has been applied to cause the lock-out tool to deposit the ring of FIG. 1 within the safety valve; and
FIGS. 6A-6D are cross-sectional views of successive axial sections of the lock-out tool of FIGS. 2A-2D, the lock-out tool being shown in a configuration in which it is being retrieved from within the safety valve.
DETAILED DESCRIPTION
Representatively illustrated in FIG. 1 is a radially deflectable ring 10 which embodies principles of the present invention. In the following description of the ring 10 and other apparatus and methods described herein, directional terms, such as "above", "below", "upper", "lower", etc., are used for convenience in referring to the accompanying drawings. Additionally, it is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., without departing from the principles of the present invention.
The ring 10 is uniquely formed in a circumferentially continuous manner. To accomplish this construction, a series of circumferentially spaced apart cantilevers 12 are attached to each other at opposite ends. Thus, a particular cantilever 12a is attached at one of its opposite ends to another circumferentially adjacent cantilever 12b, and is attached at its other opposite end to another circumferentially adjacent cantilever 12c. In this manner, the cantilever 12a is disposed circumferentially between the cantilevers 12b and 12c, and is attached to each of them.
Each of the cantilevers 12 is attached to two others of the cantilevers, progressing circumferentially about the ring 10. Thus, the ring 10 is circumferentially continuous, with there being no complete axial break between any adjacent pair of the cantilevers 12. The applicant prefers that the ring 10 described herein be circumferentially continuous in order to evenly distribute stresses and resulting deflection throughout the ring, however, it is to be clearly understood that a ring including a series of circumferentially spaced apart cantilevers could be constructed in accordance with the principles of the present invention without that ring being circumferentially continuous.
In the representatively illustrated ring 10, the cantilevers 12 are attached at their opposite ends utilizing a series of circumferentially spaced apart segments 14, 16. One series of segments 14 is attached at one axial end of the cantilevers 12, and the other series of segments 16 is attached at the other axial end of the cantilevers. In this manner, each one of the cantilevers 12 is attached at one of its ends to one of the segments 14, and is attached at the other one of its ends to one of the segments 16. Each one of the segments 14, 16 is attached to two circumferentially adjacent cantilevers 12.
Since the segments 14 are circumferentially spaced apart from each other, and the segments 16 are circumferentially spaced apart from each other, the ring 10 may be radially deflected to, for example, radially compress the ring, by forcing the segments circumferentially toward each other. Of course, the ring 10 may also be radially expanded by forcing the segments 14, 16 further circumferentially apart from each other.
When the circumferential spacing between the segments 14, 16 is altered by, for example, forcing the segments circumferentially toward each other, the cantilevers 12 are laterally deflected from their at rest positions as shown in FIG. 1. Referring momentarily to FIG. 2B, the ring 10 is representatively illustrated installed in a lock-out tool 20, wherein the ring is radially compressed, thereby forcing the segments 14, 16 circumferentially toward each other. Note that each of the cantilevers 12 is laterally deflected and does not extend perfectly axially as compared to the cantilevers shown in FIG. 1. It is to be clearly understood that it is not necessary in keeping with the principles of the present invention for the cantilevers 12 to extend perfectly axially in their free states, for example, the cantilevers may extend spirally or helically between the segments 14, 16. However, the applicant prefers that the cantilevers 12 be laterally deflectable without causing yielding of, or other damage to, the cantilevers, so that the ring 10 will be capable of being radially compressed and then released for radial expansion when desired.
The segments 14, 16 are generally annular shaped and are somewhat radially enlarged relative to the cantilevers 12, and have externally sloped end portions 18 formed thereon. In a manner that will be more fully described hereinbelow, the ring 10 is radially inwardly retained in a radially inwardly compressed configuration at the end portions 18 when installed in the tool 20. However, it is to be clearly understood that it the segments 14, 16 may be other than annular shaped, may not be radially enlarged, and may include otherwise shaped end portions, without departing from the principles of the present invention.
The applicant has found through experimentation that a prototype of the ring 10 is capable of resisting very large axially compressive loads, and may be significantly radially compressed from its free state. Since the cantilevers 12 are permitted to deflect laterally along their entire axial lengths without yielding, the ring 10 returns to its free state without taking a "set" after being radially compressed. Furthermore, due to its circumferentially continuous construction, the ring 10 may easily be radially compressed, returned to its free state, radially extended, etc., while maintaining a generally cylindrical shape. The above benefits make the ring 10 particularly suitable for use in a lock-out tool, such as the lock-out tool 20 described hereinbelow, although the ring may also be used in other tools, devices, etc., without departing from the principles of the present invention.
Although the ring 10 has been described herein with reference to the illustrated representative embodiment shown in the figures, it is to be understood that changes may be made thereto without departing from the principles of the present invention. For example, instead of the ring 10 being generally cylindrical or annular-shaped, it may actually be elliptical or polygonal in lateral cross-section, the segments 14, 16 may be otherwise shaped and may not be utilized at all, the cantilevers 12 may be otherwise attached to each other, etc. Such changes are contemplated by the principles of the present invention.
Referring additionally now to FIGS. 2A-2D, the lock-out tool 20 embodying principles of the present invention is representatively illustrated. The lock-out tool 20 is described herein as it may be utilized in a secondary lock-out of a subterranean safety valve, but it is to be understood that a lock-out tool constructed in accordance with the principles of the present invention may be used in other operations. For example, a lock-out tool constructed in accordance with the principles of the present invention may be utilized in a primary lock-out operation. As another example, a tool constructed in accordance with the principles of the present invention may be used to deposit a radially displaceable ring with respect to a packer, plug, sliding side door, or other downhole tool.
As representatively illustrated, the lock-out tool 20 includes a latch mechanism 22, a displacement mechanism 24, and a blocking member, representatively, the ring 10. Blocking members other than the ring 10 may be used in the tool 20 without departing from the principles of the present invention. In the tool 20, the latch mechanism 22 is used to releasably secure the tool relative to a safety valve, and the displacement mechanism 24 is used to displace an actuator member of the safety valve to thereby open the valve. The blocking member 10 is then deposited in the safety valve to restrict displacement of the actuator member, thereby preventing closure of the safety valve. Displacement of the actuator member and deposition of the blocking member 10 are achieved by applying fluid pressure to the tool 20. In the following description of the tool 20, the construction of each of the mechanisms will first be detailed, and then use of the tool in a secondary lock-out operation will be described.
The latch mechanism 22 includes an upper head 26. The upper head 26 facilitates threaded attachment of the tool 20 to a conveyance, such as a wireline, slickline, coiled tubing, etc. In addition, an axially downwardly directed force may be applied to the upper head 26 to shear a shear screw 28 installed radially therethrough and into a generally tubular latch mandrel 30. Such force may be applied by jarring down on the upper head 26 in a conventional manner after the tool 20 has been positioned within the safety valve as described more fully hereinbelow.
The upper head 26 is threadedly attached to a generally tubular key support 32, which is axially slidingly disposed about the latch mandrel 30. When the shear screw 28 is sheared, the upper head 26 and key support 32 are permitted to displace axially downward relative to the latch mandrel 30. Furthermore, the key support 32 is permitted to displace downward relative to a generally tubular key retainer 34 and a series of circumferentially spaced apart keys 36 extending radially through the key retainer.
Each of the keys 36 is biased radially outward by a spring 38. The keys 36 have an external profile 40 formed thereon which is complementarily shaped relative to an internal profile formed within, or attached to, the safety valve. As described more fully hereinbelow, when the tool 20 is conveyed into the safety valve, the keys 36, biased outward by the springs 38, engage the internal profile and prevent further downward displacement of the tool. The downwardly directed force may then be applied to the upper head 26 to shear the shear pin 28 and downwardly displace the upper head and key support 32.
When the key support 32 is downwardly displaced relative to the key retainer 34 and keys 36, it will radially outwardly support the keys 36, so that the keys cannot disengage from the internal profile of the safety valve. Additionally, a shear pin 42 extending radially through the key retainer 34 will displace radially inwardly, due to a biasing force exerted by a spring 44, into a groove (not shown) formed externally on the key support 32 to thereby prevent upward displacement of the key support relative to the key retainer. In order to disengage the keys 36 from the safety valve internal profile, an upwardly directed force is applied to the upper head 26 to shear the shear pin 42 and thereby permit the key support 32 to be displaced axially upward, so that it no longer radially outwardly supports the keys 36.
The latch mandrel 30 is threadedly attached at its lower end to a generally tubular expander sleeve 46. The expander sleeve 46 extends radially outwardly through a shear sleeve 48 of the displacement mechanism 24 at a series of circumferentially spaced apart and axially extending slots 50 formed through the shear sleeve. The shear sleeve 48 is, thus, axially displaceable relative to the expander sleeve 46, even though the lower end of the expander sleeve extends radially through the shear sleeve.
The expander sleeve 46 is threadedly attached to a generally tubular spring housing 52 where the expander sleeve extends radially through the shear sleeve 48. The spring housing 52 is threadedly attached to a generally tubular piston housing 54. The piston housing 54 is threadedly attached to a generally tubular bottom nose 56, thereby axially retaining a circumferential seal, representatively, a packing stack 58, externally thereon.
When the tool 20 is conveyed into the safety valve as described more fully hereinbelow, the seal 58 will sealingly engage an internal seal bore within, or attached to, the safety valve. Such sealing engagement will preferably occur at, or just prior to, engagement of the keys 36 with the safety valve internal profile. Thus, when the latch mechanism 22 releasably secures the tool 20 within the safety valve, the tool is also sealingly engaged therewith. Note that the axial distance between the keys 36 and seal 58 preferably remains constant during the lock-out operation, but it is to be clearly understood that it is not necessary for this distance to remain constant in a lock-out tool constructed in accordance with the principles of the present invention.
The shear sleeve 48 is releasably secured against axial displacement relative to the latch mechanism 22 by one or more shear screws 60 (only one of which is visible in FIG. 2C) installed radially through the spring housing 52 and into the shear sleeve. An annular piston 62 is axially slidingly and sealingly engaged within a piston bore 64 of the piston housing 54. The piston 62 is axially retained and sealingly engaged on a generally tubular piston sleeve 66 by a generally tubular cap 68, which is threadedly attached to the piston sleeve. The piston sleeve 66 is, in turn, threadedly attached to the shear sleeve 48, thereby effectively attaching the piston 62 to the shear sleeve. As will be more fully described hereinbelow, when a predetermined fluid pressure is applied across the piston 62, the shear screw 60 will shear, thereby permitting the displacement mechanism 24 to downwardly displace relative to the latch mechanism 22.
Fluid pressure is applied across the piston 62 in operation of the tool 20 after the seal 58 has sealingly engaged the safety valve seal bore. Fluid pressure may then be applied to a tubing string from which the safety valve is suspended at the earth's surface. The fluid pressure will enter one or more ports 70 and pass into an axial fluid passage 72 which extends through the tool 20.
The fluid passage 72 is blocked in the tool 20 as shown in FIGS. 2A-2D by a generally cylindrical drop 74. The drop 74 is axially slidingly received within the expander sleeve 46. A generally axially extending slot 76 is formed through the drop. A screw 78 is installed laterally through the slot 76 and is secured to the expander sleeve 46. Thus, cooperative engagement of the screw 78 in the slot 76 limits axial displacement of the drop 74 relative to the expander sleeve 46.
A generally conical nose 80 is formed on a lower end of the drop 74. As shown in FIG. 2C, the nose sealingly engages a seal 82 retained axially between shear sleeve 48 and the piston sleeve 66. Such sealing engagement between the nose 80 and seal 82 prevents fluid pressure in a portion of the fluid passage 72 above the seal from entering a lower portion of the fluid passage below the seal. Thus, with the tool 20 configured as shown in FIGS. 2A-2D, fluid pressure may be applied across the piston 62 by applying the fluid pressure to the upper portion of the fluid passage 72 with the drop 74 sealingly engaged with the seal 82.
Note that the seal 82 is rigidly secured relative to the displacement mechanism 24, but that the drop 74 is axially slidingly secured relative to the expander sleeve 46. It will be readily appreciated that, when the displacement mechanism 24 is downwardly displaced relative to the latch mechanism 22 as described more fully hereinbelow, the drop 74 will be permitted to displace downwardly therewith, but only to the extent that the engagement of the screw 78 in the slot 76 permits. Thus, if the seal 82 displaces further downwardly after the screw 78 has contacted an upper edge of the slot 76, the drop 74 will no longer sealingly engage the seal 82. It will be apparent to a person of ordinary skill in the art that, if the drop 74 no longer sealingly engages the seal 82, the fluid pressure will enter the lower portion of the fluid passage 72 and pass through the piston sleeve 66, piston 62, cap 68, etc., and a pressure differential across the piston can no longer be maintained.
The shear sleeve 48 is threadedly attached at its upper end to a dog retainer 84. A series of three dogs 86 extend radially slidingly through the dog retainer 84. As shown in FIG. 2B, the dogs 86 are radially retracted and contact a radially reduced portion 88 of the expander sleeve 46. During conveyance of the tool 20 into the safety valve, the dogs 86 are preferably radially retracted as shown in FIG. 2B. However, upon downward displacement of the displacement mechanism 24, the dogs 86 will be downwardly displaced relative to the expander sleeve 46, radially extended by an inclined face 90 formed on the expander sleeve 46, and maintained in their radially extended position by a radially enlarged portion 92 formed on the expander sleeve. In this manner, the dogs 86 radially outwardly engage an actuator member of the safety valve and permit the actuator member to be downwardly displaced along with the displacement mechanism 24.
The dog retainer 84 has a circumferential recess 94 formed thereon. The recess 94 is complementarily shaped relative to the end portions 18 of the segments 16. Thus, when the ring 10 is radially compressed, and the end portions 18 of the segments 16 are inserted into the recess 94 and axially maintained therein, the ring 10 is prevented from radially expanding relative to the dog retainer 84.
Similarly, a generally tubular ring retainer 96 has a circumferential recess 98 formed thereon which is complementarily shaped relative to the end portions 18 of the segments 14. When the ring 10 is radially compressed, and the end portions 18 of the segments 14 are inserted into the recess and axially maintained therein, the ring 10 is prevented from radially expanding relative to the ring retainer 96.
The ring 10 is maintained axially between the dog retainer 84 and the ring retainer 96 by means of a generally tubular retainer sleeve 100. The retainer sleeve 100 is threadedly attached to the dog retainer 84 and is axially slidingly disposed about the latch mandrel 30. One or more balls 102 (only one of which is visible in FIG. 2B) is radially slidingly received through the retainer sleeve 100. As shown in FIG. 2B, the ball 102 is radially retained between an outer side surface 104 of the latch mandrel 30 and a recess 106 internally formed on the ring retainer 96.
Engagement of the ball 102 in the recess 106 prevents axial displacement of the ring retainer 96 relative to the retainer sleeve 100. Thus, with the ball 102 engaged in the recess 106, the ring retainer 96 is not permitted to axially displace relative to the dog retainer 84, and the ring 10 is axially retained between the recesses 94, 98. However, when the displacement mechanism 24 has displaced downwardly a sufficient distance, the ball 102 will no longer be retained radially outward into engagement with the recess 106 by the surface 104 and the ring retainer 96 will be permitted to displace axially upward relative to the dog retainer 84, thereby releasing the ring 10 for radial expansion, as will be more fully described hereinbelow.
A spirally wound compression spring 108 applies an upwardly biasing force to the ring retainer 96. When the ball 102 is permitted to disengage from the recess 106, the spring 108 assists in axially upwardly displacing the ring retainer 96 to release the ring 10, and maintains the ring retainer in its axially upwardly displaced position relative to the retainer sleeve 100. It is to be understood that it is not necessary for the spring 108 to assist in radially upwardly displacing the ring retainer 96 in the tool 20, but the applicant prefers its use so that the ring retainer will remain in its axially upwardly displaced position upon retrieval of the tool to the earth's surface. In this manner, an operator at the earth's surface may verify proper operation of the tool 20, that is, that the displacement mechanism 24 displaced sufficiently to permit the ball 102 to be released from the recess 106. In a method of using the tool 20 described more fully hereinbelow, sufficient displacement of the displacement mechanism 24 ensures that the actuator member of the safety valve has displaced sufficiently to open the safety valve.
Note that another spirally wound compression spring 110 is included in the tool 20. The spring 110 is retained radially between the piston sleeve 66 and the spring housing 52, and axially between an internal shoulder of the spring housing and an external shoulder of the shear sleeve 48. The spring 10 exerts an upwardly biasing force on the displacement mechanism 24, so that, if the displacement mechanism malfunctions, or the tool 20 must be retrieved before the displacement mechanism has been sufficiently downwardly displaced to release the ring 10, the spring 110 will act to prevent further downward displacement of the displacement mechanism and reset the tool back to its original configuration wherein the dogs 86 are permitted to radially retract. In this manner, the tool 20 may be retrieved without danger of the ring 10 being deposited inadvertently.
Referring additionally now to FIGS. 3A-3D, the lock-out tool 20 is representatively illustrated received within a subterranean safety valve 112 interconnected as a portion of a tubing string 114 extending to the earth's surface. Such safety valves, which are designed for interconnection in tubing strings, are commonly referred to as tubing retrievable safety valves. The safety valve 112 is schematically representative of the WELLSTAR® safety valve referred to above, and which is more fully described on page 4-5 of a Halliburton Completion Products catalog no. CPP5653 and a sales brochure no. H00105, the disclosures of which are hereby incorporated by this reference. It is to be clearly understood, however, that a lock-out tool constructed in accordance with the principles of the present invention may be utilized with other safety valves, and with other types of safety valves, such as wireline retrievable safety valves, etc.
Additionally, it is to be clearly understood that a tool constructed in accordance with the principles of the present invention may be utilized to deposit a radially displaceable ring with respect to other downhole tools. The tool may deposit the ring within, or external to, the other downhole tools, and the tool may facilitate radial expansion or contraction of the ring upon its deposition.
As shown in FIGS. 3A-3D, the tool 20 has been partially actuated. The keys 36 of the latch mechanism 22 have radially outwardly engaged an internal profile 116 formed in an upper sub 118 of the safety valve 112. The upper sub 118 is threadedly attached to an outer housing 120 of the safety valve 112. Thus, the latch mechanism 22 is prevented from displacing further axially downward relative to the safety valve 112. Note that it is not necessary for the latch mechanism 22 to engage an internal profile formed directly on the safety valve 112, for example, the internal profile 116 could instead be formed internally on a nipple (not shown) interconnected in the tubing string 114 above the safety valve.
A downwardly directed force has been applied to the upper head 26, for example, by jarring downwardly thereon. The shear screw 28 has been sheared, permitting the upper head and key support 32 to displace axially downward relative to the remainder of the latch mechanism 22. Such downward displacement of the key support 32 radially outwardly supports the keys 36 in engagement with the profile 116 and releasably prevents radially inward retraction of the keys. Thus, the latch mechanism is releasably secured relative to the safety valve 112 as shown in FIGS. 3A-3D. Note that the springs 38 are not shown in FIG. 3A for illustrative clarity.
The seal 58 is sealingly engaged within a seal bore 126 formed internally on a lower sub 128 of the safety valve 112. The lower sub 128 is threadedly attached to the outer housing 120 of the safety valve 112. Note that it is not necessary for the seal bore 126 to be formed directly on the safety valve 112, it may instead be formed, for example, internally on another component of the tubing string 114 below the safety valve.
As shown in FIGS. 3A-3D, a portion of a sequence of increasing fluid pressure has been applied to the tubing string 114 above the safety valve 112. This sequence of increasing fluid pressure may be applied in a continuous manner, however, for clarity of description of the operation of the tool 20, specific portions of the sequence will be separately described along with the corresponding alterations in the configuration of the tool 20 and safety valve 112. It is to be clearly understood that the portions of the sequence of increasing fluid pressure may or not be interrupted, may or not be applied in the specific order described herein, and may or may not be continuous without departing from the principles of the present invention.
The fluid pressure applied to the tool 20 as shown in FIGS. 3A-3D has entered the port 70 and the upper portion of the fluid passage 72. However, with the drop 74 sealingly engaging the seal 82, the fluid pressure is not permitted to enter the fluid passage 72 below the seal. Thus, a pressure differential is created across the piston 62, causing a downwardly directed force to be applied to the displacement mechanism 24. As a result, the shear screw 60 has sheared, thereby permitting the displacement mechanism 24 to displace somewhat axially downward.
Such axially downward displacement of the displacement mechanism 24 has displaced the dogs 86 downward relative to the expander sleeve 46, thereby causing the dogs to radially outwardly extend relative to the dog retainer 84. The dogs 86 now engage and axially contact an inclined face 122 formed internally on an actuator member 124 of the safety valve 112. In the schematically represented safety valve 112, the actuator member 124 is an opening prong, which is axially displaced to open a flapper (not shown) of the valve in normal operation of the safety valve.
It is to be understood, however, that where a lock-out tool constructed in accordance with the principles of the present invention is utilized in another safety valve, another type of safety valve, or another type of valve, the actuator member may be other than an opening prong without departing from the principles of the present invention. For example, where the tool 20 is utilized to lock-out a ball valve (in either a closed or open position), the actuator member 124 may instead be a piston, sleeve, arms, etc. associated with causing rotation of a ball. Thus, although the lock-out tool 20 as described herein is utilized to prevent closure of a certain type of tubing retrievable safety valve, a tool constructed in accordance with the principles of the present invention may be utilized to prevent opening or closure of another type of valve, or perform another operation.
Referring additionally now to FIGS. 4A-4D, a further portion of the sequence of increasing fluid pressure has been applied to the tubing string 114 above the safety valve 112. This increase in fluid pressure has caused the displacement mechanism 24 to further downwardly displace, thereby displacing the actuator member 124 downwardly therewith. This downward displacement of the actuator member 124 has opened the safety valve 112, similar to the valve having been opened in a normal manner by applying fluid pressure to a control line attached to the valve.
Of course, it will be readily apparent to one of ordinary skill in the art that when the tool 20 was initially inserted into the valve 112 the nose 56 would have deflected the flapper (not shown) out of sealing engagement with its seat (not shown). However, the applicant prefers that the actuator member 124 be downwardly displaced to maintain the valve 112 in its open configuration after the ring 10 is deposited therein, as more fully described hereinbelow.
Note that the dogs 86 remain radially outwardly engaged with the actuator member 124. The actuator member 124 is, thus, maintained in its downwardly displaced position during deposition of the ring 10.
Note, also, that the balls 102 are about to be completely released from the recess 106 of the ring retainer 96. This is due to the fact that the displacement mechanism 24 has downwardly displaced relative to the latch mandrel 30. When the balls 102 are permitted to radially inwardly retract completely out of engagement with the recess 106, the balls no longer being radially outwardly supported by the surface 104, the ring retainer 96 will be permitted to upwardly displace relative to the retainer sleeve 100 and the ring 10 will be released from the tool 20.
At this point, the drop 74 remains in sealing engagement with the seal 82. Note, however, that the screw 78 is disposed very near the top of the slot 76. Further downward displacement of the displacement mechanism 24 will cause the seal 82 to displace downward relative to the drop 74, thereby relieving any pressure differential across the piston 62.
Referring additionally now to FIGS. 5A-5D, a further portion of the sequence of increasing fluid pressure has been applied to the tubing string 114 above the safety valve 112. The displacement mechanism 24 has now displaced the actuator member 124 fully downwardly, such that it now axially contacts the lower sub 128. Such downward displacement of the displacement mechanism 24 has also caused the seal 82 to disengage from the drop 74. This, in turn, causes the pressure differential across the piston 62 to be relieved, at least partially reducing the fluid pressure in the tubing string 114 above the safety valve 112, thereby giving an indication at the earth's surface that the displacement mechanism 24 has fully downwardly displaced.
The balls 102 are now fully inwardly retracted out of engagement with the recess 106. The ring retainer 96 has axially upwardly displaced relative to the retainer sleeve 100, thereby permitting the ring 10 to radially outwardly extend into an annular recess 130 axially between an internal shoulder 132 formed on the actuator member 124 and a lower end of the upper sub 118.
The recess 130 was axially elongated by the downward displacement of the actuator member 124 relative to the upper sub 118 and, in order to close the safety valve 112, the recess would have to be radially compressed. The presence of the ring 10 within the recess 130 restricts axially upward displacement of the actuator member relative to the upper sub 118 and thereby prevents closure of the safety valve 112. It is to be clearly understood, however, that the ring 10 may be otherwise deposited within the safety valve 112 to prevent its closure without departing from the principles of the present invention.
Referring additionally now to FIGS. 6A-6D, an axially upwardly directed force has been applied to the upper head 26 to release the latch mechanism 22 from the upper sub 118. Note that the keys 36 are permitted to radially inwardly retract out of engagement with the profile 116, the key support 30 no longer radially outwardly supporting the keys. The tool 20 is now in a configuration in which it may be retrieved to the earth's surface through the tubing string 114.
The ring 10 remains in the recess 130 as the tool 20 is displaced axially upwardly out of the safety valve 112. As shown in FIG. 6B, the actuator member 124 has displaced axially upward somewhat relative to the outer housing 120, for example, due to the upwardly directed biasing force exerted on the actuator member by a spring (not shown) of the safety valve 112. However, such axially upward displacement of the actuator member 124 is limited by the ring 10, which is capable of withstanding this force. Thus, even though the actuator member 124 may axially upwardly displace somewhat, it cannot upwardly displace sufficiently far to permit closure of the safety valve 112.
Note that the dogs 86 no longer contact the inclined face 122, but now contact the lower end of the upper sub 118. Such will not prevent withdrawal of the tool 20 from the safety valve 122, however, because the dogs 86 are no longer radially outwardly supported by the radially enlarged portion 92 of the expander sleeve 46 and may radially inwardly retract.
When retrieved to the earth's surface, the ring retainer 96 will be in its axially upwardly displaced position as shown in FIG. 6B, due to the upwardly biasing force of the spring 108. An operator may thus verify that the ring 10 was properly released by the axial displacement of the ring retainer 96 relative to the retainer sleeve 100.
As shown in FIG. 6C, the spring 110 is axially compressed. As described above, the spring 110 exerts an upwardly biasing force on the displacement mechanism 24. Thus, the spring 110 may cause the displacement mechanism 24 to axially upwardly displace relative to the latch mechanism 22 after deposition of the ring 10 and/or during retrieval of the tool 20.
Thus has been described the tool 20 which is capable of utilizing the ring 10 instead of a thin or weak expandable ring, and which is releasably secured relative to an outer housing of a safety valve instead of being located relative to a moveable point of reference during its operation. The tool 20 conveniently prevents closure of a safety valve by depositing the ring 10 within the valve.
Of course, modifications, additions, deletions, substitutions, and other changes may be made to the tool 20 and ring 10 utilized therewith, which changes would be obvious to a person of ordinary skill in the art. For example, the tool 20 may be modified to permit its use in a primary lock-out operation, to permit its use in preventing opening or closure of another type of valve or other equipment, to deposit an expandable ring in another type of operation etc. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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Apparatus and associated methods provide convenient and reliable deposition of a radially deflectable blocking member relative to a downhole tool. In a described embodiment of the apparatus, a lock-out tool has mechanisms which effect latching of the tool to an internal profile of a safety valve, displacement of an opening prong of the safety valve to open the safety valve, and deposition of an expandable ring to prevent closure of the safety valve. The ring is accurately positioned by the tool and is constructed in a manner which enables it to resist relatively large axial loads, but which also enable it to be significantly radially compressed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of, and claims priority from, commonly-owned, co-pending U.S. application Ser. No. 11/774,163, filed on Jul. 6, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED-RESEARCH OR DEVELOPMENT
[0002] None.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] None.
FIELD OF THE INVENTION
[0004] The invention disclosed broadly relates to the field of web services and more particularly relates to the field of versioned web services.
BACKGROUND OF THE INVENTION
[0005] Web services are increasingly viewed as an important component in building distributed applications. As these services inevitably evolve and change, service version management will increasingly become a key part of the service lifecycle. In this context the lack of an end-to-end versioning model provides challenges to the service provider when trying to manage version transitions, especially in a continuous availability context, especially in the web services model of once published, always published. Versioning of web services is challenging, because it inevitably affects each part of the service lifecycle.
[0006] A common scenario is the rollout of a new version which is backward compatible with a previous version. Compatible version transition should ideally be handled in such a way that existing service consumers are insulated from any knowledge of the change. In a continuous availability context, the service provider ideally wants to manage this type of version transition smoothly in such a way that there is no service disruption. Ideally, a new version is appropriately tested in the production environment before committing to the transition. The transition is rolled out gradually (at whatever rate is appropriate) and with a way to smoothly back out or rollback problem versions. In order to support these types of transitions it is necessary to support concurrent deployment of multiple service versions. If two or more compatible versions of a service are deployed concurrently, the problem of how to route service requests to an appropriate version must be explicitly addressed.
[0007] The known art in supporting versioning of web services falls into two approaches. One focuses on methods of dealing with and or simplifying the problem of adaptation by the service consumer to service changes, i.e. requiring the active participation of the service consumer to cooperate with service provider changes. For a backward compatible change another approach is to address the version transition aspect with for example, an orchestration scheme to manage the transition as quickly as possible without any service disruption. This insulates the service consumer from any awareness of the change with the constraint being that only one version of the service can be active at a time.
[0008] The web services versioning problem is a subset of the second approach, the more general distributed programming model. A distributed programming model service, such as a web service, consists of a service implementation which performs some function (an implementation module), a service specification which describes the function and how the service can be invoked (such as a WSDL file), and service requestors which make service requests of the service provider following the service specification (such as a web service client). We use the more general term service in the following discussion with the understanding that it is applicable to a web services model as well as other distributed service models.
[0009] Versioning is an often overloaded term, which can have different meanings depending on the context or the viewpoint. From the service consumer's point of view, a web service “version” would describe and apply to the interface of the service—the operations and parameters, results, etc. of this particular version. A service provider, hosting multiple versions of a service, manages implementation versions which need to be installed, started, stopped, and so on. These two versioning concepts, while inter-related, are not the same.
[0010] During a service's lifetime, it will usually go through one or more revisions as requirements or business needs change. When a new version of a service is ready to be deployed, the service provider necessarily needs to plan for the upgrade. In selecting a version transition strategy, the service provider is faced with the task of introducing the new version in such a way so as to provide a smooth, managed transition, with support to back out a problem version, while maintaining continuous availability and minimizing the impact on service consumers.
[0011] One strategy which provides a smoother and more flexible (compatible) version transition is to support the side-by-side deployment of two versions. During a phased transition period, both versions can operate simultaneously until such a time as the system administrator is confident and ready to retire the old version. In practice, these transition periods can be arbitrarily long, especially with stateful services or long running business processes which have instantiated data associated with a particular version of the service.
[0012] In an unversioned environment, a common approach is usually limited to swapping the old version with a backward compatible new version. Without support for multiple version coexistence, some sort of rollout orchestration is used to handle the changeover as quickly as possible while maintaining continuous availability. This type of in place exchange, while transparent to the service consumer, provides little flexibility to the service provider. To get around the version coexistence limitation, the service provider can deploy a new version with a new name which, while giving more flexibility, has the unattractive quality of requiring the explicit cooperation of service consumers to adjust to the version change.
SUMMARY OF THE INVENTION
[0013] Briefly, according to an embodiment of the invention, a method for hosting versioned web services includes steps of: receiving a request from a service requestor, the request comprising version metadata; parsing the request; extracting the version metadata from the parsing step; and locating a target implementation version using the version metadata. If the target implementation version is located, the method proceeds by dynamically routing the versioned request to the target implementation version.
[0014] A system for hosting versioned web services includes: a deployable module for implementing a service, the deployable module comprising an implementation version for supporting a particular interface version; a versioned implementation module for supporting concurrent deployment of multiple versions of the service; and a service proxy for a version group, the version group including at least one implementation version, wherein the service proxy is a local gateway to the collection of implementation versions of the service and provides a single destination for service requests for all versions of the service.
[0015] Further, a service for routing versioned service request includes steps of acts of: receiving a request from a service requestor, the request including version metadata, parsing the request; extracting the version metadata from the parsing step; locating a target implementation version using the version metadata; and dynamically routing the versioned request to the target implementation version.
[0016] The method steps above can be performed by a computer program product tangibly embodied on a computer readable medium and including code for enabling the computer to perform the method steps.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] To describe the foregoing and other exemplary purposes, aspects, and advantages, we use the following detailed description of an exemplary embodiment of the invention with reference to the drawings, in which:
[0018] FIG. 1 is a simplified block diagram of a service hosting environment according to an embodiment of the present invention;
[0019] FIG. 2 is a simplified block diagram of an exemplary implementation of the hosting environment of FIG. 1 , according to an embodiment of the present invention;
[0020] FIG. 3 is a flowchart of a method according to an embodiment of the present invention;
[0021] FIG. 4 shows pseudo-code for the matching algorithm, according to an embodiment of the present invention;
[0022] FIG. 5 shows the elements of the version metadata, according to an embodiment of the present invention; and
[0023] FIG. 6 is a simplified block diagram of a programmable computer configured to operate according to an embodiment of the present invention.
[0024] While the invention as claimed can be modified into alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention.
DETAILED DESCRIPTION
[0025] We describe a method for hosting versioned web services. Our approach separates the interface and implementation versions of a service. The interface version of a service is the (published) version of the service which describes the service interface characteristics (operations, parameters, results, behavior, and so on). The implementation version is the version of the deployed component which supports a particular interface. Each implementation version is accompanied by new version metadata which explicitly describes the interface version supported and (if any) set of other compatible interface versions supported. This metadata forms a version configuration model which is then used to dynamically link interface version requests to implementation versions at runtime.
[0026] The advantage of this approach is that it gives the service provider the flexibility to manage the transition between compatible versions, allowing concurrent deployment of multiple versions in a way that is transparent to the service consumer. An interface change can be picked up by new service consumers at development time, while existing service consumers which are bound to a previous version are identified by the service request version. The dynamic mapping at runtime allows the service provider to flexibly deploy and manage multiple versions of a service in a way that is transparent to a service consumer.
[0027] We draw a distinction between a service's interface and implementation version. We borrow the terminology of the software contract to describe the interface version, because it effectively defines a software contract between the client and the service provider. A client necessarily binds to a particular version of a service, with that particular version's set of operations, parameters, results, and so forth. When that client later invokes the service, it has an expectation of consistency of behavior. For example, the client expects that the service provider will adhere to the terms of the software contract in effect when the service was built. The service provider has a responsibility to assure that whichever implementation version handles this request, it will meet its contractual expectations. We call this the contract version or interface version, and it is this metadata which identifies a versioned service request.
[0028] Any discussion of the evolution of services and change is necessarily hinge on the question of compatibility. If change is inevitable, it is up to the service developer to decide how to introduce that change. The impact of a change can range from seamlessly backward compatible to incompatible requiring a whole new programming model. However, because of its inherent disruptive effects, incompatible change is relatively rare. The more typical pattern introduces change with some level of compatibility. For example, a bug-fix release would likely have the same (therefore compatible) interface. Or a version may introduce new operations or parameters while maintaining backward compatibility with the previous version.
[0029] Knowing the explicit compatibility relationship between two versions can be leveraged in the hosting environment. If version 2 is backward compatible with version 1, then it is eligible to have version 1 requests routed to it and can in fact replace version 1. However, if version 3 drops compatibility with the older version 1, the service provider may choose to keep both versions 2 and 3 deployed in order to not break clients using the old version 1 interface. Therefore, in addition to the contract version and the implementation version, we also add a compatibility assertion to our version metadata model.
[0030] This version metadata (service contract version, implementation version, and associated version compatibility assertions) is added to the system configuration and is used in controlling the version matching behavior of the service provider. Table 1 illustrates the version metadata of an exemplary service with three contract versions. Each implementation version supports a particular contract version, and has a set of other contract versions with which it is compatible.
[0031] Note that while contract version 1.1 is backward compatible with version 1.0, contract version 1.2 has dropped compatibility with the older 1.0 version.
[0000]
TABLE 1
Version metadata
contract
implementation
compatible
version
version
contracts
1.0
1.0.3
1.0
1.1
1.1.2
1.0, 1.1
1.2
1.2.1
1.1, 1.2
[0032] Using a layered hosting approach, with a version routing point, or gateway, which maps interface versioned requests to deployed implementation versions, provides the service provider the flexibility to manage phased version transitions while insulating service consumers from backend changes. Three of the key aspects of this service are: 1) distinguishing between a public interface version and a private implementation version; 2) creating a metadata version model to link implementation versions to supported interface versions; and 3) creating a metadata-driven selection algorithm to dynamically map interface versioned requests onto implementation versioned services. FIG. 1 illustrates our approach, with version aware service consumers 150 submitting versioned service requests 190 to a Version Group Gateway 120 .
[0033] The gateway's functions are broken down into three steps as follows: 1) extract any version metadata from the request; 2) version selection (calling the version selection algorithm 130 ); and 3) route the request to the selected endpoint. To extract the metadata, the gateway 120 parses the request message 190 to extract any version metadata (e.g. the contract version). Depending on the messaging protocol, the version metadata will need to be encoded differently, so this step must be protocol aware. Once the version metadata is retrieved, the gateway 120 invokes the Version Selection Algorithm 130 to determine the correct implementation target version 160 or 165 for a particular request 190 . The gateway 120 then dynamically re-routes the request to the selected implementation version. It should be noted that the example of FIG. 1 shows only two target versions, for clarity. Any number of target versions and consumers may benefit from the hosting service as described herein.
[0034] In this design, one or more versions of a particular service deployed side-by-side form a version group. The aggregate of the individual service's versioning metadata forms the version group configuration which controls the request routing behavior of the system 100 .
[0035] The Service Proxy 175 is logically positioned between service implementation versions 160 and 165 and the version aware clients 150 . The Service Proxy 175 is the endpoint to which client applications bind. This structure insulates the client applications from the details of the implementation versioning changes and effectively puts the service provider in control of version routing selection.
[0036] Referring to FIG. 2 there is shown an exemplary implementation of the embodiment of FIG. 1 . The three main logical components of the gateway 120 are shown in FIG. 2 : Version Metadata Extractor 210 , Dynamic Endpoint Selector 220 , and Version Selector 230 .
[0037] Referring to FIG. 3 there is shown a flow chart of the process steps for hosting versioned web services according to an embodiment of the present invention. In step 310 the Service Gateway 120 receives the versioned requests 190 . In step 320 the Version Metadata Extractor 210 parses the request message 190 to extract any version metadata (that is, the contract version).
[0038] Once the version metadata is extracted, in step 330 the Gateway 120 invokes the Version Management Controller (VMC) 135 , possibly through its version mapping API, to determine the correct target. In step 340 the Endpoint Selector 220 parses the service context and the contract version metadata extracted in step 320 to the VMC 135 which determines the correct endpoint in the service group 162 . It should be noted that the separation of functionality between the VMC 135 and the gateway 120 as depicted in FIG. 2 is just one example of how the roles can be assigned. In an alternate embodiment, the Gateway 120 is configured to perform the role of the VMC 135 as well. On the other hand, the VMC 135 may also be configured to take on some of the roles shown as performed by the Gateway 120 .
[0039] In step 350 the Gateway 120 then dynamically re-routes the request 190 through a service bus to the endpoint of the target implementation version ( 160 or 165 in this example).
[0040] When a new implementation version of a service is installed, a version group member is created and its versioning metadata is added to the existing hosting configuration. The metadata contains the contract version, implementation version (and associated implementation endpoint or address) and compatibility assertions. In addition to these fixed attributes, we add three tunable parameters (active interface set, the version state, and the default indicator) which are used to control how the Gateway 120 routes requests.
[0041] Referring now to FIG. 5 , there is shown a list summarizing the version configuration metadata 500 :
[0042] implementation version—this is the version of the deployed module implementing the service;
[0043] implementation address—target address;
[0044] service interface version—this is the published interface version which is used by the client;
[0045] compatible interface versions—this is the set of interface versions this implementation can support;
[0046] currently active interface versions—this is the subset of the compatible interface versions this implementation is currently actively supporting;
[0047] default version flag (true/false)—One member of each version group can be tagged as the default version which is designated as the default target to route unversioned requests or in certain cases, versioned requests that cannot be matched with any of the deployed versions in the group; and
[0048] state (active/inactive)—this is the state (active/inactive) flag indicates whether this implementation is able to handle requests
[0049] The default version is also useful in dealing with the transition from unversioned legacy services; an implementation which has been marked as inactive is not eligible to receive requests. Multiple implementation versions supporting the same interface version would not be activated concurrently. The endpoint is the unique target for this implementation version which the gateway uses as the routing destination.
[0050] Table 2 shows an example of the configurable metadata of four deployed versions of a service with their deployed endpoints purposely omitted for simplicity. In this version group, version 1.0.3 can support service contract 1.0, version 1.1.2 can support both contract versions 1.0 and 1.1 and version 1.2.1 can support only contract version 1.2. Currently, three deployed versions are serving requests side-by-side, and version 1.0.3 is designated as the default version of the group for unversioned requests. Note that while there are two deployed versions which support the 1.1 contract, only one of them (1.1.2) is active.
[0000]
TABLE 2
Sample Version Routing Metadata.
Contract
Active
Compatible
Deployed
Version
Contracts
Contracts
Version
Active
Default
1.0
1.0
1.0
1.0.3
Yes
Yes
1.1
1.1
1.0, 1.1
1.1.1
No
No
1.1
1.1
1.0, 1.1
1.1.2
Yes
No
1.2
1.2
1.2
1.2.1
Yes
No
[0051] Since an interface version can be supported by multiple implementation versions in a version group, care must be exercised when configuring the metadata to avoid routing conflicts. For example, if the service administrator decides to retire version 1.0.3 and to forward all the traffic for service contract 1.0 to version 1.1.2, the version metadata of version 1.0.3 is configured to turn the active flag to be false and contract version 1.0 needs to be added to the active contracts that version 1.1.2 currently supports. This is represented in the configuration shown in Table 3. Therefore, configuration validation is necessary to assure a consistent configuration.
[0000]
TABLE 3
Sample Version Routing Metadata.
Contract
Active
Compatible
Deployed
Version
Contracts
Contracts
Version
Active
Default
1.0
1.0
1.0
1.0.3
No
No
1.1
1.0, 1.1
1.0, 1.1
1.1.2
Yes
Yes
1.2
1.2
1.2
1.2.1
Yes
No
[0052] The version metadata discussed so far are sufficient to handle basic version management. They can be extended to include other attributes for more complex scenarios. For example one could add time-based version routing with the addition of a valid-from/valid-to time window.
[0053] The Version Selection algorithm 130 takes the requested interface version 190 as input and searches the version group configuration to find the appropriate implementation version to handle this request. This matching algorithm is described in the pseudo-code of FIG. 4 . If a match is found, the Algorithm 130 returns the matching implementation address to the Gateway 120 . If no match is found, the algorithm 130 returns an error and the Gateway 120 can return an appropriate error result to the service requestor 150 .
[0054] FIG. 6 is a simplified block diagram of a programmable computer that can be configured to operate according to an embodiment of the invention. According to an embodiment of the invention, a computer readable medium, such as a CDROM 601 can include program instructions for operating the programmable computer 600 according to the invention. The processing apparatus of the programmable computer 600 comprises: random access memory 602 , read-only memory 604 , a processor 606 and input/output controller 608 . These are linked by a CPU bus 609 . Additionally, there is an input/output bus 629 , and input/output interface 610 , a disk drive controller 612 , a mass storage device 620 , a mass storage interface 614 , and a removable CDROM drive 616 .
[0055] It is important to note that the present invention as shown in FIG. 6 has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of signal bearing media include CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communication links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The signal bearing media make take the form of coded formats that are decoded for use in a particular data processing system.
[0056] According to another embodiment of the invention, a computer readable medium, such as the CD-ROM 601 can include program instructions for operating the programmable computer 600 according to the invention. What has been shown and discussed is a highly-simplified depiction of a programmable computer apparatus 600 . Those skilled in the art will appreciate that a variety of alternatives are possible for the individual elements, and their arrangement, described above, while still falling within the scope of the invention.
[0057] This method as described can be performed as a service for a second party. In a service embodiment, the Gateway 120 , the VMC 135 , or both, can perform their respective functions for a fee. The fee can be a per-usage fee or a monthly subscription fee.
[0058] An interface to dynamically modify the version configuration has been described. This version configuration interface gives the service provider control over the routing behavior through functions to view, modify and verify the version group configuration. To guard against an inconsistent configuration, the controller validates and rejects the configuration before committing any changes which create routing conflicts. Through this interface the service provider can modify the active interface version set, the version state (active/inactive) and the default indicator. These controls allow the system provider the flexibility to dynamically control the version selection behavior of the system.
[0059] Therefore, while there has been described what is presently considered to be the preferred embodiment, it will understood by those skilled in the art that other modifications can be made within the spirit of the invention. The above descriptions of embodiments are not intended to be exhaustive or limiting in scope. The embodiments, as described, were chosen in order to explain the principles of the invention, show its practical application, and enable those with ordinary skill in the art to understand how to make and use the invention. It should be understood that the invention is not limited to the embodiments described above, but rather should be interpreted within the full meaning and scope of the appended claims.
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A method for hosting versioned web services includes steps of: receiving a request from a service requestor, the request comprising version metadata; parsing the request; extracting the version metadata from the parsing step; and locating a target implementation version using the version metadata. If the target implementation version is located, the method proceeds by dynamically routing the versioned request to the target implementation version.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to the field of efficient channel coding and modulation with large system bandwidths. In particular, the invention relates to a method and to a transmitter for channel coding and modulation in the frequency domain of Orthogonal Frequency-Division Multiplexing wireless networks.
BACKGROUND OF THE INVENTION
[0002] Orthogonal Frequency-Division Multiplexing (OFDM) is a proven access technique for efficient user and data multiplexing in the frequency domain. One example of a system employing OFDM is Long-Term Evolution (LTE). LTE is the next step in cellular Third-Generation (3G) systems, which represents basically an evolution of previous mobile communications standards such as Universal Mobile Telecommunication System (UMTS) and Global System for Mobile Communications (GSM). It is a Third Generation Partnership Project (3GPP) standard that provides throughputs up to 50 Mbps in uplink and up to 100 Mbps in downlink. It uses scalable bandwidth from 1.4 to 20 MHz in order to suit the needs of network operators that have different bandwidth allocations. LTE is also expected to improve spectral efficiency in networks, allowing carriers to provide more data and voice services over a given bandwidth.
[0003] One of the key features in OFDM is the ability to perform frequency-selective scheduling of users, as happens in LTE. In this scheme, estimation of the channel frequency response must be performed in both uplink and downlink directions (and reported to the base station in the downlink case), so that schedulers can perform optimum allocation of resources by choosing the appropriate parts of the spectrum for each user.
[0004] To facilitate this, the base station estimates the uplink channel frequency response and additionally receives downlink channel quality reports from the users, in which an estimation of the downlink channel frequency response is included. Based on these reports the scheduler allocates resources trying to avoid parts of the spectrum with poor frequency response on a per-user basis.
[0005] However, the resource allocation procedure in prior art techniques usually assigns an overall Modulation and Coding Scheme (MCS) to the whole transmission (independently for each code-word in case of employing multiple spatial streams), according to the overall perceived channel quality. This MCS determines the modulation and coding rate to be applied to the whole information packet, with greater redundancy and lower-order modulations when experiencing poorer channel responses (and vice versa). If the bandwidth reserved for a single user is much greater than the channel coherence bandwidth, then the channel will exhibit significant fluctuations in frequency along the scheduled resources. In that case the MCS will have to be fitted to the average channel conditions rather than to the detailed frequency response as reported by the mobile users.
[0006] With the use of ever higher frequency bands, the trend in future cellular systems is to extend the usable system bandwidth up to several hundreds of MHz, as foreseen for the Fifth Generation of mobile communications (5G). Such large bandwidths will translate into similarly large bandwidth allocations for the users, especially in small cells with good radio conditions.
[0007] An example of a simplified procedure for channel encoding and modulation used in prior art techniques is illustrated in FIG. 1 . Essentially, the information passes through a Forward Error Correction (FEC) encoder where redundancy is added to the original data for protection against channel impairments. Depending on the FEC code, and in order to adapt the physical block lengths to the available block sizes accepted by the FEC encoder, the input data may optionally enter in the form of a number of smaller blocks, denoted as “codeblocks”. The FEC Encoder accepts each of these codeblocks as inputs and performs forward error correction to each of them with a fixed coding rate (usually ½ or ⅓, depending on the system). An optional Rate Matching function then accepts the encoded blocks and matches their sizes to the available physical resources according to the chosen MCS, thereby applying a common overall coding rate. The rate-matched codeblocks enter a Constellation Mapping function, where bits are transformed into complex symbols according to the modulation scheme given also by the MCS. These symbols are mapped to physical resources in a Physical Resources Mapping function, thus resulting in a number of modulated subcarriers that comprise the OFDM signal in the frequency domain.
[0008] It must be noted that the operation of transforming the input data into smaller codeblocks is not essential in prior art techniques, as the FEC encoding operation can be directly applied to the input block in some encoding schemes. This may happen e.g. when the sizes of the input data blocks are fixed in the system, or when the performance of the FEC encoder does not change significantly over the range of input sizes foreseen in the system. The same happens with the Rate Matching function, as it is only intended to adapt the variable input sizes to the available physical resources when there is a significant variability in any of them. The examples and figures in the proposed invention are only included for ease of explanation, but are not intended to restrict the applicability of the proposed ideas as will be explained in following sections.
[0009] Problems with existing solutions are that the demand for wider bandwidths aggravates the effect of frequency-selective radio channels, especially in outdoors where the coherence bandwidth is usually much smaller than the system bandwidth because of the large delay spread of the channel.
[0010] Traditional solutions to cope with small coherence bandwidths involve reserving only part of the spectrum for resources allocation in order to avoid nulls in the channel. In current LTE macro deployments this solution fits well with the user expectations, as users are unlikely to demand very large bit rates for high-quality services and thus are not allocated large portions of the spectrum. However when using large system bandwidths, and especially in small cells deployments, large bandwidth allocations can be expected for video services.
[0011] LTE base stations usually try to allocate the whole system bandwidth to the active users in the cell in order to avoid under-utilization of resources. This brings significant channel variations within the scheduled resources that should be tracked by the encoding and modulation scheme. The MCS will suit the average channel conditions along the allocated spectrum rather than the instantaneous frequency response. This effect reduces the effectiveness of the coding scheme and its resilience against multipath.
[0012] Apart from that, current resource mapping procedures in some technologies (like e.g. LTE) do not allow differentiated channel coding and modulation for each of the blocks comprising a given packet, because each block is spread along the scheduled bandwidth and thus cannot be given a separate MCS but rather an average one.
[0013] More specific solutions for efficient modulation and coding schemes are therefore needed when deploying large system bandwidths in OFDM under frequency-selective radio channels.
SUMMARY OF THE INVENTION
[0014] The present invention proposes a change in prior art channel encoding/decoding and modulation techniques in wireless OFDM systems in order to increase the link adaptation to frequency-selective radio channels, especially suitable for large system bandwidths and low-mobility situations.
[0015] To that end, in accordance with a first aspect there is provided a method for channel coding and modulation in the frequency domain of Orthogonal Frequency-Division Multiplexing wireless networks comprising, as commonly in the field: a) applying, by a transmitter, a Forward Error Correction to at least one information block, or data, to be sent to a receiver; and b) modulating, by the transmitter, said at least one encoded information block prior to its transmission to said receiver, the transmitter having knowledge of a channel frequency response as seen by the receiver.
[0016] On contrary of the known proposals, in the method of the first aspect, the steps a) and b) are performed at a variable-rate by performing, at the transmitter side, the following steps: transforming the information block into a number of smaller packets denoted as codeblocks, said codeblocks fitting the input sizes accepted by said Forward Error Correction; selecting a set of modulation and coding schemes to be independently applied to each of said codeblocks, said set of modulation and coding schemes comprising values of the coding rates and the modulation orders that best fit the channel frequency responses as experienced by said codeblocks; including information about said selected set of modulation and coding schemes within part of physical resources devoted to user data by reserving specific subcarriers and OFDM symbols; and mapping the encoded and modulated information within the physical resources devoted to user data and not reserved for carrying said selected set of modulation and coding schemes, first in order of ascending OFDM symbols and then in order of ascending subcarriers.
[0017] According to the invention, the transmitter comprises at least one base station or a user terminal. In addition, the channel frequency response is reported from the receiver to the transmitter side in Frequency Division Duplex, FDD, mode, or directly estimated by the transmitter in Time Division Duplex, TDD, mode.
[0018] The different modulation and coding schemes to apply on each codeblock may be characterized according to the following expression: MCS i =MCS avg +ΔMCS i ; where MCS i denotes the modulation and coding scheme of the i-th codeblock, MCS avg is the average modulation and coding scheme for the whole transmission and ΔMCS i denotes the differential MCS values with respect to said average modulation.
[0019] The information about the selected set of modulation and coding schemes included within part of the physical resources devoted to user data may include only differential MCS values.
[0020] According to the invention, the differential MCS values may be encoded through any Forward Error Correction method, some examples may include a convolutional turbo, a turbo code, Reed-Muller, etc. Then, it is used a constellation mapping function, including at least a Binary Phase Shift Keying modulation, for modulating the encoded codeblocks and protecting them against channel impairments.
[0021] Preferably, the codeblocks have the same sizes prior to be encoded by the Forward Error Correction.
[0022] According to an embodiment, a Rate Matching function then further matches the sizes of the codeblocks after the Forward Error Correction to available physical resources adjusting the different coding rates of each of the codeblocks. Furthermore, the Rate Matching function further adjusts the sizes of the codeblocks after Forward Error Correction to reserve part of the available physical resources for carrying indications on the modulation and coding schemes to be used.
[0023] According to a second aspect there is provided a transmitter for channel coding and modulation in the frequency domain of Orthogonal Frequency-Division Multiplexing wireless networks, the transmitter, including at least one of a base station or a user terminal, having knowledge of a channel frequency response as seen by a receiver and comprising as commonly in the field: coding means to apply a Forward Error Correction to at least one information block to be sent to a receiver; and modulation means to modulate the at least one encoded information block prior to its transmission to said receiver.
[0024] On contrary of the known proposals, the transmitter also comprises: adaptation means to transform the information block into a number of smaller packets denoted as codeblocks, said codeblocks fitting the input sizes accepted by said Forward Error Correction; tuning means to select a set of modulation and coding schemes to be independently applied to each of said codeblocks; means to include information about said selected set of modulation and coding schemes within part of physical resources devoted to user data; and mapping means to map the encoded and modulated information within the physical resources devoted to user data and not reserved for carrying said selected set of modulation and coding schemes, first in order of ascending OFDM symbols and then in order of ascending subcarriers.
[0025] The transmitter of the second aspect may also include rate matching means to at least match the sizes of the codeblocks after the Forward Error Correction to available physical resources.
[0026] The subject matter described herein can be implemented in software in combination with hardware and/or firmware, or a suitable combination of them. For example, the subject matter described herein can be implemented in software executed by a processor. For instance, a computer program comprising software code adapted to perform the steps according to the method of the first aspect when said program is run on a computer, or even on a digital signal processor, a field-programmable gate array, an application-specific integrated circuit, a micro-processor, a micro-controller, or any other form of programmable hardware may be also provided by the invention.
[0027] Summarizing, the positive effect of the varying modulation and coding scheme values, or MCS, will be a higher adequacy of the modulation and coding scheme to the channel conditions in the frequency domain, especially when allocating large chunks of bandwidths for user allocations. Channel variations in the frequency domain can be moderate (for values of the channel coherence bandwidth higher than the allocated bandwidth) or very significant (for values of the channel coherence bandwidth smaller than the allocated bandwidth). Therefore the MCS variations can be suitably described by positive and negative indices around the average MCS according to the maximum observed channel variations for a given user.
[0028] The suitability of the proposed variable-rate coding scheme will be higher in low-mobility conditions, where the channel coherence time is large and channel variations in the time domain are sufficiently small. Channel conditions as known at the base station will thus remain valid for the time elapsed between application of the proposed MCS variations and reception of the codeblocks by the user.
[0029] The proposed invention can be applied on a per-user basis depending on the allocated bandwidth, expected user traffic, channel conditions and degree of user mobility, in both uplink and downlink directions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The previous and other advantages and features will be more fully understood from the following detailed description of embodiments, with reference to the attached, which must be considered in an illustrative and non-limiting manner, in which:
[0031] FIG. 1 illustrates an encoding and modulation process according to prior art techniques.
[0032] FIG. 2 illustrates the encoding and modulation process proposed in the present invention.
[0033] FIG. 3 illustrates the different codeblock sizes after encoding, rate matching and mapping on OFDM physical resources.
[0034] FIG. 4 is a flow chart for applicability of the invention at a transmitter including a base station.
[0035] FIG. 5 illustrates the encoding and modulation processing steps showing the required changes for application of the proposed invention according to some embodiments.
[0036] FIG. 6 is a comparison between a resource mapping technique in prior art techniques (a) and in the proposed invention (b).
[0037] FIG. 7 illustrates the encoding and mapping method for the MCS incremental values.
[0038] FIG. 8 is an example of a possible resource mapping scheme for the MCS indications.
[0039] FIG. 9 illustrates an exemplary embodiment for the proposed invention in downlink direction.
[0040] FIG. 10 illustrates an exemplary embodiment for the proposed invention in uplink direction.
DETAILED DESCRIPTION OF THE INVENTION
[0041] FIG. 2 illustrates the proposed method for variable-rate channel coding and modulation, with the modified processing blocks filled in with dots. Irrespective of whether prior art techniques partition the data into smaller codeblocks or not, this invention proposes to exploit such partitioning with a completely different intention. As seen in FIG. 2 , instead of applying a fixed modulation and coding scheme to the whole block of information, different modulation and coding schemes (MCS) values will be employed for each of a series of codeblocks in which the input data are previously partitioned, with the purpose of matching them with the channel conditions in the frequency domain. These instantaneous MCS values will be obtained by tuning means 140 or MCS Fine Tuning as termed in the figure, from the available channel frequency responses.
[0042] The fine-tuned MCS values will be preferably characterized by an average MCS value, similar to the one employed in prior art techniques, plus a number of MCS variations ΔMCS i that track the variations in the channel conditions around the average value in the frequency domain.
[0043] Channel conditions will be assumed to be known at a transmitter side via direct estimation of the received signals (in Time-Division Duplex mode, or TDD, where channel reciprocity can be assumed) or by means of channel state reports received from the users (in Frequency-Division Duplex mode, or FDD). It is not unusual that base stations in OFDM systems have detailed knowledge of the wideband channel characteristics of each of the users in order to perform frequency-selective scheduling. These channel quality indications in the frequency domain may have coarse granularity, but they usually suffice in order to know where the best regions of the spectrum are located. The same indications can be exploited for obtaining the most suitable MCS values for each of the codeblocks.
[0044] A Rate Matching means 110 then can perform rate matching of the codeblocks according to the different MCS values assigned to each of them, as opposed to prior art techniques where a single MCS is assigned to all the codeblocks. It is thus conceptually indicated in FIG. 2 as multiple blocks operating in parallel over the input codeblocks (although practical implementations may not present this parallelized structure at all). It may happen that the Rate Matching means 110 is not actually needed in practical implementations, whenever the FEC Encoding module/means 100 is able to operate at different code rates as envisioned in the system; however it is depicted for ease of reference and other possibilities are not precluded without departure from the ideas proposed in this invention.
[0045] Then, a Constellation Mapping module/means 120 will transform the information into complex samples on a per-codeblock basis, eventually considering a different modulation for each of them. At that time, a mapping means or Physical Resources Mapping module 130 as termed in the figure will finally map the complex modulated signals into OFDM symbols and subcarriers, in such a way that the encoded codeblocks will undergo different modulation and coding rates according to their relative channel qualities. After Physical Resources Mapping 130 each of the encoded codeblocks will have a different length according to the actual MCS values. FIG. 3 sketches how the different codeblocks end up with different sizes after encoding even having the same lengths prior to encoding. The amplitude of the channel transfer function |H(f)| determines the MCS values corresponding to each of the blocks, yielding higher block sizes for poorer channel responses and vice versa.
[0046] The average MCS value will be signaled to the user according to any suitable prior art technique, but the MCS variations are proposed to be encoded separately across the resources allocated for user data by employing a specific encoding scheme. The reduced amount of extra signaling implied by the additional MCS variations will thus be negligible compared to the available data space, given that the proposed invention makes especial sense when allocating large bandwidths to a user. Different coding rates for each codeblock translate into different amounts of redundancy to be applied by the FEC encoder 100 processing, thereby varying the level of protection against channel impairments. If the MCS variations are adapted to the channel fluctuations then the encoding process will be better suited to the effects of the channel in the frequency domain. In addition, eventual variations in the modulation order translate also into different amounts of available information in a given time-frequency resource, by which a varying degree of channel protection can also be applied.
[0047] FIG. 4 illustrates a chart containing a suitable decision process whereby a base station can decide whether or not to apply the proposed variable-rate channel coding and modulation method. From the user's amount of expected data traffic, mobility conditions and availability of the detailed channel frequency response in uplink or downlink, the scheduler will decide whether or not the proposed scheme is applied for the next transmission(s). The base station first evaluates whether wideband frequency response characteristics of the channel are available and up to date for that user. If it is not the case then the system switches to prior art encoding and modulation techniques. If they are available, the base station then evaluates the degree of user mobility. User mobility can be estimated from a number of techniques, such as the rate of variation of the channel quality indicators (as reported from the users), the number of cell reselections or handovers over a given period in time, or explicit velocity indications from the users, among others. If mobility is high it is preferable to perform prior art encoding and modulation techniques, with a common MCS value for the whole transmission. If it is low, then the base station evaluates whether the allocated bandwidth is greater than the coherence bandwidth of the channel. Again, if it is not the case the system switches to prior art techniques, on the contrary the present invention can be applied.
[0048] If the base station decides to perform the changes described in this invention then these changes can be performed both in uplink or downlink, as part of the link adaptation unit at Medium Access Control (MAC) level. Changes in transmission for the downlink direction will be performed by the base station, while changes for the uplink direction will instead be performed by the user terminal.
[0049] Application of the proposed variable-rate encoding and modulation method implies a number of steps to be taken at the transmit side (base station or user terminal), as illustrated in FIG. 5 where blocks with substantial changes are filled with dots. According to prior art techniques, the Link Adaptation module/means 150 decides the average MCS (MCS avg ) as well as the allocated bandwidth reserved for a given user from the available channel quality indicator, and thus determines the transport block size to be used. The input/information block is segmented in the Codeblock Segmentation module/means 90 into the codeblocks that fit the available block sizes prior to the FEC encoder 100 .
[0050] The MCS Fine Tuning 140 then calculates appropriate MCS variations (ΔMCS i ) for each of the codeblocks that enter the FEC encoder 100 according to the detailed channel frequency response. These MCS variations will correspond to integer positive and negative values around the average MCS, with a maximum variation given by the maximum channel variation and the maximum allowed signaling overhead. The codeblocks will undergo a FEC encoding process whereby each block is encoded with a different MCS value (MCS i ), as given by the sum of the average MCS (MCS avg ) and the MCS variations (ΔMCS i ):
[0000] MCS i =MCS avg +ΔMCS i .
[0051] The FEC encoder 100 includes a fixed-rate Forward Error Correction such as convolutional, turbo, Low-Density Parity Check, or any other that operates independently over each input codeblock. It is then followed by a Rate Matching stage 110 that adjusts the amount of redundancy in each of the codeblocks in order to match the resulting block lengths with the available physical resources. Redundancy is determined by the actual MCS value to be applied on each codeblock, as opposed to prior art techniques where the same average MCS value is applied for all codeblocks.
[0052] The different MCS values to be applied over each codeblock will imply different coding rates and, eventually, different modulation schemes. However, and for ease of decoding, the size of the codeblocks prior to FEC encoding will be the same as when using a common average MCS value, and given by the codeblock segmentation module/means 90 . Thus each codeblock will only differ in the amount of added redundancy after the FEC encoder 100 and Rate Matching 110 . The total amount of encoded information in the whole packet will roughly be similar to the case of having a single average MCS value, as channel variations will be somewhat symmetric around the average, but in any case the differences shall be taken into account at the rate matching process as will be further explained.
[0053] A Codeblock Concatenation module/means 115 puts together all the encoded (and rate-matched) codeblocks that comprise the transmission. The Constellation Mapping module/means 120 then transforms them into complex samples from a suitable constellation, usually QPSK, 16QAM or other higher-order modulations, with possibly different modulations for each of the concatenated codeblocks depending on their MCS values. This is in contrast with prior art techniques where all complex symbols contained within the user payload usually have the same modulation order.
[0054] The Physical Resources Mapping 130 then transforms complex symbols into actual subcarriers in the OFDM time-frequency grid. This invention proposes to perform the mapping function in horizontal order, from lower to higher OFDM symbols and from lower to higher subcarriers (as seen in FIG. 6 ), rather than in vertical order. Other prior art techniques sometimes perform the mapping in vertical order, from lower to higher subcarriers and from lower to higher OFDM symbols, as e.g. in LTE, to further increase frequency diversity. However this would conflict with the desire that each codeblock undergoes a given MCS corresponding to the frequency-domain channel characteristics. Given that the channel characteristics are usually estimated, and reported to the base station, over certain portions of the spectrum, and averaged over the OFDM symbols in the time domain, this invention performs the mapping in order that the MCS of each codeblock fits the corresponding frequency response.
[0055] The proposed changes can coexist with the use of transmit or receive diversity antenna techniques, where two or more antennas cooperate in transmission or reception for increased diversity and robustness. Should any diversity scheme be applied, it would comprise the same operations upon transmission or reception irrespective of the actual encoding and modulation process in use. The only difference would be the increased quality generally perceived for each codeblock as a result of the diversity process; combined channel values would anyway be obtained from the additional antennas, and reported to the base station as in the single-antenna case.
[0056] An exception would be the case of using spatial multiplexing techniques, as e.g. in Multiple-Input Multiple-Output (MIMO) 2×2 or 4×4. In these cases the resulting qualities of the codeblocks depend fundamentally on the inter-stream interference that arises from the MIMO operation, which is difficult to predict at the base station on a codeblock basis. In addition, signaled MCS i values reported for each of the spatial streams would also suffer from inter-stream interference that could prevent correct detection of the whole packet. Therefore the proposed invention should not be used in MIMO spatial multiplexing and prior art encoding techniques should be employed instead.
[0057] With respect to the calculation of the MCS values, such MCS values to apply on each codeblock can be characterized by positive and negative increments around the average MCS, denoted in what follows as MCS incremental values, according to the expression:
[0000] MCS i =MCS avg +ΔMCS i .
[0058] The average MCS is always calculated in prior art techniques from the average channel quality and thus it is not covered by the present invention. Calculation of the incremental MCS values however requires knowledge of the channel frequency response prior to transmission. The situation differs in downlink and uplink directions.
[0059] In downlink direction the base station knows the channel frequency response either from reported channel quality indications sent by the terminals (in FDD mode) or by direct estimation from uplink signals (in TDD mode). In both cases the base station can perform variable-rate coding on a per-user and transmission basis as described in the present invention. Even a coarse granularity for the reported channel quality indicators may be sufficient to modulate the MCS values and thus exploit the variable channel characteristics.
[0060] However in uplink direction the user terminal would only know the channel frequency responses from direct estimation of downlink signals in TDD mode, or else from explicit channel quality reports sent by the base station in FDD mode. The latter is usually not contemplated in wireless cellular systems and thus a special procedure would have to be explicitly devised. It is therefore desirable that variable-rate encoding as proposed in the present invention is only applied in TDD mode for uplink direction, as in FDD a specific procedure should be devised for channel quality reporting from the base station to the users. In downlink however the changes can be applied both for FDD and TDD modes with no particular restrictions.
[0061] The average MCS value can be signaled as in prior art techniques by any suitable control indication. As an example, in LTE a Downlink Control Indication (DCI) contained in the Physical Downlink Control Channel (PDCCH) carries the downlink and uplink scheduling assignments as well as the MCS format. However the incremental MCS values around the average MCS must be separately signaled to the users for appropriate decoding. These indications should be sent on a per-user basis, as each would receive different MCS values according to their perceived channels. The resulting signaling overhead can be significant when transmissions comprise a high number of codeblocks. Therefore it is proposed to include a special indication interspersed with user data, as further explained below.
[0062] It can be very onerous to signal the MCS incremental values ΔMCS i on standard control channels devoted to the assignment of resources, especially for the cases of large system bandwidths and a high number of codeblocks per transmission. Therefore, it is proposed to include them as part of the data payload after suitable channel encoding.
[0063] FIG. 7 illustrates an embodiment of the proposed encoding and mapping method of the MCS incremental values for a given transmission. The set of values are first represented in suitable digital format with a given word length (that determines the maximum and minimum ΔMCS i values), and then conveniently FEC-encoded for protection against channel impairments. FEC coding 100 should be very robust as any incorrectly detected values of ΔMCS i would lead to a packet loss. Repetition or Reed-Muller coding, along with Walsh spreading, could be suitable for this case, as they are employed e.g. in LTE for the Physical HARQ Indicator Channel or PHICH; however any other suitable technique can also be employed. It is desirable that the resulting protection level of ΔMCS i is similar to that of the MCS average value, in order to have similar robustness in the decoding of MCS avg and ΔMCS i .
[0064] After the FEC encoder 100 , the Constellation Mapping module/means 120 transforms the digital information into complex symbols from a given constellation. Binary Phase Shift Keying (BPSK) modulation is desirable in this case for increased robustness, but other modulation orders can also be used depending on each implementation.
[0065] The resulting complex symbols are mapped along suitable subcarriers and OFDM symbols in the Resource Mapping 130 , interspersing them with user data along time and frequency dimensions for increased diversity. A predefined mapping function can be devised along the allocated spectrum that exploits time and frequency diversity, skipping subcarriers reserved for purposes other than data, e.g. pilots, reference signals, synchronization signals, etc.
[0066] FIG. 8 schematically illustrates a possible mapping of the signaling information that exploits frequency diversity by spreading the complex symbols throughout the bandwidth and OFDM symbols reserved for the user. Given N values of ΔMCS i , each of them requiring d complex symbols after FEC coding and constellation mapping, the set of N·d complex symbols can be suitably mapped over subcarriers exploiting frequency diversity as shown in the figure.
[0067] The details of the mapping function shall be known in advance by the users in order to locate the MCS indications prior to decoding the data. The number of codeblocks will be given by the transport block size (as appropriately signaled with prior-art techniques) and the codeblock segmentation function.
[0068] In case that any transmit diversity technique is applied (as e.g. Alamouti), it will also affect the MCS indications in such a way that the ΔMCS i values undergo the same precoding operations as user data for the involved antennas.
[0069] Apart from signaling the MCS values, the base station shall deliver an indication to the user equipment when the proposed changes are applied through any suitable procedure, e.g. a special field within a resources assignment message or any other control message. Such control indication is outside the scope of the present invention.
[0070] The rate matching function, for the cases where it is applied as part of the encoding process, is modified with respect to prior art according to three principles:
[0071] Rate matching for each codeblock shall be variable and dependent on the actual MCS value that best fits the channel conditions. The codeblock lengths before FEC encoder 100 remain equal to the value obtained without application of the proposed invention, but after FEC encoder 100 and Rate Matching 110 the encoded block lengths will be different because of the variable added redundancy.
[0072] As a result of the variable-rate encoding of the codeblocks, the whole resulting packet length can be slightly different than without considering the proposed invention. This is due to the variable redundancy added or deleted from the encoded blocks as compared to the overall redundancy present in a fixed MCS scheme. The resulting differences shall be absorbed by the rate matching function in order to suit the available physical resources, with little impact on the overall coding rate as differences should be minimal.
[0073] Furthermore, the signaling indications for ΔMCS i included within the space reserved for the payload leave less space available for data resources. The rate matching function shall take this into account when adjusting the sizes of the codeblocks after FEC encoder 100 to the available physical resources. However the impact will be negligible with practical codeblock sizes: e.g. in turbo coding a typical codeblock size of 3000 bits would be augmented with a ΔMCS indication of, say, 4 or 5 bits, which is completely negligible.
[0074] The proposed encoding scheme does not affect Hybrid Automatic Repeat Request (HARQ) operation as successive retransmissions will employ the same transport block sizes as the original transmission, thus leading to the same codeblock lengths prior to FEC encoder 100 . The HARQ function controls retransmissions at MAC level. It is intimately related to the rate matching function as separate retransmissions undergo different redundancy versions (in incremental redundancy schemes), which in turn require different rate-matched blocks. The proposed invention can be used with HARQ adaptive retransmissions where MCS formats and frequency locations can be different upon each new retransmission, provided that each codeblock is always rate-matched independently from the others.
[0075] With respect to FIG. 9 it is illustrated a preferred embodiment for the proposed invention in downlink direction, i.e. the transmitter being a base station. Assuming that a base station 91 activates the proposed encoding method for a given user, it schedules a transmission for a given user 911 and calculates the set of incremental MCS values 912 that best suits the channel characteristics for that user. The incremental MCS indications are included within physical resources reserved for user data 913 , and variable-rate encoding and modulation is performed according to the present proposal 914 . The user terminal 92 receives the downlink signal transmitted from the base station, and decodes the MCS incremental values corresponding to each codeblock 921 . With such indications it can then perform variable-rate decoding of user data according to the detected MCS values 922 .
[0076] With respect to FIG. 10 it is illustrated a preferred embodiment for application of the proposed invention in uplink direction, i.e. the transmitter being a user terminal. The user terminal 102 receives from the base station a suitable uplink scheduling grant 1021 indicating the allocated resources for uplink transmission. The MCS incremental values are calculated 1022 from the a-priori known uplink channel frequency response, and encoded within the resources reserved for data transmission 1023 . The user terminal thus performs variable-rate encoding and modulation of user data 1024 as described in the present invention. The base station 101 receives the uplink signals, decodes the incremental MCS values 1011 and performs variable-rate decoding of the user data 1012 .
[0077] Application of the proposed invention in both uplink and downlink is decided by the base station as part of the normal scheduling process, depending on the degree of user mobility, availability of channel frequency responses and amount of data to be served. A suitable control indication should also be sent to the user terminal whenever the proposed invention is applied for a given transmission, but such indication is outside the present invention.
[0078] Consequently, present invention exploits the availability of frequency-selective channel quality indications in order to better fit the encoded blocks that comprise a packet to the channel variations in the frequency domain. By fine-tuning the modulation and coding schemes separately for each of the blocks that comprise a transmission it is possible to match the channel variations much more precisely.
[0079] Current cellular systems devise link adaptation mechanisms that fit transmissions to the instantaneous channel variations in the time domain. However similar variations in the frequency domain are only exploited for scheduling decisions, not for efficient coding and modulation. Systems employing large bandwidths would benefit from the proposed variable-rate encoding and modulation technique, as in this case the channel coherence bandwidth would be much lower than the spectrum granted for each user. Channel variations would therefore be very significant in the frequency domain, and the encoded blocks comprising a transmitted packet would undergo large channel fluctuations around the average value. The proposed invention would better adjust the encoding and modulation process especially in good, static conditions with large bandwidths granted for a user. High-quality wireless services would thus benefit from lower error rates and a lower number of physical retransmissions.
[0080] The preferred embodiments can be applied to any OFDM wireless communications system, such as LTE, IEEE 802.11 (Wi-Fi) or IEEE 802.16 (WiMAX), not precluding other OFDM wireless technologies. Modifications to the described invention can be devised by people skilled in the art in order to adapt it to the specifics of each technology without departure from the fundamental ideas described here.
[0081] The proposed embodiments can be implemented as a collection of software elements, hardware elements, firmware elements, or any suitable combinations of them.
[0082] The scope of the present invention is defined in the following set of claims.
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The method comprising: applying, by a transmitter, a Forward Error Correction to an information block to be sent to a receiver and modulating said information block prior to its transmission, wherein the transmitter has knowledge of a channel frequency response seen by the receiver and the applying and modulating are performed at a variable-rate, at the transmitter side, by: transforming the information block into a number of smaller packets denoted as codeblocks fitting the input sizes accepted by the Forward Error Correction; selecting, a set of modulation and coding schemes to be independently applied to each of the codeblocks; including, information about the selected set of modulation and coding schemes within part of physical resources devoted to user data by reserving specific subcarriers and OFDM symbols; and mapping, said information within physical resources devoted to user data and not reserved for said selected set of modulation and coding schemes, first in order of ascending OFDM symbols and then of ascending subcarriers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to receptor sheets for use in transfer or deposit imaging systems and particularly to receptor sheets having indicia on a nonimage receiving surface.
2. Background of the Art
Many imaging materials and processes require specialty papers in order to perform at their highest levels. Photographic paper often comprises a white paper base with a coating of resin or pigmented resin. Usually the pigment is white (e.g., TiO 2 ) in order to provide a bright white background (U.S. Pat. No. 4,481,289, 4,447,524, and 4,312,937). Transfer or deposit imaging systems such as thermal transfer (e.g., U.S. Pat. No. 4,690,858 and 4,614,682), photoresist transfer (e.g., U.S. Pat. No. 4,710,445, 4,656,114, and 4,666,817), ink jet printing, and the like perform best when a surface has been particularly designed to function in combination with the imaging material being deposited. Sometimes the design is enhanced to contribute to either the optical qualities of the material or to its physical adherence properties.
For example, U.S. Pat. No. 4,614,682 describes a paper receiving sheet for thermal image transferring processes as plain paper, or paper with a coating of resin and filler (e.g., pigments such as titanium oxide, or zinc oxide) for facilitating the transfer of a dye component from the donor layer to the transfer sheet. U.S. Pat. No. 4,690,858 describes the use of coated paper as a receptor sheet (col. 4, lines 31-34).
These receptor sheets do not necessarily have the same type of surfaces on both sides of the base layer. This can be done to save costs during manufacture or to prevent images from being deposited on both sides of the receptor With many types of differences between the surfaces of the receptor sheet, it is still somewhat difficult to distinguish the receptor surface from the backside. This can create an appearance of poor performance in the product if the wrong surface is used. To assist in the proper recognition of the receptor surface, the backside of the receptor sheet is sometimes printed with ink as with a logo of the manufacturer, to distinguish the front side from the back. Dark inks can often be seen through the sheet, and even the low optical density printing used can be observed with transmitted lighting. The printing step may also require a separate processing line, which adds to the expense, and certain preferred coatings (e.g., olefins and polyester) do not accept print easily.
Polyolefin film filled with titania and having a backside adhesive coating are used as diaper tabs. The film is sometimes marked by embossing after extrusion. The embossing creates significant variations in the transmission optical density as well as the reflection optical density of the film. The embossing affects both surfaces of the film, but is partially masked on one side by the adhesive.
SUMMARY OF THE INVENTION
Chill roll marking of the backside of polymer coated paper receptor sheets after extrusion of the polymer coating onto the paper and before cooling of the coating produces a differentially reflected image which is clearly discernible visually and distinguishes the backside of the receptor sheet from the front side.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE shows the actual performance of the process of the present invention.
DETAILED DESCRIPTION OF THE DRAWING
The figure shows the operation of the process of the present invention. A sheet of paper (2) passes under an extrusion device (4) where a thermoplastic polymer coating composition stream (6) is deposited upon one surface (8) of the paper (2). The coated paper (10) then passes between two nip rollers (12,14). The nip roller (16) in contact with the polymer coated surface of the paper (10) is at a temperature below that of temperature of the polymer (6) on the paper (2). After passing through the nip rollers (12,14), the surface (16) of the polymer coated paper bears an image (not shown) produced by the surface characteristics of nip rollers (14).
DETAILED DESCRIPTION OF THE INVENTION
Coated papers for use as photographic bases on receptor sheets for images can be produced normally in a multistage process which involves 1) providing a paper base, (2) optionally priming the paper base, (3) extruding a polymer coating composition onto said paper base, (4) passing the coated paper between nip rollers, the coated surface of the paper contacting the surface of a chill roll as part of the nip rollers, (5) moving said coated sheets in contact with said chill roll to cool said extruded polymer, (6) removing said coated paper from the chill roll and (7) winding up said coated paper. The practice of the present invention does not require a major change in the apparatus used in the general paper coating process. By providing a chill roll having a surface with differential surface characteristics, a readily readible image can be produced on the coated paper. By the term "differential surface characteristics" is meant that between predetermined areas in the chill roll surface there is a difference in the physical properties or dimensions (i.e., height above a reference axial level) so that visually observable different characteristics can be imposed on a softened polymeric surface. This term does not require the presence of a relief image (either positive or negative) on the surface of the chill roll. In fact, relief images are not preferred. It is desirable to have the surface of the chill roll provided with areas of different smoothness so that a difference in reflectivity is imposed upon the coated paper. This offers a number of significant benefits. If there is no relief embossing composed upon the coated paper, there is no significant differential in paper and there is no significant differential in transmissivity created in the coated paper because of variations in the thickness of the polymer coating. It is desirable to keep the surface variations on the chill roll and the resultant impressions on the polymer coating surface to less than 30 microns, preferably less than 20 microns, more preferably less than 15 microns and even less than 8 microns. With these small variations in thickness, very little or no variations can be seen in the optical density of the paper, even in a transmission mode. There need be no variation in thickness at all, as a difference in the smoothness (roughness) of the surface creates a visually observable characteristic.
The paper base itself may comprise either natural fiber, synthetic fiber, or a mixture of both materials. The paper usually weighs between 20 and 200 g/m 2 without the coating thereon. Each polymer coating on the paper usually weighs between 5 and 150 g/m 2 , depending upon the particular purpose of the sheet. This weight is inclusive of any whitening pigment which is usually present as from 1 to 50% by weight of the coating. Titanium oxide is the most preferred pigment but other inorganic oxides and even carbonates can be used.
It is desirable that the paper not exhibit a variation in optical density between the marked or unmarked areas on the backside when there is backlighting on the paper base. There should be an optical density variation of less than 0.2 when viewed in the transmission mode with high intensity room lighting. Preferably there should be an optical density variation of less than 0.1 when so viewed.
The temperature of the resin during extrusion is usually between 90 and 200° C., the temperature of the chill roll is usually between 0 and 40° C. The speed of the paper through the operation is usually between 100 and 500 ft/min (30 to 150 m/min).
The polymer used in the coating operation may be substantially any transparent (preferably colorless) thermoplastic resin such as polyolefins, nylons, polyesters, polyvinyl resin and the like. Polyolefins such as polyethylene, polypropylene, and mixtures, blends, and copolymers thereof are most preferred.
These and other aspects of the invention will be understood from a reading of the following non-limiting Example.
EXAMPLE
A roll of commercially available white, primed paper stock is fed by rollers towards an extrusion head at about 91 meters per minute. A composition comprising 85 percent by weight polyethylene and 15 percent by weight titania is extruded at 120° C. onto the paper at a coating weight of about 30 g/m 2 . The coated paper passes into a nip roll. The roll contacting the coated face of the paper is maintained at an average temperature of about 10° C. The paper is wound after leaving the surface of the chill roll.
The surface of the chill roll had areas that were roughened to outline a repeat image that showed "SCOTCH". The image area was smooth. Unwinding a portion of the rolled paper and viewing the sheet in a reflective mode, the more reflective areas of the sheet outlined the figure "SCOTCH". Looking at the paper with material sunlight from a northern exposure, no variation in optical density through the sheet could be observed.
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A receptor sheet for image-transfer processes is provided by providing a backside polymeric coating on the sheet with differential surface characteristics which can be visually observed. The characteristics may define a logo to differentiate the backside from the receptor surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a sensing and warning system for ladder load, and particularly to a sensing and warning system composing of sensing means, a recording and calculation device, and an alarm for detecting, recording and evaluating the ladder load, and sending an alarm signal in case the ladder load exceeds its maximum withstandable value.
2. Description of the Prior Art
A ladder, a foldable or an extension type, is widely used in domestic and professional construction work.
FIG. 1 is a drawing of a common foldable ladder. The ladder has at least two pairs of ladder legs 11 , 12 , each pair of legs 11 and 12 is provided with a pair of feet 111 , 112 and 121 , 122 respectively, and each of them wears a mat 15 for increasing friction with the ground so as to prevent accidental slipping. A platform 13 is hinged to the top ends of the legs 11 , 12 and a pair of hasps 14 is provided each releasably secured to the opposite leg 11 or 12 such that the ladder is developed in a derrick figure when in use.
For ensuring the use's safety, both the manufacturer and the inspection authority are very careful in upgrading the construction material and design criteria and always reminding the user how to use a ladder securely without overloading. As a matter of fact, people occasionally hear of accidents arising from misuse of ladders such as overloading and ignoring safety rules. Relief measures for victims' rehabilitation often cause great trouble to the manufacturer, the employer and the insurance company.
In order to overcome the problems inherent to the conventional ladders described above, the present inventor has studied this matter for a long time and developed the present invention.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a sensing and warning system for ladder load to be installed in the ladder feet for detecting, recording and calculating the ladder load, and sending an alarm signal in case the ladder load is dangerous.
It is another object of the present invention to provide a sensing and warning system for ladder load whose recorded and calculated loading data can assist to identify the responsibility in case of the occurrence of accident.
It is one more object of the present invention to provide a sensing and warning system for ladder load that the sensing means can be equipped in the hasp between two ladder legs so as to promptly warn the user entrained on the ladder in a critical situation such as collapse of the ladder by slipping.
To achieve these and other objects described above, the sensing and warning system for ladder load according to the present invention is composed of sensing means, a recording and calculation device, and an alarm. The sensor means further includes a connecting member, a sensor and a base. The connecting member is formed in a block structure and is concealed and engaged to each ladder foot. A sensor is installed under the connecting member, the base is located beneath the sensor but can be enclosed by a foot mat. The sensor is connected to a CPU of the recording and calculation device whose output terminal is further connected to the alarm. With this structure, the sensing means detects the ladder load at any moment and sends the detected data to the recording and calculation device for evaluation. If the ladder load exceeds the predetermined maximum allowable value, the alarm delivers a warning signal to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
For 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:
FIG. 1 is a three dimensional view of a conventional ladder.
FIG. 2 is a block diagram of the present invention.
FIG. 3 is a cross sectional view showing the arrangement of the present invention.
FIG. 4 is a partial cross sectional view illustrating the detail construction of the sensing means according to the present invention.
FIG. 5 is a cross sectional view illustrating the operation of the sensing means according to the present invention.
FIG. 6 is a block diagram in a first embodiment of the present invention.
FIG. 7 is an exemporary view illustrating that the ladder is under an offset loading of the user's weight.
FIG. 8 is a view wherein the sensing means is equipped in a hasp connecting two ladder legs in a second embodiment of the present invention.
FIG. 9 is a view wherein a lever type sensor is employed by the sensing means in a third embodiment of the present invention.
FIG. 10 is a view wherein a type sensor is employed by the sensing means in a fourth embodiment of the present invention.
FIG. 11 is a view wherein a diaphragm sensor is employed by the sensing means in a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to block diagram of FIG. 2, the sensing and warning system of the present invention is composed of sensing means 2 , a recording and calculation device 3 (with a CPU), and an alarm 4 .
Referring to FIG. 3, the sensing means 2 is equipped in each ladder foot, and the recording and calculation device 3 , and the alarm 4 are equipped in each ladder leg above the sensing means 2 .
Referring to FIGS. 4 and 5, wherein the detail construction of the sensing means 2 is shown. The sensing means 2 includes a connecting member 5 , a sensor 6 , and a base 7 . The connecting member 5 is formed in a block structure with a diameter corresponding to the inner diameter of a ladder foot 82 so as to be concealed in each ladder foot and screw combined to the ladder foot 82 through tapped holes 51 , 52 at both sides thereof. Lower end of the sensor 6 is inserted into an oil container 71 formed at the center of the base 7 such that a liquid oil 72 filled in the oil container 71 is in contact with the probe of the sensor 6 thereby enabling the sensor 6 to detect a change of pressure and sending the detected data to the recording and calculation device 3 .
Each base 7 wears a foot mat 8 which is snugly enclosing the ladder foot 82 with a collar 81 so that the ladder is able to vary its height as the loading of the ladder changes.
Referring to FIG. 5, when the ladders is in use, the sensing and warning system performs a monitoring function through built-in interconnection wiring. In case the ladder loading exceeds predetermined maximum allowable value of the system, the value is detected by the sensor 6 and sent to the CPU of the recording and calculation device 3 for evaluation, and the recording and calculation device 3 sends a warning signal to the alarm 4 indicate it to operate. The alarm 4 may be a buzzer, and electronic strobe light (flasher), or other equivalents.
Referring to FIG. 6, in a first embodiment of the present invention, the sensing means 4 is equipped in each four ladder feet. The circuit conductors are all connected to the recording and calculation device 3 to sum up individual loading on each ladder foot. As soon as the total value exceeds the predetermined maximum allowable value of the ladder load, the sound or light warning signal is delivered from the alarm 4 .
Referring to FIG. 7, in case the ladder is suffering from an offset loading, the ladder is likely to turn over (Pressure A>B) notwithstanding total load of the ladder has not yet exceeded its maximum allowable value. When a case occurs it can be evaluated by the recording and calculation device 4 for precaution and to help provide data for judging causes of accidents.
Referring to FIG. 8, in a second embodiment of the present invention, the sensing means 2 can be equipped in a hasp 9 jointing two ladder legs. One end of the sensing means 2 is engaged with the hinged end 91 of the hasp 9 while the other end thereof is engaged to the hooking end 92 of the hasp 9 . By installing so the sensing means 2 is able to detect whether the tension exerting on the hasp 9 has exceeded the predetermined value or not.
The sensor 6 used in the sensing means 2 may be a lever type 95 in a third embodiment (FIG. 9 ), or an S type 96 in a fourth embodiment (FIG. 10 ). In the above two embodiments, only a connecting rod 97 is required to connect the sensor to the connecting member 5 . As described above, the connecting member 5 may be formed into a block structure to be fitted into the ladder foot, or enclosed over the ladder foot, and then in the both cases, screw bolted with the ladder foot.
Referring FIG. 11, wherein a diaphragm sensor 98 is used in a fifth embodiment, the diaphragm sensor 98 is directly attached to a ladder truss or other suitable place so as to detect the deformation of the truss.
It emerges from the description of the above several embodiments that the invention has several noteworthy advantages that the ladder provided with such a sensing and warning system can be used without worrying about the security of users so that the labor efficiency will be improved. Should there be an accident on the ladder equipped with the sensing and warning system of the present invention, it can provide reference data for judging the cause of accident and for precaution.
Those who are skilled in the art will readily perceive how to modify the invention. Therefore, the appended claims are to be constructed to cover all equivalent structures which fall within the true scope and spirit of the invention.
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Disclosed is a sensing and warning system for ladder load composed of sending means, a recording and calculation device, and an alarm for detecting, recording and evaluating the ladder load, and sending an alarm signal in case the ladder is suffering from an overload so as to warn the user a dangerous state which should be evaded.
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This application is a continuation-in-part of U.S. application Ser. No. 08/984,752, filed Dec. 4, 1997 now abandened.
BACKGROUND OF THE INVENTION
The present invention relates to the decontamination and cleaning arts. It finds particular application in conjunction with the decontamination of medical instruments and equipment. It will be appreciated, however, that the invention is also applicable to the microbial decontamination, including disinfection or sterilization, of other articles such as food processing equipment, pharmaceutical processing equipment, animal cages, and other equipment.
Various methods and apparatus are known for decontaminating and/or sterilizing medical instruments and devices. For example, medical instruments and other devices are commonly sterilized in a steam autoclave. Autoclaves kill life forms with a combination of high temperature and high pressure. However, steam autoclaves have several drawbacks. The pressure vessels are bulky and heavy. Also, the high temperature and pressure tend to reduce the useful life of medical devices having rubber and plastic components. The medical devices must be precleaned before being placed in the autoclave to remove bodily tissues and fluids. Moreover, the autoclave sterilization and cool-down cycles take an excessive amount of time, especially in light of the need to minimize the “down time” of expensive, reusable medical devices.
Another known sterilization method utilizes ethylene oxide gas. Ethylene oxide gas sterilization and aeration cycles are even longer than steam autoclave sterilization and cool-down cycles. Ethylene oxide is also hazardous to humans and, therefore, environmental concerns are associated with its use.
Low temperature liquid disinfection and sterilization devices are also known. These devices typically utilize one of several known liquid anti-microbial solutions such as peracetic acid, glutaraldehyde, alcohol, aqueous hydrogen peroxide, and the like. In general, these low temperature liquid systems have been found to be effective. However, hospitals and other health care facilities continue to demand improved sterilization effectiveness and efficiency to reduce the risk of infection and to reduce the percentage of time that expensive medical devices are out of use for sterilization procedures. Also, certain low temperature liquid anti-microbial solutions have fallen out of favor. For example, the use of glutaraldehyde presents environmental concerns and also requires an excessively long cycle time to sterilize, rather than simply disinfect, medical devices. The environmentally harmful glutaraldehyde must be specially disposed of, increasing the cost of sterilization. Other agents, such as alcohols, have been found to be destructive to certain plastic components of medical instruments.
Recently, there has been an increased emphasis on the effective cleaning of post-operative debris from the medical instruments and devices. Most known sterilization equipment require that the contaminated medical devices be precleaned before the sterilization cycle. Others simply sterilize without regard to cleaning which results in a sterile device having sterile debris adhered thereto.
Certain sterilization devices rely upon the filtering of water with a 0.2 μm or smaller pore size microbe-removal filter media to provide a sterile rinse liquid. However, it would be desirable to provide an additional safeguard against the recontamination of medical devices with rinse liquid by ensuring a virus-free rinse solution. A virus-free rinse solution may not be assured with simple filtration of the rinse liquid. Therefore, there has been found a need to provide a sterilization apparatus that ensures a bacteria and virus free rinse liquid to prevent the accidental recontamination of the sterilized medical device during rinsing operations.
Most recently, the cleaning and decontamination properties of solutions formed via the electrolysis of water under special conditions have been explored. Electrolysis devices are known which receive a supply of water, such as tap water, commonly doped with a salt, and perform electrolysis on the water to produce (I) an anolyte produced at the anode of the electrolysis unit; and, (ii) and catholyte produced at the cathode of the electrolysis unit. The anolyte and catholyte may be used individually or as a combination. The anolyte has been found to have anti-microbial properties, including anti-viral properties. The catholyte has been found to have cleaning properties.
To create these anolyte and catholyte solutions, tap water, often with an added electrically conducting agent such as halogen salts including the salts sodium chloride and potassium chloride, is passed through an electrolysis unit or module which has at least one anode chamber and at least one cathode chamber which may be separated from each other by a membrane. An anode contacts the water flowing in the anode chamber, while the cathode contacts the water flowing in the cathode chamber. The anode and cathode are connected across a source of electrical potential to expose the water to an electrical field. The membrane may allow the transfer of electron carrying species between the anode and the cathode but limits fluid transfer between the anode and cathode chambers. The salt and minerals naturally present in and/or added to the tap water undergo oxidation in the anode chamber and reduction in the cathode chamber. The solution resulting at the anode (anolyte) and the solution resulting at the cathode (catholyte) remain separate or are recombined and can be used for a wide variety of different purposes.
However, electrochemically activated (ECA) water is not without shortcomings. ECA waters have high surface energies comparable to the incoming water. The high surface energies of ECA water have been found to cause lower penetration ability of the ECA water. In the medical instrument field, for example, high penetration ability is desired due to the complex nature of medical instruments. A sterilant must be able to penetrate even the smallest crevices in order to ensure the sterility of the instrument. The high surface energy of ECA water does not allow for penetration of the ECA water into creviced areas of medical instruments. Thus, complete kill may not be achieved.
Further problems have arisen on metal surfaces coming into contact with the ECA water, including the sterilization equipment and metal medical devices. The ECA water is corrosive to metal. Stainless steel, used to produce many medical devices, is particularly susceptible to corrosion by ECA water.
ECA water as a decontamination and cleaning agent can therefore produce some results which are problematic when decontaminating complex metal objects such as stainless steel medical equipment.
The present invention contemplates an improved ECA water solution. The improved ECA water solution has enhanced penetration ability and reduced corrosiveness compared to prior ECA water solutions.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, an anticorrosive composition for cleaning and decontaminating is provided which comprises electrochemically activated (ECA) water as the decontamination agent. The anticorrosive decontamination composition has, as the anticorrosive agent, a compound or mixture of compounds capable of inhibiting corrosion of various metals used in sterilization systems and objects such as medical instruments.
In accordance with another aspect of the invention, other additives, including wetting agents, are added to reduce the surface energy of the ECA water. This reduced surface energy permits the ECA water to penetrate into complex objects thus permitting complete decontamination of the treated object.
A further aspect of the invention includes a method for decontamination of metal objects, including medical equipment, by using ECA water which contains anticorrosive agents. The ECA water may additionally contain wetting agents to enhance penetration of the ECA water into crevices of objects to be treated. This assures complete decontamination of the treated object.
One advantage of the present composition is that metal objects may be effectively decontaminated using ECA water with considerably reduced metal corrosion.
Another advantage of the present invention resides in its improved solution penetration into complex objects due to lower surface energy of the solution.
A further advantage relates to the use of the treated ECA water as a final rinse solution in a sterilization apparatus without corroding the sterilization apparatus or instruments being sterilized therein.
Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description of the preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Water to be used in a sterilization procedure is introduced into a suitable water electrolysis apparatus. Such an apparatus includes at least one electrolysis unit or module having an anode chamber and a cathode chamber and may be separated by a membrane. The membrane, if present, divides the water into two parts, a first part in the anode chamber and a second part in the cathode chamber. In flow through systems, incoming water is divided into two flows that are channeled to the anode and cathode chambers, respectively. Examples of such water electrolysis units are as described in U.S. Pat. Nos. 5,635,040; 5,628,888; 5,427,667; 5,334,383; 5,507,932; 5,560,816; and 5,622,848 whose disclosures are incorporated herein by reference. Any other suitable water electrolysis units may be used, including an electrolysis unit that utilizes a batch type electrochemical activation. The invention is not meant to be limited to any particular electrolysis apparatus.
The electrode chamber of an electrolysis unit includes an anode electrode and a cathode electrode that contacts the passing water. The membrane, if present, prevents the anolyte and catholyte from mixing. The membrane allows electron carrying species to transfer between the anode and cathode chambers. A source of electric potential is connected across the anode and the cathode to expose the water to an electric field that produces an oxidation reaction at the anode and a reduction reaction at the cathode. These reactions convert the water into an anolyte solution and a catholyte solution. If desired, first and second reservoirs or holding tanks may be provided in fluid communication with the outlets of the chambers in a system separating the anolyte and catholyte to hold the catholyte and anolyte solutions, respectively, as they are produced so that these solutions may be used subsequently for decontamination and/or cleaning, including disinfection, sterilization, and rinsing operations.
In a first embodiment, corrosion inhibiting and surface energy reducing additives are introduced into the water prior to or during electrolysis. The corrosion inhibitors and surface energy reducing additives which are added to the water prior to or during the electrolysis are those which are not decomposed upon passage through the electrolysis unit. Consequently, the additives, such as corrosion inhibitors, retain their anticorrosive activity upon circulation through the electrolysis unit. Further, the ECA water's decontamination properties are not compromised by the inclusion of the additives prior to or during electrochemical activation of the water.
In a second embodiment, the additives (corrosion inhibitors and/or surface energy reducing agents) are added after electrolysis. If added after electrolysis, the additives may be added to the catholyte or the anolyte. Other additives, including, but not limited to, detergents and pH buffers, may also be added to the catholyte and/or anolyte solution.
The corrosion inhibitory agents are selected in accordance with the nature of the materials in the items being cleaned and/or decontaminated with the electrochemically activated water. Corrosion inhibitors which protect against corrosion of aluminum and steel, including stainless steel, include phosphates, sulfates, chromates, dichromates, borates, molybdates, vanadates, and tungstates. Some additional aluminum corrosion inhibitors include 8-hydroxyquinoline and ortho-phenylphenol.
More specifically, phosphates are preferred for inhibiting stainless steel corrosion. Preferred phosphates include, but are not limited to, monosodium phosphate (MSP), disodium phosphate (DSP), sodium tripolyphosphate (TSP), sodium hexametaphosphate (HMP), and sodium sulfate either alone or in combination. Preferred borates include sodium metaborate (NaBO 2 ).
The copper and brass corrosion inhibitors include triazoles, azoles, benzoates, tolyltriazoles, dimercapto-thiadiazoles, and other five-membered ring compounds. Preferably, the copper and brass corrosion inhibitors include sodium salts of benzotriazole and tolyltriazole which are preferred due to their stability in the presence of strong oxidizing compounds. Mercaptobenzothiazole can also be utilized but is apt to be oxidized or destabilized by strong oxidizers. Salicylic acid is an example of an acceptable benzoate corrosion inhibitor.
In hard water, the phosphates tend to cause calcium and magnesium salts present in hard water to precipitate and coat the instruments being decontaminated and/or cleaned and also leaves deposits on parts of the electrolysis system. A sequestering agent appropriate to prevent precipitation such as sodium hexametaphosphate (HMP), or trisodium nitrolotriacetic acid (NTA Na 3 ) is preferably provided. Because sodium hexametaphosphate is also a corrosion inhibitor, it serves a dual purpose, both as a corrosion inhibitor and as a sequestering agent. Other sequestering agents include sodium polyacrylates. Of course, if soft or deionized water is utilized, the sequestering agent may be eliminated. However, to ensure universal applicability with any water that might be utilized, the presence of a sequestering agent is preferred. It is noted that the sequestering agent can be added to the water prior to, during or after electrochemical activation of the water without any negative impact on the decontamination properties of the ECA water or the activation of the water in general.
A surface energy reducing agent is added to the electrochemically activated water in order to reduce the surface energy of electrochemically activated water thereby increasing the ability of the electrochemically activated water to penetrate into crevices of items being treated. This is particularly important when cleaning and decontaminating complex medical instruments which may contain microbial contaminants in crevices, joints, and lumens.
Surface energy reducing agents usable in accordance with the present invention include various wetting agents. Such wetting agents include anionic, cationic, nonionic, amphoteric, and/or zwitterionic surfactants. Specific classes of wetting agents which useful include anionic and nonionic surfactants or combinations thereof. Examples of nonionic wetting agents usable in the present invention include surfactants such as fatty alcohol polyglycol ethers, nonylphenoxypoly (ethyleneoxy) ethanol, and ethoxylated polyoxypropylene. Specific examples include Genapol UD-50™ (Oxoalcohol polyglycol ether), Igepal™ (Nonylphenoxypoly (ethyleneoxy) ethanol), Fluowet™ (Fluoroxo-alcohol polyglycol ether), and Pegal™ (Ethoxylated polyoxypropylene). The wetting agents set forth above may be used alone or in combination with each other.
In a first embodiment, corrosion inhibitors such as monosodium phosphate, disodium phosphate, and sodium hexametaphosphate, either alone or in combination, are added to water along with a wetting agent prior to or during electrochemical activation. Addition of such corrosion inhibitors prior to or during electrochemical activation of water, wherein said corrosion inhibitors are passed through the electrolysis unit during actual electrochemical activation of the water, does not decompose the corrosion inhibitory activity of the agent. Further, addition of such corrosion inhibitory agents prior to or during electrochemical activation of the water does not negatively affect the decontamination properties of the activated water. The above treated water is especially useful as a decontamination and/or cleaning agent for stainless steel medical instruments wherein the treated instrument remains free of corrosion but is microbially decontaminated. In addition, the above treated water is highly effective as a rinsing agent for use in conventional sterilization systems. The ECA water acts not only as a rinse but as an antimicrobial-anticorrosive protective rinse. By adding the corrosion inhibitors and wetting agents prior to or during electrochemical activation, the sterilization system and instruments are protected from corrosion and decontamination from the rinse solution.
A second embodiment introduces the corrosion inhibitors and/or wetting agents to the catholyte or anolyte produced after electrolysis of the water. The same advantages described above remain readily realized.
Amounts of corrosion inhibitor and wetting agents to be added to the electrochemically activated water will vary depending upon the type of agent being added and whether or not one or more agents are added.
The inorganic corrosion inhibitors are preferably present in amounts ranging from about 0.01% to 20.0% weight per volume (w/v). Organic corrosion inhibitors are preferably present in amounts ranging from about 0.01% to 5.0% w/v. Phosphates are preferably effective at rates in the range of about 0.01% to about 11.0% w/v.
The wetting agents are preferably present in amounts ranging from about 0.0001% to about 5.0% w/v. More preferably, the wetting agent is present in amounts ranging from about 0.0001% to about 0.5% w/v.
FORMULATION EXAMPLE
An example of a formulation according to the invention is set forth below:
FORMULATION 1
Component 1) Disodium phosphate (DSP) 4.766 g/L (corrosion inhibitor)
Component 2) Monosodium phosphate (MSP) 0.40 g/L (corrosion inhibitor)
Component 3) Sodium hexametaphosphate (HMP) 0.330 g/L (corrosion inhibitor)
Component 4) Genapol 462 μl/L (wetting agent)
The following are examples that illustrate the corrosion inhibiting effectiveness, anti-microbial, and surface tension reducing properties of the compositions of the present invention.
The examples below all utilize the composition identified hereinbefore as Formulation 1. Additionally, the ECA solution was prepared according to the method described hereinbefore.
Surface Tension Reduction
Surface tension of ECA solutions without additives vs. surface tension of ECA solutions with additives (Formulation 1) are given in Table 1:
TABLE 1
ECA Solutions
ECA Solutions
Without Additives
With Additives
Surface Tension
69.9, 64.1, 72.8
28.7, 28.6, 28.0,
(dynes/cm)
28.3, 28.4
Note:The surface tension of deionized water at 25° C. is 72.8 dynes/cm.
As can be seen, when using the formulation of the invention with ECA water, surface tension decreased to less than half of the amount present in an untreated ECA solution.
Antimicrobial Properties
D-value comparison for ECA solution without additives vs. ECA solution with additives (Formulation 1) are given in Table 2:
TABLE 2
Longest
Test
Avg. linear reg.
endpoint
Test
Solution
Temp., ° C.
n
D-value (sec)
(sec)
organism
ECA
20
7
28.4 ± 6.6
240
B. subtilis
ECA
20
1
33.0
210
B. subtilis
w/Formu-
lation 1
n = number of tests
As is evident from the above comparison, the additives do not adversely affect the antimicrobial properties of the ECA water.
Corrosion Inhibitory Properties
The data in Table 3 compares the corrosion occurring on materials exposed to ECA water (without additives) and a bleach solution. Both the ECA water and bleach solution have ˜300 ppm free chlorine. As can be seen from the results, metallic materials show a more significant degree of degradation than polymeric materials.
TABLE 3
MATERIALS COMPATIBILITY IN ELECTROCHEMICALLY ACTIVE SOLUTION AND BLEACH SOLUTION
The following materials were tested in ECA Solution or in a bleach use dilution (˜300 ppm).
One hour of solution exposure is equivalent to 1 cycle.
ECA SOLUTION
BLEACH SOLUTION
MATERIAL
Cycles
Observations
Cycles
Observations
Aluminum, 6061-T6
24
˜70% surface discoloration
24
˜70% surface discoloration
Anodized Aluminum 6061-T6
720
no change
672
75-80% anodization degraded
Aluminum 1100 (Calgon Vestal)
24
˜50% surface discoloration
24
˜70% surface discoloration
Anodized Aluminum (Calgon Vestal)
672
no change
672
75-80% anodization degraded
Brass
24
˜50% surface discoloration
24
˜70% surface discoloration
Borosilicate
720
no change
600
no change
CDA 110 (Calgon Vestal; 99.9% copper)
24
˜50% surface discoloration
24
˜50% surface discoloration
CDA 443 (Calgon Vestal; 75% copper, 28% zinc)
24
˜50% surface discoloration
24
˜50% surface discoloration
Ethylene propylene
720
no change
600
no change
Ethylene propylene diamine (EPDM)
720
no change
600
no change
Fluorosilicone (Viton O-ring)
720
no change
600
no change
Latex (medical glove)
600
little elasticity
600
elasticity in tact;
material “bleached” to white color
Polycarbonate
720
no change
600
no change
Polyethylene (high density)
720
no change
600
no change
Polytetrafluoroethylene (Gore-tex tubing)
600
no change
600
no change
Polypropylene
720
no change
600
no change
Polyurethane
48
white label slightly discolored;
N/A
N/A
tackiness
Polyvinyl chloride (Tygon tubing)
720
no change
600
no change
Polyvinyl chloride (Tygon tubing - medical grade)
720
no change
600
no change
Polyvinyl chloride (UPVC)
720
no change
600
no change
Silicone (0-ring)
720
cracking
600
cracking
Stainless Steel 17-4P11
24
<5% surface discoloration;
24
<5% surface discoloration;
pitting (˜3 mm diam.)
pitting (˜3 mm diam.)
Stainless Steel 316L
24
<10% surface discoloration
24
<2% surface discoloration;
pitting (˜2 mm diam.)
Stainless Steel 316 (Calgon Vestal)
24
<10% surface discoloration
24
<2% surface discoloration;
pitting (˜2 mm diam.)
The data in Table 4 demonstrates the ability of the additives of the invention, such as Formulation 1 above, to reduce corrosion attributed to untreated ECA water.
TABLE 4
ECA SOLUTION MATERIALS COMPATIBILITY SUMMARY
The following materials were tested in ECA solution, Formulation #1, and in a bleach use dilution ˜300 ppm).
One hour of solution exposure is equivalent to one cycle. All solutions had a 300 ± 30 ppm
free chlorine concentration, which were evaluated spectrophotometrically.
*BLEACH USE DILUTION
*ECA SOLUTION
*FORMULA #1
Aluminum 6061
@ 24 cycles:
@ 24 cycles:
@ 24 cycles:
˜70% surface discoloration
˜70% surface discoloration
˜5% surface corrosion
Aluminum 6061 - anodized
@ 672 cycles:
no change
no change
˜75-80% anodization degraded
Brass
@ 24 cycles:
@ 24 cycles:
@ 24 cycles:
˜70% surface discoloration
˜50% surface discoloration
˜10% surface discoloration
Stainless Steel 316L
@ 24 cycles:
@ 24 cycles:
@ 24 cycles:
<2% surface corrosion; pitting
˜10% surface discoloration
˜5% surface discoloration
in small area (˜3 mm diam.)
Stainless Steel 17-4PH
@ 24 cycles:
@ 24 cycles:
@ 24 cycles:
<5% surface corrosion; pitting
˜5% surface corrosion; pitting
˜2% surface discoloration
in small area (˜3 mm diam.)
in small area (˜3 mm diam.)
*All solutions had a 300 ± 30 ppm free chlorine concentration, which were evaluated spectrophotometrically.
As can be seen from Table 4, ECA with Formulation #1 additives substantially reduced corrosion in comparison to untreated ECA and a bleach solution on aluminum, brass, and stainless steel. As noted hereinbefore, these are the main metals used in medical equipment.
An additional test was conducted which compared untreated ECA water with ECA water having Formulation #1 added on PENTAX® medical device components. Below, in Table 5, is a comparative analysis of the results.
TABLE 5
MATERIALS COMPATIBILITY OF PENTAX MEDICAL DEVICE COMPONENTS
IN ELECTROCHEMICALLY ACTIVE SOLUTION OR FORMULA #1
The following materials were tested in ECA Solution with additives, Formula #1 in ECA solution.
One hour of solution exposure is equivalent to one cycle.
ECA SOLUTION
ECA FORMULA #1 SOLUTION
MATERIAL
Cycles
Observations
Cycles
Observations
Black, plastic cylinder
120
no change
120
no change
Thin, black collar
120
no change
120
no change
Treated metal tube
8
black “specks”—qty increases with time;
120
no change
possible inner corrosion
Screw w/wide threads
1-120
40% surface corrosion at 120 cycles
120
no change
Screw w/narrow threads
72
<1% corrosion
120
no change
Thin metal piece w/1 hole
120
no change
120
no change
Thin, bent metal piece w/4 holes
120
no change
120
no change
Metal nut
8-120
corrosion at 15 minutes;
1-120
corrosion at 24 hrs.;
increased corrosion over time;
increased corrosion over time;
possible leeching of metal-metal
possible leeching of metal-metal
binding adhesive
binding sdhesive
Air/water valve
120
no change
Metal inlet/outlet port
1-120
corrosion at 1 hr;
120
no change
increased corrosion over time;
all corrosion appears at
soldered joints/pieces
Black,metal sleeve w/threads
120
no change
As can be seen from Table 5, those components of PENTAX medical equipment which were susceptible to corrosion due to ECA water were either not corroded when Formulation #1 was added or the corrosion was substantially reduced in the presence of the additives.
Further, testing has been conducted which demonstrates that the functionality of corrosion inhibitors is maintained and not destroyed by circulation through an electrolysis unit during electrochemical activation of water.
The following Example demonstrates that the corrosion inhibition activity of corrosion inhibitors which are added to ECA water during electrochemical activation does not destroy the corrosion inhibitory activity of the corrosion inhibitors.
EXAMPLE 1
Hard water containing 400 ppm CaCO 3 was circulated through an electrolysis unit at 12 A (current) and a flowrate of 80L/hr to generate 10.0L of ECA solution having the following properties:
10.0L ECA Solution
pH = 8.24
Conductivity = 10.31 mS/cm
free chlorine = 264 ppm
Surface tension = 65.3 dynes/cm
Temp. = 50° C.
ORP = 770 mV
To the 10.0L ECA solution, while in the electrolysis unit, the following components were added:
monosodium phosphate (MSP) at 4.00 g
disodium phosphate (DSP) at 47.66 g
sodium hexametaphosphate (HMP) at 3.30 g
Genapol (wetting agent) at 4620 μL
The resulting modified ECA solution had the following properties:
Modified ECA solution
pH = 7.70
Conductivity = 14.5 mS/cm
Free Chlorine = 246 ppm
Surface Tension = 29.4 dynes/cm
Temp = 53° C.
ORP = 805 mV
Bovine serum art 0.1% was then added to the modified ECA solution.
The bovine/modified ECA solution had the following properties:
Bovine/Modified ECA solution
pH = 7.69
Conductivity = 14.5 mS/cm
free chlorine = 199 ppm
Surface tension = 29.3 dynes/cm
Temp = 53° C.
ORP = 803 mV
Five coupons of various metals were then introduced into the solution in the electrolysis unit and the solution was allowed to continue to recirculate through the unit. The free chlorine of the solution was monitored during recirculation until it reached 300 ppm. After seven (7) minutes, a twelve (12) minute timer was set and the solution parameters were measured after twelve minutes. The solution, after the twelve (12) minute period had the following properties:
Modified ECA solution after 12 minute circulation period
pH = 7.86
Conductivity = 14.86 mS/cm
free chlorine = 393 ppm
Surface tension = 30.1 dynes/cm
Temp. = 50° C.
ORP = 820 mV
A control hard water bath was also provided which had 400 ppm (CaCO 3 ) at 53.3° C. (±3° C.). The five coupons were also placed in the control water bath.
The following results were observed from the coupons introduced into the electrolysis unit containing the modified ECA solution according to the invention and from the control hard water bath:
Control
Metal Coupon
Modified ECA Solution
(hard water)
Brass
<5% Corrosion
NC
Aluminum (6061)
NC
NC
Anodized Aluminum
NC
NC
(6061)
Stainless Steel
NC
NC
316L (S.S. 316L)
Stainless Steel
NC
NC
(S.S. 17-4 PH)
As is evident from the above, even after recirculation through the ECA system for at least 12 minutes, the corrosion inhibitor continued to function to reduce the corrosive properties of the ECA water.
In addition to the above, five additional test runs were conducted in accordance with the procedure of Example 1. The results from these tests are provided below:
Test No.
2
3
4
5
6
10L ECA
pH
7.95
8.10
8.21
8.30
8.24
free C1 − (ppm)
312
340
323
308
337
Temp. (° C.)
52
51
54
54
53
Conductivity
11.06
11.64
11.74
10.66
11.70
(mS/cm)
Surface tension
64.0
63.8
64.1
64.0
65.4
(dynes/cm)
ORP (mV)
798
804
800
758
796
Modified ECA
pH
7.68
7.72
7.71
7.71
7.69
free C1 − (ppm)
298
319
298
284
294
Temp. (° C.)
53
53
53
54
54
Conductivity
15.78
16.23
15.12
14.60
14.96
(mS/cm)
Surface tension
28.0
27.8
31.0
27.4
28.4
(dynes/cm)
ORP (mV)
820
825
820
825
825
0.1% Bovine Solution
pH
7.70
7.73
7.69
7.65
7.71
free C1 − (ppm)
250
258
233
228
219
Temp. (° C.)
53
53
53
53
53
Conductivity
15.71
17.5
15.28
13.81
15.7
(mS/cm)
Surface Tension
28.4
28.4
29.9
28.3
28.7
(dynes/cm)
ORP (mV)
815
845
840
840
840
Circulation
4
4
3
4
3.5
Time to get 300 ppm
Free chlorine (min.)
After 12 minute recirculation
pH
7.75
7.70
7.65
7.69
7.80
free C1 − (ppm)
383
408
504
399
453
Temp. (° C.)
50
50
51
50
51
Conductivity
15.62
17.60
<20
15.28
15.3
(mS/cm)
Surface Tension
32.4
30.4
31.9
30.0
30.1
(dynes/cm)
ORP (mV)
831
840
850
850
844
Changes in coupons
(Test/control)
2
3
4
5
6
Brass
<5%/NC
<5%/NC
<5%/5% (color)
<5%/5% (color)
<5%/>5% (corrosion)
Aluminum
NC/NC
NC/NC
NC/NC
NC/NC
NC/NC
Anod. Aluminum
NC/NC
NC/NC
NC/NC
NC/NC
NC/NC
S.S 316L
<5% (color)/NC
<5% (color)/NC
>5% (color)/NC
>5% (color)/NC
<5% (color)/NC
S.S. 17-4 pH
NC/NC
NC/NC
NC/NC
NC/NC
NC/NC
Based on the results as shown above, it is evident that the functionality of the corrosion inhibitor in the ECA water, during electrochemical activation of the water, did not get destroyed by the electrochemical activation system. Also, the surfactants were not modified during the recirculation because surface tensions did not change significantly.
Further, based on the above comparative tests, the advantages of reduced corrosion and enhanced penetration attained from using ECA water with the above-described corrosion inhibitors and/or surface tension reducing agents are readily apparent wherein the treated ECA water can be utilized without any loss in its biocidal properties.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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An anticorrosive, penetration enhancing composition for cleaning decontaminating and rinsing includes electrochemically activated (ECA) water as the decontamination agent. The anticorrosive decontamination composition has, as the anticorrosive agent, a compound or mixture of compounds capable of inhibiting corrosion of various metals used in sterilization decontamination and rinsing systems and objects such as medical instruments. Preferred anticorrosive compounds include phosphates, azoles, and sulfates. Other additives, including wetting agents, are added to reduce the surface energy of the ECA water. This reduced surface energy permits the ECA water to penetrate into objects of complex design thus permitting complete decontamination of the treated object.
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PRIORITY/CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 62/146,121 filed Apr. 10, 2015, the disclosure of which is incorporated by reference.
TECHNICAL FIELD
The presently disclosed technology relates to a light fixture, and more particularly to an overhead LED light fixture in which the light pattern can be adjusted according to the needs at a particular site.
BACKGROUND
A problem with current lighting strategies is that the typical lighting fixture sends light out in a generally symmetrical pattern. This can result in areas being illuminated which should not be illuminated, such as vehicular roadways where the light can distract drivers. Light is often wasted as it is mistakenly directed upward into the night sky. This costs money, and needlessly contributes to light pollution in a city. A lighted area can also have a border along its edge that does not need to be lighted, and is detrimental to drivers or pedestrians if it is lighted. If the spread of light could be accurately controlled, savings in energy would be achieved, and only those areas selected to be lighted would receive light. If the configurable light is also an LED fixture, further savings could be achieved.
SUMMARY OF THE DISCLOSURE
The purpose of the Summary is to enable the public, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Summary is neither intended to define the inventive concept(s) of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the inventive concept(s) in any way.
Disclosed is a configurable overhead light fixture, meaning that the output of the light can be adjusted to fit the requirements of a particular site, before or after the light is installed. The overhead light is made up of a heat sink and initial LEDs which are typically installed first. The heat sink is planar, and has a first and a second surface. It has LED lights attached to the first surface, which would typically be the surface which faces down, so that an area where people may be present is illuminated from above. The heat sink has a second surface, to which are attached a plurality of heat radiating fins. The heat sink and fins could be an extruded piece, comb line in cross section, and as long as the user desires.
The lighting pattern selected can be asymmetrical, oblong, circular, squarish, or other shapes, with the lighting pattern determined by the LED covers that are selected. The LEDs are connected to the heat sink and to a power source outside the heat sink. The LEDs in the heat sink would be chosen for a lumen output from 1000 to 10,000 lumens, and color temperature range typically from 2700K to 5600K. The selection of specific LEDs would depend on the location and desired light pattern of a particular installation.
The overhead light could be over a parking lot, over a sidewalk, over an entry to a building, in a hallway or warehouse, etc. It would typically be installed in an area where it is desirable to have a weather resistant light, and weather resistance is a feature of the light. The lenses can also be selected to minimize light going up into the night sky, to reduce light pollution in a city and also get the most usable light out of any amount of power.
After the heat sink is installed with LEDs of the desired characteristic, lenses are attached directly to the heat sink. The surface of the heat sink has grooves, typically circular, which correspond to the rim (circumferential edge) of the generally curvilinear dome shaped lenses. The term curvilinear dome shaped includes hemispherical shapes, bulbous shapes, columnar shapes with curved tops, flat domes, tall domes, sections of a sphere, and similar bulbous, protruding and rounded shapes.
The lens grooves are incised into the heat sink surface, and would typically be 1.75″ in diameter, and 0.050″ deep in the heat sink material. The heat sink may have multiple LEDs on its surface, each with a groove for the lens. Each lens groove may also surround multiple LEDs. Lenses are selected for the spread of light which is desired, and for this a wide selection of lenses are possible. Some lenses which can be selected include:
Clear lens, for maximum lumen output Frosted lens, for light dispersion, hiding the LED and for cutting glare Lens with ribs on the outside of the dome, for accurate distribution of light at various angles to the LED Lens with ribs on the inside of the dome, for redirecting light away from certain directions Lens with internal opaque reflective surface(s) for blocking light in one direction and reflecting light in another direction Directional lens, with a protruding wedge shaped portion for directing light in a particular pattern.
The lenses may be attached to the heat sink by placing an adhesive in the lens grooves, and then placing the base of the lenses in the lens groove. The adhesive may be silicone, epoxy, or other waterproof materials. This method also provides a weather tight seal for the LED light.
Another option for attaching the lenses to the heat sink is cutting screw threads in the outside edge of each groove and using matching screw threads on the base of each lens with a rubber or other flexible weather tight gasket in the base of each groove. This method also provides a weather tight seal for the LED light.
Another attachment method can be to install an o-ring in the sidewalls of the lens groove, which would form a seal as the lens is pressed or screwed in place. This method also provides a weather tight seal for the LED light.
The disclosed technology also includes a method of retrofitting a configurable LED light into an existing overhead light. The method is made up of the following steps:
removing a non-LED light body from an overhead light fixture; placing a power source for the LED lamp body in the now empty overhead light fixture; placing an LED lamp body in the now empty overhead light fixture, with the replacement lamp body made up of a planar heat sink with a first surface and a second surface. More than one heat radiating fins attached to said second surface of the heat sink; At least one and preferably two LED lights mounted on the first surface of the heat sink, the LED lights surrounded by a lens groove defined in the first surface of the heat sink. Typically the lens groove surrounds each LED light, or each grouping of LED lights. The first surface of the heat sink would typically be installed to face down, onto an area to be illuminated. The LED lights are connected to a power source; determining a preferred light pattern to be illuminated by the light fixture; selecting a curvilinear dome shaped lens with a shape and surface pattern matching the selected light pattern to be illuminated; attaching the selected lenses to the lens groove to cover and seal off the LEDs.
The method also includes the step of shaping the light pattern as the light is mounted in a fixture, by use of one or more of these options: The spread of the light field can be adjusted during or after installation of the light body. This can be done is several ways.
1. placing the proper various lens on the heat sink 2. rotating the lens on the heat sink before “locking” the lens, or permanently sealing it. 3. rotating the light body in the fixture.
Still other features and advantages of the presently disclosed and claimed inventive concept(s) will become readily apparent to those skilled in this art from the following detailed description describing preferred embodiments of the inventive concept(s), simply by way of illustration of the best mode contemplated by carrying out the inventive concept(s). As will be realized, the inventive concept(s) is capable of modification in various obvious respects all without departing from the inventive concept(s). Accordingly, the drawings and description of the preferred embodiments are to be regarded as illustrative in nature, and not as restrictive in nature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the light fixture with lenses attached.
FIG. 2 is a perspective view of the light fixture with no lenses attached
FIG. 3 is a perspective view of a lens with an asymmetrical region.
FIG. 4 is a perspective view of a lens with a frosted finish.
FIG. 5 is a perspective view of a lens with a ribbed surface pattern.
FIG. 6 is a perspective view of a lens with a clear material.
FIG. 7 is a top view of a two way lateral light distribution
FIG. 8 is a top view of a two way lateral light distribution for wide walkways.
FIG. 9 is a top view of a two way lateral light distribution for roadway or parking area lighting.
FIG. 10 is a top view of a semi-circular lighting spread, for along the sides of buildings.
FIG. 11 is a top view of a circular light distribution with the light intensity equal and symmetrical in all directions.
FIG. 12 is a top view of a generally square light spread, in which light symmetry is equal in all directions, such as in parking lots.
FIG. 13 is an overhead view of asymmetrical light spread from light sources.
FIG. 14 is a perspective view which shows light sources installed over a parking lot.
FIG. 15 is a front view of a lens with a prism in the lens shape.
FIG. 16 is a side view of a lens with a prism in the lens shape. FIG. 17 is a back view of a lens with a prism in the lens shape. FIG. 18 is a top view of the lens with a prism in the lens shape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the presently disclosed inventive concept(s) is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the inventive concept(s) to the specific form disclosed, but, on the contrary, the presently disclosed and claimed inventive concept(s) is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the inventive concept(s) as defined in the claims.
FIG. 1 shows the configurable overhead light 10 which is made up of the lamp body 12 , which is a heat sink 14 , with lens positions 16 on a first surface 18 . Second surface 20 of said heat sink 14 has attached to it a number of heat radiating fins 22 . Shown in FIG. 1 are two lenses 24 , which cover an LED 26 . Shown are screw or bolt holes 28 which are used to secure the lamp body to the underside of a surface, which as the underside of a covered walkway, or the inside of an overhead light, such as found in a parking lot.
FIG. 2 shows the same overhead light 10 with the lens 24 removed, which more clearly shows the LEDs 26 , and a lens groove 30 . Also shown is wiring 32 which is attached at one end to the LEDs 26 and at the other end to a power source 34 . The power source would be wall current in a covered walkway, or power terminals in a light fixture housing.
The size of the heat sink can vary based on the particular application, but a typical size is 4″ by 4″, and 3/16″ thick, made of aluminum. The size of the heat sink would be based on approximately 6 square inches per watt of heat sink surface area. The heat radiating fins would typically be aluminum, approximately 2″×4″, and 2″ long. The entire unit of the heat sink and fins could be extruded as one piece. The lenses can also be different diameters and shapes, with a typical diameter of the lens being about 1¾″. The lenses are preferably made of plastic, with polycarbonate being a preferred material. A suitable LED is made by Bridgelux, such as the BXRC-50C1000 model.
FIGS. 3, 4, 5, 6, and 7, 15 and 16 show different shaped lenses 24 which are possible to use with the disclosed configurable overhead light 10 . These include the columnar wedge shape lens 42 attached to a curvilinear dome of FIG. 3 , a frosted hemisphere 44 of FIG. 4 , a ribbed hemisphere 46 of FIG. 5 , and the clear hemisphere 48 of FIG. 6 . Each of these provide a light spread of a different shape, and would be selected depending on the desired pattern of light.
FIGS. 7-12 show different light dispersion patterns which might be selected for a particular application, with appropriate lenses 24 and LEDs 26 selected to illuminate the selected pattern. Typical spreads of these patterns might be 100 feet long in any direction, to smaller patterns of 20 feet in a direction. FIG. 7 is a pattern for a walkway, path or sidewalk. In this application, an overhead light 10 is placed approximately in the center of the pathway. This is referred to as a two-way lateral distribution and has a preferred lateral width of 15 degrees in the cone of maximum candlepower.
The two principle light concentrations are in opposite directions in the roadway. This type is generally applicable to illuminate locations near the center of the roadway where the mounting height is approximately equal to the roadway width.
FIG. 8 shows a light distribution pattern referred to as TYPE II. This distribution is used for wide walkways, on-ramps and entrance roadways, as well as other long, narrow lighting situations such as warehouse aisle ways. This type of lighting is meant for lighting larger areas and usually is located near the roadside or warehouse pallet racks. This type of lighting is found mostly on smaller side streets, jogging paths, or warehouses.
TYPE II light distributions have a preferred lateral width of 25 degrees. They are generally applicable to luminaries located at or near the side of a relatively narrow roadway where the width of the roadway does not exceed 1.75 times the designed mounting height.
FIG. 9 shows a light distribution referred to as TYPE III. TYPE III distribution is meant for roadway lighting, general parking areas, and other areas where a larger area of lighting is required. TYPE III lighting needs to be placed to the side of the area, allowing the light to project outward and fill the area. This produces a filling light flow.
TYPE III light distributions have the preferred lateral width of 40 degrees. This distribution is intended for luminaries mounted at or near the side of medium width roadways or areas, where the width of the roadways or area, does not exceed 2.75 times the mounting height.
FIG. 10 is a type of light distribution referred to as TYPE IV. The TYPE IV distribution produces a semicircular light meant for mounting on the sides of buildings and walls. It's best for illuminating the perimeter of parking areas and businesses. The intensity of the Type IV lighting has the same intensity at angles from 90 degrees to 270 degrees. Type IV light distributions have a preferred lateral width of 60 degrees. This distribution is intended for side-of-road mounting and is generally used on wide roadways where the roadway width does not exceed 3.7 times the mounting height.
FIG. 11 shows a type of illumination pattern referred to as TYPE V. Type V produces a circular distribution that has the same intensity at all angles. This distribution has a circular symmetry of candlepower that is essentially the same at all lateral angles. It is intended for a luminaire mounting at or near center of roadways, on the center island of a parkway, and intersections. It is also meant for large, commercial parking lot lighting as well as areas where sufficient, evenly distributed light is necessary.
FIG. 12 shows a type of lighting referred to as TYPE VS (square). Type VS produces a square distribution that has the same intensity at all angles. This distribution has a square symmetry of a candlepower that is essentially the same at all lateral angles. It is intended for luminaire mounting at or near center of roadways, center islands of parkway, and intersections. It is also meant for large, commercial parking lot lighting as well as areas where sufficient, evenly distributed light is necessary. TYPE VS is used where the light pattern needs a more defined edge.
FIG. 13 shows one potential installation in which a pair of overhead lights 50 are mounted in one location with each of the overhead lights 50 providing an asymmetrical area of illumination 36 . In this particular case the overhead lights are in a parking lot and it is desired to not illuminate the nearby roadway or sidewalk. To achieve this lenses are selected which illuminate the asymmetrical light distribution patterns 36 shown in the figure.
FIG. 14 is a perspective view of the same potential lighting of the same possible lighting situation, with the overhead lights 10 mounted on a pole 38 above the parking lot 40 .
FIGS. 15 and 16 shows a different type of light fixture, which is used to provide a light spread of Type II and Type III. This type of lens is generally oval in shape. To use this shape of lens the base plate is machined to provide a lens groove in an oval pattern. This type of lens is hollow inside, with the prism portion typically being solid. The heat sink can have lens grooves of different shapes, such as round, or ovals at various orientations, or other lens shapes and orientations, and a lens can be placed on a matching lens groove at the time of installations. The lens of FIGS. 15 and 16 has a base place which is screwed down, and the prism can be directed in different directions for a varied light pattern.
The spread of the light field can be adjusted during or after installation of the light body. This can be done is several ways.
1. By placing the proper various lens on the heat sink 2. By rotating the lens on the heat sink before “locking” permanently sealing it. 3. By rotating the module in the fixture.
For example, in FIG. 13 the asymmetrical light patterns are created by selection of lenses and by rotation of those lenses to create the light spread shown.
While certain preferred embodiments are shown in the figures and described in this disclosure, it is to be distinctly understood that the presently disclosed inventive concept(s) is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the disclosure as defined by the following claims.
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A configurable LED overhead light with a selection of lenses. The lenses are selected for the pattern of light, distance and shape of the desired illumination, of a particular installation. By varying the lens shapes and surface textures, asymmetric patterns can be achieved, and non-LED fixtures can be replaced with LED fixtures that optimize the light distribution to a particular installation site.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. 119(a) of Korean Patent Application No. 2005-120696, filed Dec. 9, 2005 in the Korean Intellectual Property Office, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for transmitting and receiving messages and a mobile terminal employing the same. More particularly, the present invention relates to a method and mobile terminal for creating and transmitting/receiving a message between users who speak different languages.
[0004] 2. Description of the Related Art
[0005] In general, mobile terminals include a cellular phone, a personal digital assistant (PDA), a personal communication services phone (PCS), an international mobile telecommunication-2000 (IMT-2000) terminal, a GSM (Global System for Mobile Communication) terminal, etc. These terminals can provide a communication function (such as communication or data exchange) while in motion.
[0006] Such mobile communication terminals are now widely used by all kinds of people, of all ages and sexes, throughout the world, and are recognized by people as indispensable. As such, these terminals are routinely carried by their users so that designs of the terminals have tended toward compactness, slimness and lightness in consideration of portability. The design of the terminals has also tended towards multimedia availability so as to have a wider variety of functions.
[0007] One function of a mobile terminal is to perform phone communications. However, the mobile terminal also provides various supplementary functions. One supplementary function is the transmitting/receiving of a short message, such as a voice message, a multimedia message, and an email. Another supplementary function is that of a memory for storing and searching for phone numbers. Mobile terminals also provide various additional functions and services such as a camera function, a digital broadcasting reception function, a game function, and the like.
[0008] Through these various additional functions and services, the mobile terminal provides great convenience to modern persons.
[0009] Recently, mobile terminals are being increasingly used for providing a short message service, multimedia message service, and email service. One reason is that these services enable a desired message to be transmitted regardless of whether a counterpart mobile terminal is being concurrently used for communication. Also, these services can be provided at a lower cost than voice communication.
[0010] The function of a mobile terminal has additionally been expanded so that Internet access has been made possible. Also, the user is able to photograph a desired image regardless of the time and location using a camera function included in the mobile terminal. Accordingly, there is a further increase in the terminal's use as a multimedia messaging service (MMS) because it enables the user to transmit a photographed or stored image by attaching the image to a short messaging service (SMS).
[0011] In addition, through the combination of computer technology and wireless communication technology, email among computer users is also able to be transmitted/received among users of mobile terminals. This function of enhanced communication by email is being increasingly used by public enterprises as well as by individuals.
[0012] However, as the use of the SMS, MMS, and email rapidly increases throughout the world, there exists a difficulty in transmitting/receiving a message between users who speak different languages.
[0013] One solution of such a problem is a mobile terminal which allows the user to select a desired language and to input characters of the selected language when creating a message. However, in that case, the user must remember languages used by every receiver, which causes an inconvenience to the user.
[0014] Also, if the user misjudges the language used by a receiver and creates and transmits a message for an important engagement or business event to the receiver using the wrong language, the receiver may delete the message without reading it by misconceiving it as being a spam message.
[0015] Accordingly, there is a need for an improved method of transmitting and receiving messages on a mobile terminal between users who communicate in different languages.
SUMMARY OF THE INVENTION
[0016] Exemplary embodiments of the present invention address at least the above problems and/or disadvantages and provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a method and mobile terminal for creating a transmission message using a language that is automatically established, based on language information stored in a mobile terminal, when the message is created.
[0017] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for creating a transmission message using a language selected by the user, instead of using a language automatically established based on language information stored in the mobile terminal.
[0018] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for creating a transmission message having the same contents as the message which has been created using an automatically established language, using a language requested by the user when there is one or more receiver.
[0019] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for creating and transmitting a text message after recognizing a voice using a language established in a mobile terminal when the user inputs a voice message.
[0020] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for analyzing a received message to automatically establish a language of the received message, and creating and transmitting a reply message in the automatically established language when the user requests a reply function.
[0021] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for storing transmitter information of a received message and language information automatically established through the analysis of the received message in a storage area of a mobile terminal according to a request of the user, when the information has not been stored in the storage area.
[0022] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for displaying language information of additional receiver information stored in a mobile terminal when there is at least one additional receiver to receive the transmission message, thereby enabling the creation of a transmission message using a language selected by the user.
[0023] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for creating a transmission message using a language requested by the user when the user requests the change of a pre-established language, in the state in which a language for creating the transmission message is automatically established through the analysis of a received message, and the transmission message is created using the automatically established language according to the reply request of the user.
[0024] According to an exemplary embodiment of the present invention, there are provided a method and mobile terminal for analyzing a voice message when a received message including a voice message is selected by the user, and establishing and displaying the message in a relevant language obtained through the analysis.
[0025] In accordance with an exemplary aspect of the present invention, there is provided a method and mobile terminal for transmitting a message where, whether language information for a receiver has been established is checked when receiver information is input; the established language is displayed on a message input window when it is determined as a result of the check that the language information has been established; a message using the established language is created according to key information input from a key input unit, and the created message is transmitted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other objects, features and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
[0027] FIG. 1 is a block diagram illustrating the construction of a mobile terminal according to an exemplary embodiment of the present invention;
[0028] FIG. 2 is a flowchart illustrating the procedure of transmitting a message in a mobile terminal according to an exemplary embodiment of the present invention; and
[0029] FIGS. 3A and 3B are flowcharts illustrating a procedure of transmitting a reply message in response to a received message in a mobile terminal according to an exemplary embodiment of the present invention.
[0030] Throughout the drawings, the same drawing reference numerals will be understood to refer to the same elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0031] The matters defined in the description such as a detailed construction and elements are provided to assist in a comprehensive understanding of the embodiments of the invention and are merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0032] The term “receiver identification information” used in the exemplary embodiments of the present invention represents information relating to a receiver which is required for the user of a mobile terminal to transmit a message. The “receiver identification information” includes a telephone number, an email address, and so on. The term “receiver information” used in the exemplary embodiments of the present invention represents all information relating to a receiver which is required for the user of a mobile terminal to create, display, and transmit a message. The “receiver information” includes language information and the like in addition to the receiver identification information. The term “language information” used in the exemplary embodiments of the present invention includes the languages usually used by transmitters and receivers and languages exclusively-used by mobile terminals. The term “storage information” used in the exemplary embodiments of the present invention represents information stored in a mobile terminal in order to be used for communication and message transmission. The “storage information” includes a telephone directory, a phone book, a photo phone book, and so on. The term “additional receiver information” used in the exemplary embodiments of the present invention represents information similar to the receiver information. The “additional receiver information” is used to represent that there are at least two receivers.
[0033] FIG. 1 is a block diagram illustrating the construction of a mobile terminal according to an exemplary embodiment of the present invention.
[0034] The mobile terminal 100 includes a wireless transmission/reception unit 110 , a modem 120 , an audio processing unit 130 , a key input unit 140 , a memory 150 , a camera module 170 , an image processing unit 180 and a display unit 190 .
[0035] The wireless transmission/reception unit 110 functions to transmit/receive voice data, character data, image data, and control data, under the control of the controller 160 . To this end, the wireless transmission/reception unit 110 includes an RF transmitter and an RF receiver in which the RF transmitter up-converts and amplifies frequencies of a signal to be transmitted. The RF receiver also low-noise amplifies a received signal and down-converts the frequency of the received signal.
[0036] The modem 120 includes a transmitter for encoding and modulating the signal to be transmitted and a receiver for demodulating and decoding the received signal.
[0037] The audio processing unit 130 may include a codec, which contains a data codec for processing packet data and the like and an audio codec for processing an audio signal such as a voice.
[0038] The audio processing unit 130 modulates an electrical signal input from a microphone, thereby converting the electrical signal into voice data. The audio processing unit 130 demodulates encoded voice data input from the wireless transmission/reception unit 110 to an electrical signal, thereby outputting the demodulated electrical signal to a speaker. In an exemplary implementation, the audio processing unit 130 includes a codec, in order to convert a digital audio signal received through the wireless transmission/reception unit 110 into an analog signal and to reproduce the analog signal, and in order to convert an analog audio signal generated from a microphone into a digital audio signal. The codec contains a data codec for processing packet data and the like and an audio codec for processing an audio signal such as a voice. The codec may be included in the controller 160 .
[0039] In addition, the audio processing unit 130 outputs an audio signal of a music file reproduced in the mobile terminal 100 , through the speaker.
[0040] The key input unit 140 has a key matrix structure, includes character keys, number keys, various function keys and an exterior volume key, and outputs a key input signal corresponding to a key selected by the user to the controller 160 .
[0041] The memory 150 may include program memory and data memory. The memory 150 stores various information required for controlling the operation of the mobile terminal 100 , information required for recognizing the language of a voice and converting recognized voice data into text data, and various information selected and/or established by the user. That is, the memory 150 includes a ROM for storing an operating system accessed through the controller 160 for the general operation of the mobile terminal 100 , and a RAM for storing data according to control commands in the course of processing data.
[0042] The memory 150 may be constructed separately from the controller 160 , or may be integrated or included in the controller 160 according to necessity.
[0043] The controller 160 controls the entire operation of the mobile terminal 100 according to an embodiment of the present invention. When the controller 160 receives a specific message through the wireless transmission/reception unit 110 , the controller 160 determines if the user requests that the received message be displayed. The specific message may include a multimedia message, an email, and a voice mail.
[0044] The user may request display of the received message by a confirmation signal input through the key input unit 140 to the controller 160 . When the confirmation signal has been input, for example when a confirmation key operates after a message has been received, the controller 160 determines whether the received message is a voice mail or a text message. When a voice mail is received in the form of a voice message, the controller 160 checks language information included in the transmitter information, such as the telephone number or email address included with the received voice mail. Or, the controller 160 analyzes the voice message based on voice analysis information stored in the memory 150 , establishes a corresponding language in the receiver information of the memory 150 , and displays the corresponding language in the display unit 190 .
[0045] In addition, the controller 160 converts the voice message into a text message based on the corresponding language, and displays the converted text message through the display unit 190 . Even when a text message is received, the controller 160 analyzes the text message and transmitter information, and controls the corresponding information to be stored in the memory 150 and to be displayed through the display unit 190 .
[0046] The camera module 170 , which photographs an image, may include a lens unit capable of performing zoom-in/zoom-out action. The camera module 170 includes a camera sensor and a signal processing section. The camera sensor converts an optical signal obtained through photography into an electrical signal. The signal processing section converts an analog image signal obtained through photography by the camera sensor into digital data.
[0047] The camera sensor may be a CCD (Charge Coupled Device) sensor and the signal processing section may include a digital signal processor (DSP). Also, the camera sensor and the signal processing section may be integrally or separately constructed.
[0048] The image processing unit 180 performs a function to generate image data for displaying an image signal output from the camera module 170 .
[0049] The image processing unit 180 processes an image signal, which is output from the camera module 170 , in a unit of frame, and outputs the frame image data to be suitable for the screen size and the property of the display unit 190 . Also, the image processing unit 180 includes a video codec so as to compress frame image data displayed on the display unit 190 by using a predetermined scheme and to restore compressed frame image data to original frame image data.
[0050] In addition, the image processing unit 180 may have an On Screen Display (OSD) function and can output OSD data according to the size of a display screen under the control of the controller 160 .
[0051] The display unit 190 outputs various display data generated in the mobile terminal and may include a liquid crystal display (LCD). When the LCD is realized, it may use a touch screen scheme so that the display unit 190 may serve as an input section.
[0052] In addition, the display unit 190 displays an image signal output from the image processing unit 180 and user data output from the controller 160 on a screen.
[0053] FIG. 2 is a flowchart illustrating the procedure of transmitting a message in a mobile terminal according to an embodiment of the present invention.
[0054] That is, FIG. 2 shows a procedure for automatically establishing a language according to receiver information input by the user in a mobile terminal, creating a message using the established language, and transmitting the created message.
[0055] Referring to FIGS. 1 and 2 , first, the controller 160 determines that a message transmission function is selected by the user (step 211 ). The message to be transmitted includes, for example, a short message, a multimedia message and an email.
[0056] The controller 160 receives receiver identification information through the key input unit 140 from the user (step 213 ). In step 215 , the controller 160 checks whether or not the memory 150 , such as a telephone directory or phone book, has stored therein the same information as the received receiver identification information. When the memory 150 already has stored therein the same information as the received receiver identification information, the controller 160 checks whether or not language information corresponding to the received receiver identification information is established in the memory 150 so as to be used for creating a message (step 216 ).
[0057] When language information corresponding to the received receiver identification information is established in the memory 150 so as to be used for creating a message, the controller 160 proceeds to step 218 of storing receiver information which includes the receiver identification information and the established language information. The receiver identification information included in the receiver information represents an identification number or address required for transmitting/receiving information among devices (such as mobile terminals and information terminals), and may be a telephone number, an IP address, or an email address.
[0058] In contrast, when language information corresponding to the receiver identification information input from the user is not established in the memory 150 , the controller 160 sets a default language as a language for creating a message (step 220 ), and then proceeds to step 218 , in which receiver information including the receiver identification information and the default language is stored. The controller 160 may establish a language for creating a message by using key information input from the key input unit 140 .
[0059] When the same information as the received receiver identification information is stored but corresponding language information for creating a message is not established, the controller 160 sets a default language as a language for creating a message (step 220 ), and stores the receiver information including the receiver identification information and the basic language (step 218 ). Also, the controller 160 may establish a language for creating a message by using key information input from the key input unit 140 .
[0060] In step 222 , the controller 160 determines if additional receiver identification information for adding a receiver is input by the user. When it is determined that receiver identification information for adding a receiver is input by the user, the controller 160 returns to step 213 for processing the additional receiver identification information input for adding a receiver.
[0061] In contrast, when it is determined there is no additional receiver identification information input by the user for adding a receiver, the controller 160 determines whether one type, or two or more types of stored language information exist (step 224 ). When it is determined that there is only one type of stored language information, the controller 160 sets the language for creating a message to the language information included in the receiver information and displays a message input window through the display unit 190 (step 226 ). In contrast, when it is determined that there are two or more types of stored language information, the controller 160 sets the default language as the language for creating a message, and displays a message input window through the display unit 190 (step 228 ). That is, when there are two or more types of stored language information, in order to prevent an improper language from being transmitted to a message receiver, a default language is set as the language for creating a message and a message input window is displayed through the display unit 190 (step 228 ).
[0062] In step 230 , the controller 160 determines if the user, having confirmed language information displayed on the message input window, requests a change of the established language. When it is determined that the user does not request a change of the established language, the controller 160 receives and stores a message input through the key input unit 140 based on the established language (step 232 ). The controller 160 also transmits the stored message to one or more receivers corresponding to the receiver identification information included in the receiver information according to the transmission request of the user (step 234 ). The receiver identification information represents an identification number or address required for transmitting/receiving information among devices (such as mobile terminals and information terminals), and may be a telephone number, an IP address, or an email address.
[0063] In contrast, when it is determined that the user requests a change of the established language, the controller 160 sets the language requested by the user as the language for creating a message (step 238 ). Next, the controller 160 displays a message input window, receives and stores a message input through the key input unit 140 using the established language (step 232 ), and then transmits the stored message to one or more receivers corresponding to the receiver identification information included in the receiver information according to the transmission request of the user (step 234 ).
[0064] In a state in which a message is input and displayed using a language established in the mobile terminal, the controller 160 may also determine if the user requests a change of the established language. When it is determined that the user requests a change of the established language, the controller 160 may change the displayed message to a message in the language requested by the user, and display the changed message.
[0065] According to the procedure shown in FIG. 2 , when there are at least two types of language information, a message created by the user using a default language is transmitted to relevant receivers. However, if the mobile terminal includes a translation program, a message created using a default language is translated into a corresponding language for each receiver, and each translated message is transmitted to each corresponding receiver. In this case, while a transmitter creates a message using a default language, each receiver can receive the message comprised of a language suitable for that receiver.
[0066] FIGS. 3A and 3B are flowcharts illustrating a procedure for transmitting a reply message in response to a message received by a mobile terminal according to an exemplary embodiment of the present invention. That is, FIGS. 3A and 3B shows a procedure of analyzing transmitter information and contents of a received message in order to automatically establish a language, and creating and transmitting a message using the established language in a mobile terminal.
[0067] Referring to FIGS. 1, 3A and 3 B, the controller 160 notifies the user of a message reception event through the display unit 190 and/or through the speaker through the audio processing unit 130 . Then, when the controller 160 receives input corresponding to selection of the received message, through the key input unit 140 , from the user (step 311 ), the controller 160 analyzes the language used for creating the received message (step 313 ). In this case, the controller 160 analyzes a voice based on voice analysis information stored in the memory 150 when the received message includes a voice mail, and analyzes characters using character analysis information when the received message is a text message. The received message may be a short message, a multimedia message, or an email.
[0068] The controller 160 checks whether or not the transmitter information included in the received message is stored as storage information in the memory 150 (step 317 ). When the transmitter information is not stored in the memory 150 , the controller 160 asks the user through the display unit 190 if the user wants to store the transmitter information as storage information in the memory 150 (step 319 ). When the user requests the transmitter information to be stored, the controller 160 stores the transmitter information and corresponding language information as the storage information in the memory 150 (step 321 ), and establishes receiver information (receiver identification information and language information) by using the transmitter information (transmitter identification information and language information) (step 323 ).
[0069] In contrast, when the transmission information is stored in the memory 150 , the controller 160 determines if language information stored in the memory 150 is equal to the language information analyzed from the received message (step 325 ). When it is determined that the language information stored in the memory 150 is equal to the language information analyzed from the received message, the controller 160 establishes receiver information using the transmitter information (step 323 ). In contrast, when it is determined that the language information stored in the memory 150 is not equal to the language information analyzed from the received message, the controller 160 checks whether or not the user requests the corresponding language to be stored in the memory 150 (step 327 ). When the user requests the corresponding language to be stored, the controller 160 changes the stored language information (step 329 ). In contrast, when the user does not request the corresponding language to be stored, the controller 160 establishes receiver information using the transmitter information (step 323 ).
[0070] The controller 160 determines if the user requests that a reply message be created in response to the received message (step 331 ). When the user does not request that a reply message is created, the controller 160 may perform an alternative function as requested by the user (step 333 ). When the user requests that a reply message be created, the controller 160 determines if there is a different or additional receiver to be added to the receiver information (step 335 ).
[0071] When a different or additional receiver is requested by the user, the controller 160 receives receiver identification information (step 337 ) and determines if the received receiver identification information is included in information stored in the memory 150 (step 339 ). When the received receiver identification information is included in information stored in the memory 150 , the controller 160 determines if language information corresponding to the received receiver identification information is stored in the memory 150 (step 341 ). When language information corresponding to the received receiver identification information is stored in the memory 150 , the controller 160 stores receiver information using the additional receiver information (step 343 ) and determines if there is another additional receiver (step 335 ).
[0072] If it is determined in step 339 that the received receiver identification information is not included in information stored in the memory 150 , or when it is determined in step 341 that language information corresponding to the received receiver identification information is not stored in the memory 150 , the controller 160 stores only receiver identification information as additional receiver information (step 345 ).
[0073] In contrast, if it is determined in step 335 that there is no additional receiver, the controller 160 determines if additional receiver information exists (step 347 ). When there is no additional receiver information, the controller 160 displays a message input window through the display unit 190 by using the language information included in the receiver information (step 349 ). In contrast, when there is additional receiver information, the controller 160 determines if the additional receiver information includes language information (step 351 ).
[0074] When the additional receiver information does not include language information, the controller 160 displays a message input window through the display unit 190 by using the language information included in the receiver information (step 349 ). In contrast, when the additional receiver information includes language information, the controller 160 displays the receiver information and the additional receiver information (step 353 ).
[0075] In step 355 , the controller 160 determines if a language is selected by the user. When no language is selected by the user, the controller 160 displays a message input window through the display unit 190 by using the language information included in the receiver information (step 349 ). In contrast, when a language is selected by the user, the controller 160 displays a message input window by using the selected language (step 357 ), thereby entering a message input mode for creating a message (step 362 ).
[0076] After the message input window using the receiver's language is displayed, if a change of the language is requested by the user (step 358 ), the controller 160 establishes the language requested by the user as the language for creating a message (step 360 ). In contrast, if a change of the language is not requested by the user, the controller 160 enters a message input mode for creating a message (step 362 ).
[0077] In a state in which a message is input and displayed using a language established in the mobile terminal at the message input mode, the controller 160 may also determine if the user requests change of the established language. When it is determined that the user requests a change of the established language, the controller 160 may change the displayed message to be a message of the language requested by the user, and display the changed message.
[0078] After the user completes the input of a message, the controller 160 transmits the created message to receivers corresponding to the receiver information and additional receiver information as applicable (step 364 ).
[0079] According to exemplary embodiments of the present invention as described above, the mobile terminal can automatically establish a language according to language information stored therein and can enable a message using the established language to be created. Also, when the user requests a change of the established language, the mobile terminal enables a transmission message to be created using a language requested by the user. In addition, according to exemplary embodiments of the present invention, the mobile terminal can automatically establish a language by analyzing a received message, and can store transmitter information and language information as storage information according to selection by the user, when the transmitter and language information is not stored in the mobile terminal. Also, according to exemplary embodiments of the present invention, the mobile terminal detects language information by analyzing a voice message, and utilizes the detected language information, thereby providing better convenience to the user when using the mobile terminal.
[0080] While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
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A method and a terminal for transmitting a message are provided, where whether language information for a receiver has been established is checked when receiver information is input, the established language is displayed on a message input window when it is determined as a result of the check that the language information has been established, a message is created using the established language according to key information input from a key input unit and transmitted. Although a receiver uses a different language from that used by the transmitter, the mobile terminal can create and transmit a message based on the language used by the receiver by means of language information stored in the mobile terminal, so that the receiver may easily confirm a received message.
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This application is a divisional of application Ser. No. 09/550,554, filed on Apr. 17, 2000 which is a divisional of Ser. No. 09/146,194, which was filed on Sep. 3, 1998, now U.S. Pat. No. 6,255,312, which is a divisional of application Ser. No. 08/798,216 which was filed on Feb. 10, 1997 now U.S. Pat. No. 5,869,493, the entire contents of which are hereby incorporated by reference. Which claims priority from Swedish Patent Application 9600613-5 and 9600614-3 filed Feb. 16, 1996.
TECHNICAL FIELD
This invention relates to the field of antivirals and in particular to derivatives of acyclic nucleosides useful against herpes and retroviral infections. The invention provides novel compounds, pharmaceutical compositions comprising these compounds, methods for the treatment or prophylaxis of viral infections employing them, methods for their manufacture and novel intermediates.
BACKGROUND TO THE INVENTION
The practical utility of many acyclic nucleosides is limited by their relatively modest pharmacokinetics. A number of prodrug approaches have been explored in an effort to improve the bioavailability of acyclic nucleosides in general. One of these approaches involves the preparation of ester derivatives, particularly aliphatic esters, of one or more of the hydroxy groups on the acyclic side chain.
European patent EP 165 289 describes the promising antiherpes agent 9-[4-hydroxy-(2-hydroxymethyl)butyl]guanine, otherwise known as H2G. European patent EP 186 640 discloses 6-deoxy H2G. European patent EP 343 133 discloses that these compounds, particularly the R-(−) enantiomer, are additionally active against retroviral infections such as HIV. Various derivatives of H2G, such as phosphonates, aliphatic esters (for example, the diacetate and the dipropionate) and ethers of the hydroxy groups on the acyclic side chain are disclosed in EP 343 133. This patent also discloses methods for the preparation of these derivatives comprising the condensation of the acyclic side chain to the N-9 position of a typically 6-halogenated purine moiety or, alternatively, the imidazole ring closure of a pyrimidine or furazano-[3,4-d]pyrimidine moeity or the pyrimidine ring closure of an imidazole moiety, where the acyclic side chain is already present in the precursor pyrimidine or imidazole moiety, respectively. In the broadest description of each of these methods the acyclic side chain is pre-derivatised but individual examples also show a one-step diacylation of H2G with acetic or proprionic anhydride and DMF.
Harnden, et al., J. Med. Chem. 32, 1738 (1989) investigated a number of short chain aliphatic esters of the acyclic nucleoside 9-[4-hydroxy-(3-hydroxymethyl)butyl]guanine, otherwise known as penciclovir, and its 6-deoxy analog. Famciclovir, a marketed antiviral agent, is the diacetyl derivative of 6-deoxy penciclovir.
Benjamin, et al., Pharm. Res. 4 No. 2, 120 (1987) discloses short chain aliphatic esters of 9-[(1,3-dihydroxy-2-propoxy)-methyl]guanine, otherwise known as ganciclovir. The dipropionate ester is disclosed to be the preferred ester.
Lake-Bakaar, et al., discloses in Antimicrob. Agents Chemother. 33 No. 1, 110-112 (1989) diacetate and dipropionate derivatives of H2G and monoacetate and diacetate derivatives of 6-deoxy H2G. The diacetate and dipropionate derivatives of H2G are reported to result in only modest improvements in bioavailability relative to H2G.
International patent application WO94/24134, published Oct. 27, 1994, discloses aliphatic ester prodrugs of the 6-deoxy N-7 analog of ganciclovir, including the di-pivaloyl, di-valeroyl, mono-valeroyl, mono-oleoyl and mono-stearoyl esters.
International patent application WO93/07163, published Apr. 15, 1993 and International patent application WO94/22887, published Oct. 13, 1994, both disclose mono-ester derivatives of nucleoside analogs derived from mono-unsaturated C18 or C20 fatty acids. U.S. Pat. No. 5,216,142, issued Jun. 1, 1993, also discloses long chain fatty acid mono-ester derivatives of nucleoside analogs.
A second approach to providing prodrugs of acyclic nucleosides involves the preparation of amino acid esters of one or more of the hydroxy groups on the acyclic side chain. European patent EP 99 493 discloses generally amino acid esters of acyclovir and European patent application EP 308 065, published Mar. 22, 1989, discloses the valine and isoleucine esters of acyclovir.
European patent application EP 375 329, published Jun. 27, 1990, discloses amino acid ester derivatives of ganciclovir, including the di-valine, di-isoleucine, di-glycine and di-alanine ester derivatives. International patent application WO95/09855, published Apr. 13, 1995, discloses amino acid ester derivatives of penciclovir, including the mono-valine and di-valine ester derivatives.
DE 19526163, published Feb. 1, 1996 and U.S. Pat. No. 5,543,414 issued Aug. 6, 1996, disclose achiral amino acid esters of ganciclovir.
European patent application EP 694 547, published Jan. 31, 1996, discloses the mono-L-valine ester of ganciclovir and its preparation from di-valyl-ganciclovir.
European patent application EP 654 473, published May 24, 1995, discloses various bis amino acid ester derivatives of 9-[1′,2′-bishydroxymethyl)-cyclopropan-1′yl]methylguanine.
International patent application WO95/22330, published Aug. 24, 1995, discloses aliphatic esters, amino acid esters and mixed acetate/valinate esters of the acyclic nucleoside 9-[3,3-dihydroxymethyl-4-hydroxy-but-1-yl]guanine. This reference discloses that bioavailability is reduced when one of the valine esters of the trivaline ester derivative is replaced with an acetate ester.
BRIEF DESCRIPTION OF THE INVENTION
We have found that diester derivatives of H2G bearing specific combinations of an amino acid ester and a fatty acid ester are able to provide significantly improved oral bioavailability relative to the parent compound (H2G). In accordance with a first aspect of the invention there is thus provided novel compounds of the formula I
where
a) R 1 is —C(O)CH(CH(CH 3 ) 2 )NH 2 or —C(O)CH(CH(CH 3 )CH 2 CH 3 )NH 2 and R 2 is —C(O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl; or
b) R 1 is —C(O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl and R 2 is —C(O)CH(CH(CH 3 ) 2 )NH 2 or —C(O)CH(CH(CH 3 )CH 2 CH 3 )NH 2 ; and
R 3 is OH or H;
and pharmaceutically acceptable salts thereof
The advantageous effect on oral bioavailability of the mixed fatty acid and amino acid esters of the invention is particularly unexpected in comparison to the oral bioavailability of the corresponding fatty acid esters. Based on the results using a urinary recovery assay (Table 1A) or a plasma drug assay (Table 1B) of H2G from rats, neither the mono or di-fatty acid esters of H2G provide any improvement in oral bioavailability relative to the parent compound H2G. Indeed the di-stearate derivative provided significantly lower bioavailability than the parent indicating that a stearate ester may be detrimental for improving oral bioavailability of H2G. Converting one or both of the hydroxyls in certain other acyclic nucleoside analogues to the corresponding valine or di-valine ester has been reported to improve bioavailability. Conversion of H2G to the coresponding mono- or di-valyl ester derivatives produced similar improvement in bioavailability relative to the parent compound. Given that fatty acid derivatives of H2G are shown to be detrimental for improving bioavailability, it was unexpected that a mixed amino acid/fatty acid diester derivative of H2G would provide improved or comparable oral bioavailability to that of the valine diester derivative of H2G, based on urine recovery and plasma drug assays, respectively.
TABLE 1A
R 1 group
R 2 group
Bioavailability*
hydrogen
hydrogen
8%
hydrogen
stearoyl
12%
stearoyl
stearoyl
1%
valyl
hydrogen
29%
valyl
valyl
36%
valyl
stearoyl
56%
*see Biological Example 1 below for details
TABLE 1B
R 1 group
R 2 group
Bioavailability #
hydrogen
hydrogen
3.8%
hydrogen
stearoyl
1.9%
stearoyl
stearoyl
0%
valyl
hydrogen
31.3%
valyl
valyl
35.0%
valyl
stearoyl
29%
# see Biological Example 2 below for details
The invention also provides pharmaceutical compositions comprising the compounds of Formula I and their pharmaceutically acceptable salts in conjunction with a pharmaceutically acceptable carrier or diluent. Further aspects of the invention include the compounds of Formula I and their pharmaceutically acceptable salts for use in therapy and the use of these compounds and salts in the preparation of a medicament for the treatment or prophylaxis of viral infection in humans or animals.
The compounds of the invention are potent antivirals, especially against herpes infections, such as those caused by Varicella zoster virus, Herpes simplex virus types 1 & 2, Epstein-Barr virus, Herpes type 6 (HHV-6) and type 8 (HHV-8). The compounds are particularly useful against Varicella zoster virus infections such as shingles in the elderly including post herpetic neuralgia or chicken pox in the young where the duration and severity of the disease can be reduced by several days. Epstein Barr virus infections amenable to treatment with the compounds include infectious mononucleosis/glandular fever which has previously not been treatable but which can cause many months of scholastic incapacity amongst adolescents.
The compounds of the invention are also active against certain retroviral infections, notably SIV, HIV-1 and HIV-2, and against infections where a transactivating virus is indicated.
Accordingly a further aspect of the invention provides a method for the prophylaxis or treatment of a viral infection in humans or animals comprising the administration of an effective amount of a compound of Formula I or its pharmaceutically acceptable salt to the human or animal.
Advantageously group R 3 is hydroxy or its tautomer ═O so that the base portion of the compounds of the invention is the naturally occuring guanine, for instance in the event that the side chain is cleaved in vivo. Alternatively, R 3 may be hydrogen thus defining the generally more soluble 6-deoxy derivative which can be oxidised in vivo (e.g. by xanthine oxidase) to the guanine form.
The compound of formula I may be present in racemic form, that is a mixture of the 2R and 2S isomers. Preferably, however, the compound of formula I has at least 70%, preferably at least 90% R form, for example greater than 95%. Most preferably the compound of formula I is enantiomerically pure R form.
Preferably the amino acid of group R 1 /R 2 is derived from an L-amino acid.
Preferably the fatty acid of group R 1 /R 2 has in total an even number of carbon atoms, in particular, decanoyl (C 10 ), lauryl (C 12 ), myristoyl (C 14 ), palmitoyl (C 16 ), stearoyl (C 18 ) or eicosanoyl (C 20 ). Other useful R 1 /R 2 groups include butyryl, hexanoyl, octanoyl or behenoyl (C 22 ). Further useful R 1 /R 2 groups include those derived from myristoleic, myristelaidic, palmitoleic, palmitelaidic, n6-octadecenoic, oleic, elaidic, gandoic, erucic or brassidic acids. Monounsaturated fatty acid esters typically have the double bond in the trans configuration, preferably in the ω-6, ω-9 or ω-11 position, dependent upon their length. Preferably the R 1 /R 2 group is derived from a fatty acid which comprises a C 9 to C 17 saturated, or n:9 monounsaturated, alkyl.
The saturated or unsaturated fatty acid or R 1 /R 2 may optionally be substituted with up to five similar or different substituents independently selected from the group consisting of such as hydroxy, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 1 -C 6 alkoxy C 1 -C 6 alkyl, C 1 -C 6 alkanoyl, amino, halo, cyano, azido, oxo, mercapto and nitro, and the like.
Most preferred compounds of the formula I are those where R 1 is —C(O)CH(CH 3 ) 2 )NH 2 or —C(O)CH(CH(CH 3 )CH 2 CH 3 )NH 2 and R 2 is —C(O)C 9 -C 17 saturated alkyl.
The term “lower alkyl” as used herein refers to straight or branched chain alkyl radicals containing from 1 to 7 carbon atoms including, but not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, n-pentyl, 1-methylbutyl, 2,2-dimethylbutyl, 2-methylpentyl, 2,2-dimethylpropyl, n-hexyl and the like.
The term “N-protecting group” or “N-protected” as used herein refers to those groups intended to protect the N-terminus of an amino acid or peptide or to protect an amino group against undesirable reactions during synthetic procedures. Commonly used N-protecting groups are disclosed in Greene, “Protective Groups in Organic Synthesis” (John Wiley & Sons, New York, 1981), which is hereby incorporated by reference. N-protecting groups include acyl groups such as formyl, acetyl, propionyl, pivaloyl, t-butylacetyl, 2-chloroacetyl, 2-bromoacetyl, trifluoracetyl, trichloroacetyl, phthalyl, o-nitrophenoxyacetyl, α-chlorobutyryl, benzoyl, 4-chlorobenzoyl, 4-bromobenzoyl, 4-nitrobenzoyl, and the like; sulfonyl groups such as benzenesulfonyl, p-toluenesulfonyl, and the like, carbamate forming groups such as benzyloxycarbonyl, p-chlorobenzyloxycarbonyl, p-methoxybenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, 2-nitrobenzyloxycarbonyl, p-bromobenzyloxycarbonyl, 3,4-dimethoxybenzyloxycarbonyl, 4-methoxybenzyloxycarbonyl, 2-nitro-4,5-dimethoxybenzyloxycarbonyl, 3,4,5-trimethoxybenzyloxycarbonyl, 1-(p-biphenylyl)-1-methylethoxycarbonyl, α,α-dimethyl-3,5-dimethoxybenzyloxycarbonyl, benzhydryloxycarbonyl, t-butoxycarbonyl, diisopropylmethoxycarbonyl, isopropyloxycarbonyl, ethoxycarbonyl, methoxycarbonyl, allyloxycarbonyl, 2,2,2-trichloroethoxycarbonyl, phenoxycarbonyl, 4-nitrophenoxycarbonyl, fluorenyl-9-methoxycarbonyl, cyclopentyloxycarbonyl, adamantyloxycarbonyl, cyclohexyloxycarbonyl, phenylthiocarbonyl, and the like; alkyl gropus such as benzyl, triphenylmethyl, benzyloxymethyl and the like; and silyl groups such as trimethylsilyl and the like.
Favoured N-protecting groups include formyl, acetyl, benzoyl, pivaloyl, t-butylacetyl, phenylsulfonyl, benzyl, t-butoxycarbonyl (BOC) and benzyloxycarbonyl (Cbz).
The term “activated ester derivative” as used herein refers to acid halides such as acid chlorides, and activated esters including, but not limited to, formic and acetic acid derived anhydrides, anhydrides derived from alkoxycarbonyl halides such as isobutyloxycarbonylchloride and the like, N-hydroxysuccinimide derived esters, N-hydroxyphthalimide derived esters, N-hydroxybenzotriazole derived esters, N-hydroxy-5-norbomene-2,3-dicarboxamide derived esters, 2,4,5-trichlorophenyl derived esters and the like.
Preferred compounds of formula I include:
(R)-9-[2-(butyryloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[2-(4-acetylbutyryloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[2-(hexanoyloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(octanoyloxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(decanoyloxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(dodecanoyloxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(tetradecanoyloxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(hexadecanoyloxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-(octadecanoyloxymethyl)butyl]guanine,
(R)-9-[2-(eicosanoyloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[2-(docosanoyloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-((9-tetradecenoyl)oxymethyl)butyl]guanine,
(R)-9-[2-((9-hexadecenoyl)oxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-((6-octadecenoyl)oxymethyl)butyl]guanine,
(R)-9-[4-(L-isoleucyloxy)-2-((9-octadecenoyl)oxymethyl)-butyl]guanine,
(R)-9-[2-((11-eicosanoyl)-oxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[2-((13-docosenoyl)-oxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-2-amino-9-[2-(butyryloxymethyl)-4-(L-isoleucyloxy)butyl]purine,
R)-2-amino-9-[2-(4-acetylbutyryloxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[2-(hexanoyloxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(octanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(decanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(dodecanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(decanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(hexadecanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(octadecanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(eicosanoyloxymethyl)butyl]purine,
(R)-2-amino-9-[2-(eicosanoyloxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[2-(docosanoyloxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-((9-tetradecenoyl)oxymethyl)butyl]purine,
(R)-2-amino-9-[2-((9-hexadecenoyl)oxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-((6-octadecenoyl)oxymethyl)butyl]purine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-((9-octadecenoyl)oxymethyl)butyl]purine,
(R)-2-amino-9-[2-((11-eicosanoyl)oxymethyl)-4-(L-isoleucyloxy)butyl]purine, or
(R)-2-amino-9-[2-((13-docosenoyl)oxymethyl)-4-(L-isoleucyloxy)butyl]purine,
and their pharmaceutically accepable salts.
Further preferred compounds include:
(R)-9-[2-(butyryloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(4-acetylbutyryloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(hexanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(octanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(decanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(dodecanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(tetradecanoyloxymethyl-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-hexadecanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(octadecanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(eicosanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(eicosanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-(docosanoyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-((9-tetradecenoyl)oxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-((9-hexadecenoyl)oxymethyl)-4-(L-valyloxy)butyl]guanne,
(R)-9-[2-((6-octadecenoyl)oxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-((9-octadecenoyl)oxymethyl)-4-(L-valyloxy)-butyl]guanine,
(R)-9-[2-((11-eicosanoyl)oxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-((13-docosenoyl)oxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-2-amino-9-[2-(butyryloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(4-acetylbutyryloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(hexanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(octanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(decanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(dodecanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(tetradecanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(hexadecanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(octadecanoyloxymethyl)-4-(L-valyloxy)-butyl]purine,
(R)-2-amino-9-[2-(eicosanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-(docosanoyloxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-((9-tetradecenoyl)oxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-((9-hexadecenoyl)oxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-((6-octadecenoyl)oxymethyl)-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-((9-octadecenoyl)oxymethyl)-4-(L-valyloxy)-butyl]purine,
(R)-2-amino-9-[2-((11-eicosenoyl)-oxymethyl)-4-(L-valyloxy)butyl]purine, or
(R)-2-amino-9-[2-((13-docosenoyl)-oxymethyl)-4-(L-valyloxy)butyl]purine;
and their pharmaceutically acceptable salts.
Other preferred compounds of formula I include:
(R)-9-[4-(butyryloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(4-acetylbutyryloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(hexanoyloxy)-2-(L-valyloxy methyl)butyl]guanine,
(R)-9-[4-(octanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(decanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(dodecanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(tetradecanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-hexadecanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(octadecanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(eicosanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-(docosanoyloxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-((9-tetradecenoyl)oxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-((9-hexadecenoyl)oxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-((6-octadecenoyl)oxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-((9-octadecenoyl)oxy)-2-(L-valyloxymethyl)-butyl]guanine,
(R)-9-[4-((11-eicosenoyl)oxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-9-[4-((13-docosenoyl)-oxy)-2-(L-valyloxymethyl)butyl]guanine,
(R)-2-amino-9-[4-(butyryloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(4-acetylbutyryloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(hexanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(octanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(decanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(dodecanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(tetradecanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(hexadecanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(octadecanoyloxy)-2-(L-valyloxymethyl)-butyl]purine,
(R)-2-amino-9-[4-(eicosanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-(docosanoyloxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-((9-tetradecenoyl)oxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-((9-hexadecenoyl)oxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-((6-octadecenoyl)oxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-((9-octadecenoyl)oxy)-2-(L-valyloxymethyl)butyl]purine,
(R)-2-amino-9-[4-((11-eicosenoyl)oxy)-2-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-((13-docosenoyl)oxymethyl)-2-(L-valyloxy)butyl]purine, or
and their pharmaceutically acceptable salts.
The compounds of formula I can form salts which form an additional aspect of the invention. Appropriate pharmaceutically acceptable salts of the compounds of formula I include salts of organic acids, especially carboxylic acids, including but not limited to acetate, trifluoroacetate, lactate, gluconate, citrate, tartrate, maleate, malate, pantothenate, isethionate, adipate, alginate, aspartate, benzoate, butyrate, digluconate, cyclopentanate, glucoheptanate, glycerophosphate, oxalate, heptanoate, hexanoate, fumarate, nicotinate, palmoate, pectinate, 3-phenylpropionate, picrate, pivalate, proprionate, tartrate, lactobionate, pivolate, camphorate, undecanoate and succinate, organic sulphonic acids such as methanesulphonate, ethanesulphonate, 2-hydroxyethane sulphonate, camphorsulphonate, 2-napthalenesulphonate, benzenesulphonate, p-chlorobenzenesulphonate and p-toluenesulphonate; and inorganic acids such as hydrochloride, hydrobromide, hydroiodide, sulphate, bisulphate, hemisulphate, thiocyanate, persulphate, phosphoric and sulphonic acids. Hydrochloric acid salts are convenient.
The compounds of Formula I may be isolated as the hydrate. The compounds of the invention may be isolated in crystal form, preferably homogenous crystals, and thus an additional aspect of the invention provides the compounds of Formula I in substantially pure crystalline form, comprising >70%, preferably >90% homogeneous crystalline material for example >95% homogeneous crystalline material.
The compounds of the invention are particularly suited to oral administration, but may also be administered rectally, vaginally, nasally, topically, transdermally or parenterally, for instance intramuscularly, intravenously or epidurally. The compounds may be administered alone, for instance in a capsule, but will generally be administered in conjunction with a pharmaceutically acceptable carrier or diluent. The invention extends to methods for preparing a pharmaceutical composition comprising bringing a compound of Formula I or its pharmaceutically acceptable salt in conjunction or association with a pharmaceutically acceptable carrier or vehicle.
Oral formulations are conveniently prepared in unit dosage form, such as capsules or tablets, employing conventional carriers or binders such as magnesium stearate, chalk, starch, lactose, wax, gum or gelatin. Liposomes or synthetic or natural polymers such as HPMC or PVP may be used to afford a sustained release formulation. Alternatively the formulation may be presented as a nasal or eye drop, syrup, gel or cream comprising a solution, suspension, emulsion, oil-in-water or water-in-oil preparation in conventional vehicles such as water, saline, ethanol, vegetable oil or glycerine, optionally with flavourant and/or preservative and/or emulsifier.
The compounds of the invention may be administered at a daily dose generally in the range 0.1 to 200 mg/kg/day, advantageously, 0.5 to 100 mg/kg/day, more preferably 10 to 50 mg/kg/day, such as 10 to 25 mg/kg/day. A typical dosage rate for a normal adult will be around 50 to 500 mg, for example 300 mg, once or twice per day for herpes infections and 2 to 10 times this dosage for HIV infections.
As is prudent in antiviral therapy, the compounds of the invention can be administered in combination with other antiviral agents, such as acyclovir, valcyclovir, penciclovir, famciclovir, ganciclovir and its prodrugs, cidofovir, foscamet and the like for herpes indications and AZT, ddI, ddC, d4T, 3TC, foscarnet, ritonavir, indinavir, saquinavir, delaviridine, Vertex VX 478, Agouron AG1343 and the like for retroviral indications.
The compounds of the invention can be prepared de novo or by esterification of the H2G parent compound which is prepared, for example, by the synthesis methodology disclosed in European Patent EP 343 133, which is incorporated herein by reference.
A typical reaction scheme for the preparation of H2G is depicted overleaf:
The condensation in step 1 is typically carried out with a base catalyst such as NaOH or Na 2 CO 3 in a solvent such as DMF. Step 2 involves a reduction which can be performed with LiBH 4 /tetrahydrofuran in a solvent such as t-BuOH. The substitution in step 3 of the chlorine with an amino group can be performed under pressure with ammonia. Step 4 employs adenosine deaminase which can be conveniently immobilized on a solid support. Cooling the reaction mixture allows unreacted isomeric precursor to remain in solution thereby enhancing purity.
Starting materials for compounds of the invention in which R 3 is hydrogen may be prepared as shown in European Patent EP 186 640, the contents of which are incorporated herein by reference. These starting materials may be acylated as described for H2G below, optionally after protecting the purine 2-amino group with a conventional N-protecting group as defined above, especially BOC (t-BuO—CO—), Z (BnO—CO—) or Ph 3 C—.
The compounds of the invention may be prepared from H2G as described below in Schemes A and B.
A. Direct Acylation Method
Scheme A depicts the preparation of compounds in which R 1 is derived from the amino acid and R 2 is derived from the fatty acid, but the converse scheme is applicable to compounds where R 1 is derived from the fatty acid and R 2 is derived from the amino acid ester. In the variant specifically depicted in scheme A above, G is guanine or 6-deoxyguanine, PG is an optional N-protecting group or hydrogen, R 1 * is the valine or isoleucine side chain and R 2 * is the fatty acid chain. H2G is depicted above as a starting material but this of course may be optionally protected at R 3 or the 2 position of the purine with conventional N-protecting groups (not shown). The H2G (derivative) reacts in the first step with an activated R 1 α-amino acid derivative, as further described below, in a solvent such as dimethylformamide or pyridine, to give a monoacylated product. The R 1 α-amino acid may be suitably N-protected with N-BOC or N-CBz or the like. Under controlled conditions, the first acylation can be made to predominantly take place at the side chain 4-hydroxy group on the side chain of H2G. These controlled conditions can be achieved, for example, by manipulating the reagent concentrations or rate of addition, especially of the acylating agent, by lowering the temperature or by the choice of solvent. The reaction can be followed by TLC to monitor the controlled conditions.
After purification, the R 1 monoacylated compounds are further acylated on the side chain 2—CH 2 OH group with the appropriate activated fatty acid derivative to give diacylated products using similar procedures as for the first esterification step. The diester products are subsequently subjected to a conventional deprotection treatment using for example trifluoroacetic acid, HCl(aq)/dioxane or hydrogenation in the presence of catalyst to give the desired compound of Formula I. The compound may be in salt form depending on the deprotection conditions.
The activated R 1 /R 2 acid derivative used in the various acylations may comprise e.g. the acid halide, acid anhydride, activated acid ester or the acid in the presence of coupling reagent, for example dicyclohexylcarbodiimide, where “acid” in each case represents the corresponding R 1 /R 2 amino acid or the R 1 /R 2 fatty acid. Representative activated acid derivatives include the acid chloride, formic and acetic acid derived mixed anhydrides, anhydrides derived from alkoxycarbonyl halides such as isobutyloxycarbonylchloride and the like, N-hydroxysuccinamide derived esters, N-hydroxyphthalimide derived esters, N-hydroxy-5-norbomene-2,3-dicarboxamide derived esters, 2,4,5-trichlorophenol derived esters and the like.
B. Via Protection of the Side Chain 4-Hydroxy Group
wherein G, PG, R 1 * and R 2 * are as described for scheme A.
Scheme B has been exemplified with reference to the preparation of a compound where R 1 is derived from an amino acid and R 2 is derived from the fatty acid ester, but a converse scheme will be applicable to compounds where R 2 is derived from the amino acid and R 1 is derived from the fatty acid. This scheme relies on regioselective protection of the H2G side chain 4-hydroxy group with a bulky protecting group. In scheme B above this is depicted as t-butyldiphenylsilyl, but other regioselective protecting groups such as trityl, 9-(9-phenyl)xanthenyl, 1,1-bis(4-methylphenyl)-1′-pyrenylmethyl may also be appropriate. The resulting product is acylated at the side chain 2-hydroxymethyl group using analogous reagents and procedures as described in scheme A above, but wherein the activated acid derivative is the R 2 fatty acid, for example, myristic, stearic, oleic, elaidic acid chloride and the like. The thus monoacylated compounds are subjected to appropriate deprotection treatment to remove the side chain 4-hydroxy protecting group which can be done in a highly selective manner with such reagents, depending on the regioselective protecting group, as HF/pyridine and the like and manipulation of the reaction conditions, viz reagent concentration, speed of addition, temperature and solvent etc, as elaborated above. The then free side chain 4-hydroxy group is acylated with the activated α-amino acid in a similar way as described in scheme A above.
Additional techniques for introducing the amino acid ester of R 1 /R 2 , for instance in schemes A, B, C or D herein include the 2-oxa-4-aza-cycloalkane-1,3-dione method described in international patent application no. WO 94/29311.
Additional techniques for introducing the fatty acid ester of R 1 /R 2 , for instance in schemes A, B, C or D herein include the enzymatic route described in Preparative Biotransformations 1.11.8 (Ed S M Roberts, J Wiley and Son, NY, 1995) with a lipase such as SP 435 immobilized Candida antarcticus (Novo Nordisk), porcine pancreatic lipase or Candida rugosa lipase. Enzymatic acylation is especially convenient where it is desired to avoid N-protection and deprotection steps on the other acyl group or the purine 2-amine.
An alternative route to compounds of Formula I in which R 3 is hydrogen is to 6-activate the correponding guanine compound of Formula I (wherein the amino acid ester moiety of R 1 /R 2 is optionally protected with conventional N-protecting groups such as BOC) with an activating group such as halo. The thus activated 6-purine is subsequently reduced to purine, for instance with a palladium catalyst and deprotected to the desired 6-deoxy H2G di-ester.
A further aspect of the invention thus provides a method for the preparation of the compounds of formula I comprising
a) optionally N-protecting the purine 2 and/or 6 positions of a compound of formula I wherein R 1 and R 2 are each hydrogen;
b) regioselectively acylating the compound of Formula 1 at the side chain 4-hydroxy group with either
i) an optionally N-protected valine or isoleucine group,
ii) an optionally substituted, saturated or monounsaturated C 3 -C 21 COOH derivative, or
iii) a regioselective protecting group;
c) acylating at the side chain 2-hydroxymethyl group with
i) an optionally N-protected valine or isoleucine derivative, or
ii) an optionally substituted, saturated or monounsaturated C 3 -C 21 COOH derivative;
d) replacing the regioselective protecting group at R 1 , if present, with
i) an optionally N-protected valine or isoleucine derivative; or
ii) an optionally substituted, saturated or monounsaturated C 3 -C 21 COOH derivative; and
e) deprotecting the resulting compound as necessary.
Schemes A and B above employ selective acylation to stepwise add the amino acid and fatty acid esters. An alternative process for the preparation of the compounds of formula I starts with a diacylated H2G derivative, wherein both the acyl groups are the same, and employs selective removal of one of the acyl groups to obtain a monoacyl intermediate which is then acylated with the second, differing, acyl group in the same manner as Schemes A and B above.
Accordingly a further aspect of the invention provides a method for the preparation of a compound of the formula I, as defined above, which method comprises
A) the monodeacylation of a diacylated compound corresponding to formula I wherein R 1 and R 2 are both a valyl or isoleucyl ester (which is optionally N-protected) or are R 1 and R 2 are both —C(═O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl; and
B) acylating the thus liberated side chain 4-hydroxy or side chain 2-hydroxymethyl group with the corresponding valyl, isoleucyl or —C(═O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl; and
C) deprotecting as necessary.
This alternative process has the advantage that the preparation of the diacylated H2G derivative is facile and requires little or no purification steps. Selective removal of one only of the acyl groups of a diacylated H2G derivative can be achieved by manipulating the reaction conditions, in particular the temperature, rate of reactant addition and choice of base.
Compounds amenable to this alternative synthesis route are thus of the formula:
where R 1 and R 2 are valyl or isoleucyl (which are optionally N-protected) or a —C(═O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl; and R 3 is OH or H.
For ease of synthesis in this alternative route, it is preferred that R 1 and R 2 are both initially identical and are most preferably the same amino acid ester. Such a di-amino acid ester will generally be N-protected during its preparation and may be used directly in this condition in the selective deacylation step. Alternatively, such an N-protected di-aminoacylated H2G derivative may be deprotected and optionally reprotected, as described below. The unprotected di-aminoacyl H2G derivative thus comprises one of the following compounds:
(R)-9-[2-(L-isoleucyloxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[2-(L-valyloxymethyl)-4-(L-valyloxy)butyl]guanine,
(R)-2-amino-9-[4-(L-isoleucyloxy)-2-(L-isoleucyloxymethyl)butyl]purine, and
(R)-2-amino-9-[4-(L-valyloxy)-2-(L-valyloxymethyl)butyl]purine.
These unprotected H2G diacylated derivatives can be directly subject to selective deacylation of one of the acyl groups (typically the side chain 4-position acyl) followed by enzymatic acylation of the liberated 4-hydroxy as described above. Alternatively, the unprotected H2G diacylated derivative can be re-protected and then subjected to the selective deacylation, followed in turn by conventional acylation with the fatty acid ester, as described in Schemes A and B. Conveniently, such a reprotection step is done with a different N-protecting group, having properties appropriate to the subsequent acylation. For example, it is convenient to employ a lipophilic N-protecting group, such as Fmoc when preparing a di-amino acid H2G derivative, as the lipophilic nature of the protecting group assists with separation of the acylated products. On the other hand, the lipophilic nature of Fmoc is of less utility when conducting an acylation with a fatty acid, and thus it is convenient to reprotect a diacylated H2G with an alternative N-protecting group such as BOC.
It will also be apparent that the preparation of the compounds of formula I can commence with the novel monoacylated intermediates of step b i), ii) or iii) in the above defined first method aspect of the invention. These compounds are thus of the formula:
where one of R 1 and R 2 is
i) —C(O)CH(CH(CH 3 ) 2 )NH 2 or —C(O)CH(CH(CH 3 )CH 2 CH 3 )NH 2
ii) a —C(═O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl, or
iii) a regioselective protecting group;
the other of R 1 and R 2 is hydrogen; and
R 3 is OH or H;
Useful compounds thus include:
(R)-9-[2-hydroxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(trityloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(9-(9-phenyl)xanthenyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(1,1-bis(4-methylphenyl)-1′-pyrenylmethyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(decanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl)-4-(dodecanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(tetradecanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl)-4-(hexadecanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(octadecanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl)-4-(eicosanoyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(docosanoyloxy)butyl]guanine,
(R)-9-[4-hydroxy-2-(decanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(dodecanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(tetradecanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(hexadecanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(octadecanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(eicosanoyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(docosanoyloxymethyl)butyl]guanine,
(R)-9-[2-hydroxymethyl-4-(L-valyloxy)butyl]guanine,
(R)-9-[2-hydroxymethyl)-4-(L-isoleucyloxy)butyl]guanine,
(R)-9-[4-hydroxy-2-(L-isoleucyloxymethyl)butyl]guanine,
(R)-9-[4-hydroxy-2-(L-valyloxymethyl)butyl]guanine.
(R)-2-amino-9-[2-hydroxymethyl-4-(L-valyloxy)butyl]purine,
(R)-2-amino-9-[2-hydroxymethyl)-4-(L-isoleucyloxy)butyl]purine,
(R)-2-amino-9-[4-hydroxy-2-(L-isoleucyloxymethyl)butyl]purine, and
(R)-2-amino-9-[4-hydroxy-2-(L-valyloxymethyl)butyl]purine.
Regioselectively protected, sidechain 4-hydroxy intermediates from step c) of the above described first method aspect of the invention are also novel compounds.
Useful compounds thus include:
(R)-9-[2-decanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-dodecanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-tetradecanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-hexadecanoyloxymethyl-4-(t-butyldiphenylchlorosilane)butyl]guanine,
(R)-9-[2-octadecanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-eicosanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
(R)-9-[2-docosanoyloxymethyl-4-(t-butyldiphenylsilyl)butyl]guanine,
An alternative process for the preparation of compounds of the invention of the formula I wherein R 3 is —OH is shown in Scheme C.
Referring to Scheme C, malonate 1 (R 4 and R 5 are lower alkyl or benzyl or the like) is alkylated by reaction with from about 0.5 to about 2.0 molar equivalents of acetal 2 (R 6 and R 7 are lower alkyl or benzyl and the like or R 6 and R 7 taken together are —CH 2 CH 2 — or —CH 2 CH 2 CH 2 — or —CH 2 CH 2 CH 2 CH 2 — and X 1 is a leaving group (for example, Cl, Br or I, or a sulfonate such as methanesulfonate, triflate, p-toluenesulfonate, benzenesulfonate and the like)) in the presence of from about 0.5 to about 2.0 molar equivalents of a base (for example, potassium t-butoxide or sodium ethoxide or NaH or KH and the like) in an inert solvent (for example, DMF or THF or dioxane or dioxolane or N-methylpyrrolidone and the like) at a temperature of from about −40° C. to about 190° C. to provide alkylated malonate 3.
Reduction of 3 with from about 0.5 to about 4.0 molar equivalents of an ester to alcohol reducing agent (for example, LiBH 4 or Ca(BH 4 ) 2 or NaBH 4 or LiAlH 4 and the like) in an inert solvent (for example, THF or methyl t-butyl ether or t-BuOH and the like) at a temperature of from about −20° C. to about 100° C. provides diol 4. Enzymatic esterification of 4 by reaction with from about 1.0 to about 20.0 molar equivalents of a vinyl ester 5 (R 8 is C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl) in the presence of a lipase (for example, Lipase PS-30 or Lipase PPL or Lipase CCL and the like) or a phospholipase (for example phospholipase D and the like) provides the desired stereoisomer of ester 6. This reaction can be carried out in the absence of solvent or in the presence of an inert solvent (for example, methyl t-butyl ether or toluene or hexane and the like). The reaction is carried out at a temperature of from about −20° C. to about 80° C.
The alcohol substituent of 6 is converted to a leaving group (for example, a halogen or a sulfonate) by reaction with a halogenating agent (for example NBS/P(Ph) 3 or NCS/P(Ph) 3 or POCl 3 or NCS/P(Ph) 3 /Nal in acetone and like) in an inert solvent (for example, methylene chloride or toluene or ethylacetate and the like) or by reaction with from about 0.8 molar equivalents to about 2.0 molar equivalents of a sulfonyl halide (for example, benzenesulfonylchloride, toluenesulfonylchloride or methane sulfonylchloride and the like) in the presence of from about 1.0 to about 4.0 molar equivalents of a base (for example, triethylamine or potassium carbonate or pyridine or dimethylaminopyridine or ethyldiisopropylamine and the like) in an inert solvent (for example methylene chloride or toluene or ethylacetate or pyridine or methyl t-butyl ether and the like) at a temperature of from about −25° C. to about 100° C. to provide ester 7. (X 2 is a halogen or sulfonate leaving group).
Reaction of 7 with from about 0.9 to about 2.0 molar equivalents of 2-amino-4-chloropurine 8 in the presence of from about 1.0 to about 6.0 molar equivalents of a base (for example, potassium carbonate or NaH or KH or NaOH or KOH or lithium diisopropylamide and the like) in an inert solvent (for example, DMF or THF or acetonitrile or N-methylpyrrolidone or ethanol and the like) at a temperature of from about −25 ° C. to about 140° C. provides substituted purine 9.
Alternatively Mitsunobu coupling (for example P(Ph) 3 /diethyl azidocarboxylate) of alcohol 6 with 2-amino-4-chloropurine 8 provides 9.
Reaction of 9 with from about 2.0 to about 20 molar equivalents of an alcohol R 9 OH (R 9 is an alcohol protecting group such as benzyl and the like) in the presence of from about 1.0 to about 6.0 molar equivalents of a base (for example, potassium t-butoxide or potassium carbonate or NaH or KH or lithium diisopropylamide and the like) in an inert solvent (for example, THF or DMF and the like) at a temperature of from about −25° C. to about 150° C. provides alcohol 10.
Removal of the alcohol protecting group R 9 of 10 (for example, by catalytic hydrogenation in an inert solvent such as ethanol or benzyl alcohol or methanol or THF and the like in the presence of an hydrogenation catalyst such as Pd/C or Pd(OH) 2 and the like) provides substitued guanine 11.
Esterification of 11 by reaction with a) from about 0.8 to about 2.0 molar equivalents of (for example THF or DMF and the like) or b) from about 0.8 to about 2.0 molar equivalents of an activated derivative of R 10 COOH (for example, the acid chloride or N-hydroxysuccinimide ester or R 10 C(O)OC(O)R 10 and the like) in the presence of from about 0 to about 3.0 molar equivalents of a base (for example, pyridine or triethylamine or ethyldiisopropylamine or DBU or potassium carbonate and the like) in an inert solvent (for example, methylene chloride or THF or pyridine or acetonitrile or DMF and the like) at a temperature of from about −25° C. to about 100° C. provides ester 12.
The acetal substituent of 12 is deprotected and the resulting aldehyde is reduced by first reacting 12 with from about 0.1 to about 10.0 molar equivalents of an acid (for example, triflic acid or HCl or acetic acid or sulfuric acid and the like) in an inert solvent (for example, THF/H 2 O or methylene chloride/H 2 O or ethylacetate/H 2 O or ethanol/H 2 O or methanol/H 2 O and the like) at a temperature of from about −25° C. to about 100° C. To the crude reaction mixture is added from about 0.1 to about 10.0 molar equivalents of a base (for example, sodium bicarbonate or potassium carbonate or triethylamine or pyridine or KOH and the like), additional inert solvent (for example, THF and or methylene chloride or ethylacetate or methyl t-butyl ether or isopropoanol and the like) and from about 0.3 to about 5.0 molar equivalents of an aldehyde reducing agent (for example, sodium borohydride or RaNi/H 2 and the like) at a temperature of from about −25° C. to about 100° C. to provide alcohol 13.
Reaction of 13 with from about 0.8 to about 3.0 molar equivalents of N-protected amino acid P 1 NHCH(R 11 )COOH or an activated derivative thereof (P 1 is an N-protecting group and R 11 is isopropyl or isobutyl) in an inert solvent (for example, THF or dioxane or dioxolane or DMF or methylene chloride and the like) at a temperature of from about 25° C. to about 100° C. provides alcohol 14. N-deprotection of 14 provides the compound of the invention of formula I wherein R 3 is —OH.
Alternatively compound 13 can be reacted with the symmetrical anhydride derived from P 1 NHCH(R 11 )COOH (i.e.P 1 NHCH(R 11 )C(O)O—C(O)CH(R 11 )NHP 1 ) to provide 1 wherein R 3 is OH.
Another alternative process for the preparation of compounds wherein R 3 is —OH is shown in Scheme D.
Malonate 1 (R 4 and R 5 are lower alkyl or benzyl and the like) is alkylated with from about 0.5 to about 2.0 molar equivalents of ether 15 wherein X 1 is a leaving group (for example Cl, Br of I, or a sulfonate such as methane sulfonate, triflate, p-toluenesulfonate, benzenesulfonate and the like) and R 12 is —CH(Ph) 2 , —C(Ph) 3 or —Si(t-Bu)(Me) 2 and the like (Ph=phenyl) in the presence of from about 0.5 to about 2.0 molar equivalents of a base (for example potassium t-butoxide or sodium ethoxide or NaH or KH and the like) in an inert solvent (for example DMF or THF or dioxane or dioxolane or N-methyl pyrrolidinone and the like) at a temperature of from about −40° C. to about 190° C. to provide alkylated malonate 16.
Reduction of 16 with from about 0.5 to about 4.0 molar equivalents of an ester to alcohol reducing agent (for example LiBH 4 or Ca(BH 4 ) 2 or NaBH 4 or LiAlH 4 and the like) in an inert solvent (for example THF or methyl t-butyl ether or ethanol or t-butanol and the like) at a temperature of from about −20° C. to about 100° C. provides diol 17. Enzymatic esterification of 17 by reaction with from about 1.0 to about 20.0 molar equivalents of a vinyl ester 5 (R 8 is C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl) in the presence of a lipase (for example, Lipase PS-30 of Lipase PPL or Lipase CCL and the like) or a phospholipase (for example phospholipase D and the like) provides the desired stereoisomer of ester 18. The reaction can be carried out in the absence of solvent or in the presence of an inert solvent (for example methyl t-butyl ether or toluene or hexane or the like). The reaction is carried out at a temperature of from about −20° C. to about 80° C.
The alcohol sustituent of 18 is converted to a leaving group (for example a halogen or sulfonate) by reaction with a halogenating agent (for example NBS/P(Ph) 3 or NCS/P(Ph) 3 or POCl 3 or NCS/P(Ph) 3 /Nal in acetone and the like) in an inert solvent (for example methylene chloride or toluene or ethylacetate and the like) or by reaction with from about 0.8 molar equivalents to about 2.0 molar equivalents of a sulfonyl halide (for example benzenesulfonylchloride, toluenesulfonylchloride or methane sulfonylchloride and the like) in the presence of from about 1.0 to about 4.0 molar equivalents of a base (for example triethylamine or potassium carbonate or pyridine or methyl t-butyl ether and the like) at a temperature of from about −25° C. to about 100° C. to provide ester 19. (X 2 is a halogen or sulfonate leaving group).
Reaction of 19 with from about 0.9 to about 2.0 molar equivalents of 2-amino-4-chloropurine 8 in the presence of from about 1.0 to about 6.0 molar equivalents of a base (for example potassium carbonate or NaH or KH or NaOH or KOH or lithium diisopropylamide and the like) in an inert solvent (for example DMF or THF or acetonitrile or N-methylpyrrolidone or ethanol and the like) at a temperature of from about −25° C. to about 140° C. provides substituted purine 20.
Alternatively, Mitsunobu coupling (for example, P(PH) 3 /diethyl azidocarboxylate) of alcohol 18 with 2-amino-4-chloropurine 8 provides 20.
Reaction of 20 with from about 2.0 to about 20.0 molar equivalents of an alcohol R 9 OH (R 9 is an alcohol protecting group such as benzyl and the like) in the presence of from about 1.0 to about 6.0 molar equivalents of a base (for example, potassium t-butoxide or potassium carbonate or NaH or KH or lithium diisopropylamide and the like in an inert solvent (for example, THF or DMF and the like) at a temperature of from about −25° C. to about 150° C. provides alcohol 21.
Removal of the alcohol protecting group R 9 of 21 (for example by catalytic hydrogenation in an inert solvent such as ethanol or benzyl alcohol or methanol or THF and the like in the presence of an hydrogenation catalyst such as Pd/C or Pd(OH) 2 and the like) provides substituted guanine 22.
The ether substitutent of 23 is deprotected by reaction with a) a reducing agent (for example, HCO 2 H and Pd/C and the like) wherein R 12 is —CH(Ph) 2 or —C(Ph) 3 , or b) a desilylating agent (for example Bu 4 NF and the like) wherein R 12 is —Si(t-Bu)(Me) 2 and the like to provide 13.
Alcohol 13 can be converted to 1 as outlined in scheme C.
An additional alternative involves enzymatic esterification of alcohol 4 or 17 with the vinyl ester CH 2 =CH—OC(O)R 10 (i.e. R 8 =R 10 in Schemes C and D) to directly incorporate into 6 or 18 the desired carboxylic acid ester of the final product I. This allows the elimination of the ester hydrolysis and reesterification involved in going from 9 to 12 or from 20 to 23.
The processes of Schemes C and D are characterized by the fact that each of the hydroxyl groups of the acyclic side chain is differentiated by the use of different hydroxy protecting groups or precursor groups. This allows the selective acylation of each of the hydroxy groups with either an amino acid or a fatty acid group.
Schemes C and D have been illustrated and described with reference to embodiments of the invention wherein R 1 is derived from an amino acid and R 2 is derived from a fatty acid. However, it will be apparent that respective converse schemes will apply to compounds where R 1 is derived from a fatty acid and R 2 is derived from an amino acid.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be illustrated by way of example only with reference to the following non-limiting Examples, comparative examples and the accompanying Figures, in which:
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 depicts plasma H2G levels as a function of time in cynomolgus monkeys administered with a compound of the invention or with an alternative prodrug derivative of H2G, as further explained in Biological Example 3; and
FIG. 2 depicts survival as a function of time for Herpes simplex infected mice administered with various doses of a compound of the invention or a prior art antiviral, as further explained in Biological Example 4.
EXAMPLE 1
(R)-9-[2-(Stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
This example illustrates the application of preparation scheme A.
a) (R)-9-[4-(N-tert-Butoxycarbonyl-L-valyloxy)-2-(hydroxymethyl) butyl]guanine
H2G (5 g, 19.7 mmol) was dissolved in DMF (300 ml) under heating and was cooled to room temperature before addition of N-t-Boc-L-valine (5.58 g, 25.7 mmol), DMAP (0.314 g, 2.57 mmol) and DCC (6.52 g, 31.6 mmol). The mixture was stirred at room temperature for 24 h and was then filtered. The product was chromatographed on silica gel and eluted with CH 2 Cl 2 /MeOH to give 2.4 g of the desired intermediate product.
1 H-NMR (250 MHz, DMSO-d 6 ): δ0.95 (d, 6H), 1.47 (s, 9H), 1.5-1.8 (m, 2H), 1.96-2.20 (m, 2H), 3.40 (m, 2H), 3.91 (t, 1H), 4.05 (m, 2H), 4.21 (t, 2H), 4.89 (t, 1), 6.6 (br s, 2H), 7.27 (d, 1H), 7.75 (s, 1H), 10.7 (br s, 1H).
b) (R)-9-[4-(N-tert-Butoxycarbonyl-L-valyloxy)-2-(stearoyloxymethyl) butyl]guanine
The product from step a) (185 mg, 0.41 mmol) was dissolved in pyridine (5 ml), the solution was cooled in an ice bath and stearoyl chloride (179 μl, 0.531 mmol) was added. The solution was kept in the ice bath for 2 h, then at room temperature for 1 h. It was then evaporated and chromatographed on silica gel. It was eluted with dichloromethane/methanol to give 143 mg of the desired intermediate product.
c) (R)-9-[2-(Stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The product from step b) (138 mg, 0.192 mmol) was cooled in an ice bath and trifluoroacetic acid (5 ml) was added. The solution was kept in the ice bath for 45 minutes and was then evaporated to give an oil. Water (0.5 to 1 ml) was added and evaporated twice. The residue was once more dissolved in water (5 ml ), filtered and freeze-dried to give 148 mg of the desired product as the bistrifluoracetate salt.
1 H NMR (250 MHz, DMSO-d 6 ): 0.97 (t, 3H), 1.05 (dd, 6H), 1.34 (br s, 28H), 1.59 (m, 2H), 1.80 (m, 2H), 2.25 (m, 1H), 2.36 (t, 2H), 2.50 (m, 1H), 3.98-4.18 (m, 5H), 4.35 (t, 2H), 6.6 (br s, 2H), 8.0 (br s, 1H), 8.4 (br s, 3H), 10.9 (br s, 1H).
EXAMPLE 2
(R)-9-[2-(Myristoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistrifluoracetate salt in a manner analogous to Example 1 using myristoyl chloride instead of stearoyl chloride in step b).
1 H NMR (250 MHz, DMSO-d 6 ): δ0.97 (t, 3H), 1.05 (dd, 6H), 1.34 (br s, 20H), 1.57 (m, 2H), 1.78 (m, 2H), 2.24 (m, 1H), 2.35 (t, 2H), 2.51 (m, 1H), 3.97-4.20 (m, 5H), 4.36 (t, 2H), 6.8 (br s, 2H), 8.2 (br s, 1H), 8.5 (br s, 3H), 11.1 (br s, 1H).
EXAMPLE 3
(R)-9-[2-(Oleoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistrifluoroacetyl salt in a manner analogous to Example 1 using oleoyl chloride instead of stearoyl chloride in step b).
1 H NMR (250 MHz, DMSO-d 6 ): 0.96 (t, 3H), 1.05 (dd, 6H), 1.35 (br s, 20H), 1.59 (m, 2H), 1.76 (m, 2H), 2.09 (m, 4H), 2.24 (m, 1H), 2.35 (t, 2H), 2.50 (m, 1H), 3.97-4.17 (m, 5H), 4.35 (t, 2H), 5.43 (t, 2H), 6.7 (br s, 2H), 8.0 (br s, 1H), 8.5 (br s, 3H), 11.1 (brs, 1H).
EXAMPLE 4
(R)-9-[2-(Butyryloxymethyl)-4-(L-valyloxy)butyl]guanine
a) (R)-9-[4-(N-tert-Butoxycarbonyl-L-valyloxy)-2-(butyryloxymethyl) butyl]guanine
DCC (110 mg, 0.53 mmol) was dissolved in dichloromethane (10 ml) and butyric acid (82 mg, 0.93 mmol) was added. After 4 hours at room temperature the mixture was filtered and the filtrate was evaporated. The residue was dissolved in pyridine (5 ml) and (R)-9-[4-(N-tert-Butoxycarbonyl-L-valyloxy)-2-hydroxymethylbutyl]guanine (200 mg, 0.44 mmol) (Example 1, step a) was added. The mixture was stirred for 120 hours at room temperature. According to TLC the reaction was incomplete and more anhydride was made using the procedure above. This anhydride was added and the mixture was stirred for an additional 20 hours. The reaction mixture was evaporated and chromatographed first on silica gel and then on aluminium oxide, in both cases eluted with dichloromethane/methanol to give 79 mg of the intermediate product.
b) (R)-9-[2-(Butyryloxymethyl)-4-(L-valyloxy)butyl]guanine
The intermediate product of step a was deprotected in a manner analogous to Example 1, step 3 to give 84 mg of the desired product as the bistrifluoracetate salt.
1 H NMR (250 MHz, D 2 O): δ0.88 (t, 3H), 1.06 (dd, 6H), 1.53 (m, 2H), 1.93 (q, 2H), 2.25 (t, 2H), 2.36 (m, 1H), 2.60 (m, 1H), 4.06 (d, 1H), 4.14-4.30 (m, 2H), 4.43 (m, 4H), 8.99 (br s, 1H).
EXAMPLE 5
(R)-9-[2-(Decanoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistrifluoroacetate salt in a manner analogous to Example 1 using decanoyl chloride instead of stearoyl chloride in step b.
1 H NMR (250 MHz, D 2 O): δ0.90 (m, 3H), 1.01 (d, 6H), 1.28 (br s, 12H), 1.5 (m, 2H), 1.8 (m, 2H), 2.3 (m, 3H), 2.5 (m, 1H), 4.0-4.4 (m, 7H), 8.1 (br s, 1H).
EXAMPLE 6
(R)-9-[2-Docosanoyloxymethyl-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistrifluoroacetate salt in a manner analogous to Example 1 but using in step b the DMAP/DCC conditions of Example 1, step a) in conjunction with docosanoic acid in place of the N-t-Boc-L-valine and a mixture of DMF and dichloromethane as solvent.
1 H NMR (250 MHz, DMSO-d 6 ): δ0.97 (t, 3H), 1.05 (dd, 6H), 1.34 (br s, 36H), 1.58 (m, 2H), 1.77 (m, 2H), 2.24 (m, 1H), 2.35 (t, 2H), 2.50 (m, 1H), 3.97-4.17 (m, 5H), 4.35 (t, 2H), 6.7 (br s, 2H), 8.1 (br s, 1H), 8.4 (br s, 3H), 11.0 (br s, 1H).
EXAMPLE 7
R-9-[4-(L-Isoleucyloxy)-2-(stearoyloxymethyl)butyl]guanine
This example illustrates the application of preparative scheme B.
a) (R)-9-[2-hydroxymethyl 4-(t-butyldiphenylsilyloxy)butyl]guanine
H2G (2 g, 8 mmole) was coevaporated with dry DMF two times and was then suspended in dry DMF (120 ml) and pyridine (1 ml). To the suspension was added dropwise t-butyldiphenylchlorosilane (2.1 ml, 8.2 mmole) in dichloromethane (20 ml) at 0° C. over a period of 30 min. The reaction mixture became a clear solution at the completion of the dropwise addition. The reaction continued at 0° C. for two hours and was then kept at 4° C. overnight. Methanol (5 ml) was added to the reaction. After 20 min at room temperature, the reaction mixture was evaporated to a small volume, poured into aqueous sodium hydrogen carbonate solution and extracted with dichloromethane two times. The organic phase was dried over sodium sulphate and evaporated in vacuo. The product was isolated by silica gel column chromatography using a methanol/dichloromethane system with a stepwise increasing MeOH concentration. The product was eluted with 7% MeOH in CH 2 Cl 2 to yield 1.89 g.
b) (R)-9-[2-(Stearoyloxymethyl)-4-(t-butyldiphenylsilyloxy)butyl]guanine
(R)-9-[2-Hydroxymethyl 4-(t-butyldiphenylsilyloxy)butyl]guanine (2.31 g, 5 mmole) was coevaporated with dry pyridine twice and dissolved in pyridine (20 ml). To the solution was slowly added dropwise stearoyl chloride (1.86 ml, 5.5 mmole, technical grade) in dichloromethane (2 ml) at −5° C. The reaction was kept at the same temperature for 1 hr and then at 5° C. for 2 hr. The reaction was monitored by TLC. Additional stearoyl chloride (0.29 ml) at −5° C. was added due to incompletion of reaction. After 30 min at 5° C., methanol (3 ml) was added and the reaction mixture stirred for 20 min. It was then poured into aqueous sodium hydrogen carbonate solution, and extracted with dichloromethane. The organic phase was dried and the product purified by silica ge column chromatography with stepwise increasing MeOH, eluting with 3.5% MeOH in CH 2 Cl 2 (Yield 2.7 g).
c) (R)-9-[(4-Hydroxy-2-(stearoyloxymethyl)butyl]guanine
(R)-9-[2-(Stearoyloxymethyl)-4-(t-butyldiphenylsilyloxy)butyl]guanine (2.7 g, 3.56 mmole) was dissolved in dry THF (30 ml) and hydrogen fluoride-pyridine (1.5 ml) added to the solution. The reaction was kept at 4° C. overnight and monitored by TLC. The reaction reached about 80% conversion. Additional HF-pyridine was added (0.75 ml). After 4 hr, TLC showed that the starting material had disappeared. The reaction mixture was concentrated in vacuo without raising the temperature and more pyridine (5 ml) was added and evaporated again. The product was isolated by silica gel column chromatography. (Yield 1.26 g).
d) (R)-9-[4-(N-BOC-L-isoleucyloxy)-2-(stearoyloxymethyl)butyl]guanine
(R)-9-[4-Hydroxy-2-(stearoyloxymethyl)butyl]guanine (135 mg, 0.26 mmole) and N-BOC-L-isoleucine (180 mg, 0.78 mmole) were coevaporated with dry DMF twice and dissolved in the same solvent (3.5 ml). To the solution was added 1,3-dicyclohexylcarbodiimide (160 mg, 0.78 mmole) and 4-dimethylaminopyridine (4.8 mg, 0.039 mmole). After reaction for 18 hours, the reaction mixture was filtered through Celite and worked up in a conventional manner. The product was isolated by silica gel column chromatography, eluting at 5% MeOH in CH 2 Cl 2 . (Yield 160 mg)
e) (R)-9-[4-(L-Isoleucyloxy)-2-(stearoyloxymethyl)-butyl]guanine
(R)-9-[4-(N-BOC-L-isoleucyloxy)-2-(stearoyloxymethyl)butyl]guanine (150 mg, 0.205 mmole) from step d) was treated with trifluoroacetic acid (3 ml) at 0° C. for 20 min. The solution was evaporated in vacuo. The residue was coevaporated with toluene twice and kept under vacuum for several hours. The residue was dissolved in MeOH (2 ml) and evaporated to give the trifluoracetate salt as a glass-like product (Yield 191 mg).
H 1 NMR (DMSO-d6+D 2 O): δ8.35 (s,1H, base), 4.21 (t, 2H, H-4), 4.10 (d, 2H) 3.96 (d, 2H), 3.90 (d, 1H, isoleucine), 2.48 (m, 1H, H-2), 2.15 (2H, stearoyl), 1.85 (m, 1H, isoleucine), 1.68 (m, 2H), 1.48 (m, 4H), 1.68 (m, 28H), 0.81 (m, 9H).
EXAMPLE 8
(R)-9-[2-(Decanoyloxymethyl)-4-(L-isoleucyloxyl)butyl]guanine
The title compound was obtained as the bistrifluoroacetyl salt in a manner analogous to Example 7 using decanoyl chloride instead of stearoyl chloride in step b).
1 HNMR (DMSO-d6): δ11.1 (s, 1H, NH), 8.35 (s, br, 3H), 8.28 (s, 1H, base), 6.75 (s, 2H, NH 2 ), 4.23 (t, 2H), 4.07 (d, 2H), 4.05 (m, 3H), 2.4 (m, 1H), 2.21 (t, 2H), 1.83 (m, 1H), 1.66 (m, 2H), 1.45 (m, 2H), 1.39 (m, 2H), 1.22 (s, 12H), 0.84 (m, 9H).
EXAMPLE 9
(R)-9-[4-(L-Isoleucyloxy)-2-(myristoyloxymethyl)butyl]guanine
The title compound was obtained as the bistrifluoroacetyl salt in a manner analogous to Example 1 using N-BOC-L-isoleucine instead of N-BOC-valine in step a) and myristoyl chloride in step b).
1 H-NMR (DMSO-d6): δ10.99(s, 1H), 8.34 (br s, 3H) 8.15 (s, 1H), 6.67 (br s, 2H), 4.23 (t, 2H), 4.05 (d, 2H), 3.97 (m, 3H), 2.48 (m, 1H), 2.20 (t, 2H), 1.85 (m, 1H), 1.65 (m, 2H), 1.41 (m, 4H), 1.23 (s, 20H), 0.85 (m, 9H).
EXAMPLE 10
(R)-9-[2-(4-Acetylbutyryloxymethyl-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistrifluoroacetate salt in a manner analogous to Example 1 but using in step b) the DCC/DMAP conditions of Example 1, step a) in conjunction with 4-acetylbutyric acid instead of N-t-Boc-L-valine.
1 H-NMR (250 MHz, DMSO-d 6 ): δ1.05 (dd, 6H), 1.77 (m, 4H), 2.19 (s, 3H), 2.24 (m, 1H), 2.36 (t, 2H), 2.44-2.60 (m, 3H), 3.95-4.20 (m, 5H), 4.36 (m, 2H), 6.8 (br s, 2H), 8.3 (br s, 1H), 8.5 (br s, 3H), 11.1 (br s, 1H).
EXAMPLE 11
(R)-9-[2-Dodecanoyloxymethyl-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistriflouroacetate salt in a manner analogous to Example 1 using dodecanoyl chloride instead of stearoyl chloride in step b).
EXAMPLE 12
(R)-9-[2-Palmitoyloxymethyl-4-(L-valyloxy)butyl]guanine
The titled compound was obtained as the bistriflouroacetate salt in a manner analogous to Example 1 using palmitoyl chloride instead of stearoyl chloride in step b).
1 H-NMR(250 MHz, DMSO-d 6 ): δ0.97 (t, 3H), 1.05 (m, 6H), 1.35 (br s, 24H), 1.58 (m, 2H), 1.78 (m, 2H), 2.25 (m, 1H), 2.35 (t, 2H), 2.51 (m, 1H), 3.97-4.18 (m, 5H), 4.35 (t, 2H), 6.7 (br s, 2H), 8.1 (br s, 1H), 8.5 (br s, 3H), 11.0 (br s, 1H).
EXAMPLE 13
(R)-2-Amino-9-(2-stearoyloxymethyl-4-(L-valyloxy)butyl)purine
This example shows the deoxygenation of group R 1 .
a) (R)-2-Amino-9-(2-stearoyloxymethyl-4-(N-tert-butoxycarbonyl-L-valyloxy)butyl)-6-chloropurine
To a solution of (R)-9-(2-stearoyloxymethyl-4-(N-tert-butoxycarbonyl-L-valyloxy)butyl)guanine from step 2 of Example 1 (646 mg, 0.9 mmole) in acetonitrile were added tetramethylammonium chloride (427 mg, 2.7 mmole), N,N-diethylaniline (0.716 ml, 4.5 mmole) and phosphorous oxychloride (0.417 ml, 4.5 mmole). The reaction was kept under reflux and the progression monitored by TLC. After 3 hours the reaction mixture was evaporated in vacuo and the residue was dissolved in dichloromethane, then poured into cold sodium hydrogen carbonate aqueous solution. The organic phase was evaporated and purified by silica gel column chromatography. Yield: 251 mg.
H 1 -NMR (CDCL 3 ): δ7.76 (1H, H-8), 5.43 (br,2H, NH 2 ), 4.45-4.00 (m, 7H), 2.53 (m, 1H), 2.28 (t 2H), 2.12 (m, 1H), 1.75 (m, 2H), 1.59 (m, 2H), 1.43 (9H), 1.25 (m, 28H), 0.96 (d, 3H), 0.87 (m, 6H).
b) (R)-2-Amino-9-(2-stearoyloxmethyl-4-(N-tert-butoxycarbonyl-L-valyloxy)butyl)purine
To the solution of (R)-2-amino-9-(2-stearoyloxymethyl-4-(N-tert-butoxycarbonyl-L-valyloxy)butyl)-6-chloropurine (240 mg, 0.33 mmole) in methanol/ethyl acetate (6 ml, 3:1 V/V) were added ammonium formate (105 mg, 1.65 mmole) and 10% palladium on carbon (15 mg). The reaction was kept under reflux for 1 hour and recharged with ammonium formate (70 mg). After one hour more the TLC showed completion of the reaction and the mixture was filtered through Celite and washed extensively with ethanol. The filtrate was evaporated and purified by silica gel column. Yield: 193 mg.
H 1 -NMR (CDCL 3 ): δ8.69 (s,1H, H-6), 7.74 (s, 1H, H-8), 5.18 (br, s, 2H, NH 2 ), 4.45-4.01 (m, 7H), 2.55 (m, 1H), 2.28 (t, 2H), 2.10 (m, 1H), 1.75 (m, 2H), 1.60 (m, 2H), 1.43 (s, 9H), 1.25 (s, 28H), 0.96 (d, 3H), 0.87 (m, 6H).
c) (R)-2-Amino-9-(2-stearoyloxymethyl-4-(L-valyloxy)butyl)purine
(R)-2-Amino-9-(2-Stearoyloxmethyl-4-(N-tert-butoxycarbonyl-L-valyloxy)butyl)purine (180 mg, 0.26 mmole) was treated with trifluoroacetic acid (5 ml) at 0° C. for 40 min. It was then evaporated in vacuo and coevaporated successively with toluene and methanol. The residue was freeze-dried overnight to give 195 mg of the desired product.
1 H-NMR (DMSO-d6): δ8.78 (s, 1H, H-6), 8.32 (br, 3H), 8.29 (s, 1H, H-8), 4.27 (t, 2H), 4.13 (d, 2H), 3.98 (t, 2H, 2H), 3.89 (m, 1H), 2.47 (m, 1H), 2.18 (m, 3H), 1.43 (m, 2H), 1.23 (28H), 0.93 (m, 6H), 0.85 (t, 3H).
EXAMPLE 14
Alternative preparation of (R)-9-[4-Hydroxy-2-(stearoyloxymethyl)butyl]guanine
a) Preparation of ethyl 4,4-diethoxy-2-ethoxycarbonyl-butyrate
Potassium tert-butoxide (141.8 g, 1.11 equiv.) was dissolved in dry DMF (1L). Diethyl malonate (266 mL, 1.54 equiv.) was added over 5 minutes. Bromoacetaldehyde diethylacetal (172 mL, 1.14 mole) was added over 5 minutes. The mixture was heated to 120° C. (internal temperature), and stirred at 120° C. for 5 hours. The mixture was allowed to cool to room temperature, poured into water (5L), and extracted with methyl tert-butyl ether (MTBE, 3×600 mL). The organic solution was dried over MgSO 4 , filtered, concentrated, and distilled (0.5 mm, 95-140° C.) to yield the desired diester (244 g, 78%) as a colorless oil.
1 H NMR (CDCl 3 ) δ1.19 (t, 6H), 1.28 (t, 6H), 2.22 (dd, 2H), 3.49 (m, 2H), 3.51 (t, 1H), 3.65 (m, 2H) 4.20 (qd, 4H), 4.54 (t, 1H).
b) Preparation of 4,4-diethoxy-2-(hydroxymethyl)-butanol
LiBH4 (purchased solution, 2M in THF, 22.5 mL) and the product of Example 14 step a) (5 g in 15 mL of THF, 18.1 mmol) were combined and warmed to 60° C. and stirred at 60° C. for 4 hours. The reaction mixture was allowed to cool to room temperature and the reaction vessel was placed in a cool water bath. Then triethanolamine (5.97 mL, 1 equiv.) was added at such a rate that the temperature of the reaction mixture was maintained between 20-25° C. Brine (17.5 mL) was added at a rate such that gas evolution was controlled and the mixture was stirred for 45 minutes at room temperature. The layers were separated, the organic layer was washed with brine (2×15 mL). The combined brine washes were extracted with MTBE (methyl tert-butyl ether, 3×20 mL). The combined organic extracts were evaporated and the residue was dissolved in MTBE (50 mL) and washed with brine (25 mL). The brine layer was back-extracted with MTBE (3×25 mL). The combined organic extracts were dried over Na 2 SO 4 , filtered, and concentrated to yield the desired diol (3.36 g, 15.5 mmol, 97%) as a colorless oil.
1 H NMR (CDCl 3 ) δ1.22 (t, 6H), 1.73 (dd, 2H), 1.92 (m, 1H), 2.67 (bs, 2H), 3.52 (m, 2H), 3.69 (m, 2H), 3.72 (m, 4H), 4.62 (t, 1H).
c) Preparation of (2R)-2-acetoxymethyl-4,4-diethoxy-butanol
Into a 10 ml 1 neck round bottom flask was charged the product of Example 14 step b) (3.84 g, 20 mmol), followed by addition of vinyl acetate (2.6 g, 30 mmol) and finally Lipase PS 30 (69 mg, purchased from (Amano, Lombard, Ill.). The mixture was allowed to stir at ambient temperature for 16 hours. Progress of the reaction was closely monitored by TLC (2/1 hexane-EtOAc; stained with Ce 2 (SO 4 ) 3 and charred on hot plate; r.f. of diol is 0.1, monoacetate is 0.3, bis acetate is 0.75). The reaction mixture was diluted with CH 2 Cl 2 and filtered through a 5 micron filter. The filter was washed with additional CH 2 Cl 2 . The filtrate was then concentrated in vacuo to afford the desired product.
d) Preparation of (2S)-2-acetoxymethyl-4,4-diethoxybutyl toluenesulfonate
Into a 100 mL 1-neck round bottom flask, equipped with a magnetic stir bar and septum under N2 was charged the crude product of Example 14 step c) (4.62 g, 19 mmol), dry CH 2 Cl 2 (20 mL) and Et 3 N (5.62 mL, 40 mmol). To this solution was added tosyl chloride (4.76 g, 25 mmol). The resulting mixture was stirred at ambient temperature for 4 hours. Charged H 2 O (0.27 g, 15 mmol) and stirred vigorously for 4 hours. The reaction mixture was diluted with 80 mL EtOAc and 50 mL H 2 O and the aqueous layer was separated. To the organic layer was added 75 ml of a 5% aq. solution of KH 2 PO 4 . After mixing and separation of the layers, the aqueous layer was removed. The organic layer was washed with 50 mL of saturated NaHCO 3 solution, dried over Na 2 SO 4 , filtered and concentrated in vacuo to a constant weight of 7.40 g of the desired product.
1 H NMR (CDCl 3 ) δ1.17 (t, 6H); 1.62 (m, 2H); 1.94 (s, 3H); 2.19 (m, 1H); 2.45 (s, 3H); 3.42 (m, 2H); 3.6 (m, 2H); 4.03 (m, 4H); 4.51 (t, 1H); 7.36 (d, 2H); 7.79 (d, 2H).
e) Preparation of
Into a 50 mL 1 neck round bottom flask was charged the product of Example 14 step d) (3.88 g, 10 mmol), anhydrous DMF (20 mL), 2-amino-4-chloro-purine (2.125 g, 12.5 mmol) and K 2 CO 3 (4.83 g). The resulting suspension was stirred at 40° C. under a N 2 blanket for 20 hours. The mixture was concentrated to remove most of the DMF on a rotary evaporator. The residue was diluted with EtOAc (50 mL) and H 2 O (50 mL). The reaction mixture was transferred to a separatory funnel, shaken and the aqueous layer was separated. The aqueous layer was extracted with EtOAc (25 mL). The organic layers were combined and washed with 5% KH 2 PO 4 (75 mL). The organic layer was separated and washed with H 2 O (75 mL), brine (75 mL), dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford 3.95 g of crude product. The crude product was slurried with 40 mL of methyl-t-butyl ether. This mixture was stirred overnight at 4° C. and the mixture was filtered. The filtrate was concentrated to afford 3.35 g of the product as an oil (containing 2.6 g of the desired product based upon HPLC analysis).
300 MHz 1 H NMR (CDCl 3 ) δ1.19 (m, 6H); 1.69 (2H); 1.79 (s, 1H); 2.03 (s, 3H); 2.52 (m, 1H); 3.48 (m, 2H); 3.62 (m, 2H); 4.04 (m, 2H); 4.16 (m, 2H); 4.61 (t, 1H); 5.12 (bs, 2H); 7.81 (s, 1H).
f) Preparation of
(Bn=benzyl)
Into a 500 mL 1 neck round bottom flask was charged benzyl alcohol (136 mL), cooled to 0° C., followed by portionwise addition of KO-t-Bu (36 g, 321 mmol). The temperature was allowed to warm to 40° C., and the mixture was stirred 20 minutes. To this mixture was added at 0° C. the crude product of Example 14 step e) (24.7 g, 64.2 mmol) dissolved in 25 mL anhydrous THF and benzyl alcohol (30 mL). The temperature was allowed to slowly warm to 8° C. over 2 hours. The reaction mixture was poured into 500 mL ice and was extracted with 500 mL MTBE. The organic layer was washed with 250 mL of brine, dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford 193 g of a benzyl alcohol solution of the desired product. HPLC analysis indicated that the solution contained 25.96 g of the desired product.
300 MHz 1 H NMR (CDCl 3 ) δ1.22 (m,6H); 1.55 (2H); 2.18 (m, 1H); 3.15 (m, 1H); 3.40 (m, 1H); 3.51 (m, 2H); 3.70 (m, 2H); 4.25 (m, 2H); 4.63 (t,1H); 4.90 (bs, 2H); 5.25 (m, 1H); 5.58 (s, 2H); 7.35 (m, 3H); 7.51 (m, 2H); 7.72 (s, 1H). MS=(M+H)+=416 (CI).
g) Preparation of
Into a 100 mL 1 neck round bottom flask was charged the crude product of Example 14 step f) (9.65 g of the benzyl alcohol solution, containing 1.30 g, 3.13 mmol of the product of Example 14, step f) dissolved in absolute EtOH (20 mL). To this was added 0.45 g of 10% Pd/C slurried in 5 mL absolute EtOH. The reaction flask was evacuated and charged with H 2 three times with a balloon of H 2 . The reaction flask was pressurized with 1 atm. H 2 and the reaction mixture was stirred overnight. The reaction mixture was filtered through a pad of diatomaceous earth to remove Pd/C. The volatiles were removed in vacuo. The residue was mixed with 25 mL of isopropyl acetate and then concentrated in vacuo. The residue was diluted with EtOAc (10 mL), seeded with the desired product, heated to reflux and then CH 3 CN (2 mL) and MTBE (35 ml) were added. The mixture was stirred for 30 minutes. The precipitate was filtered and dried to a constant weight of 600 mg of the desired product.
300 MHz 1 H NMR (d6-DMSO) δ1.16 (m,6H); 1.45 (m, 1H); 1.61 (m, 1H); 2.16 (m, 1H); 3.45 (m, 2H); 3.40 (m, 1H); 3.62 (m, 2H); 4.02 (m,2H); 4.53 (t, 1H); 4.85 (t, 1H); 6.55 (bs, 1H); 7.75 (s, 1H). MS=(M+H)+=416 (CI).
h) Preparation of
Into a 25 mL 1 neck round bottom flask was charged the product of Example 14 step g) (0.650 g, 2.0 mmol), pyridine (4 mL) and CH 2 Cl 2 (2 mL), DMAP (10 mg). The mixture was cooled to −5° C. and stearoyl chloride (790 mg, 2.6 mmol) dissolved in CH 2 Cl 2 (0.5 mL) was added over 5 minutes. The resulting mixture was stirred 16 hours at −5° C. Absolute EtOH (0.138 g, 3.0 mmol) was added and the mixture was stirred an additional 1 hour. The reaction mixture was concentrated in vacuo. Toluene (30 mL) was added to the residue and then the mixture was concentrated in vacuo. Again, toluene (30 mL) was added to the residue and then the mixture was concentrated in vacuo. To the residue was added 1% KH 2 PO 4 (25 mL) and this mixture was extracted with CH 2 Cl 2 (60 mL). The organic layer was separated and was dried over Na 2 SO 4 , filtered and concentrated in vacuo to a constant weight of 1.65 g. The crude product was chromatographed on 40 g of SiO 2 , eluting with 95/5 CH 2 Cl 2 —EtOH, affording 367 mg of the desired product.
300 MHz 1 H NMR (CDCl 3 ) δ0.89 (t, 3H); 1.26 (m, 30H); 1.65 (m,3H); 2.32 (m, 1H); 3.45 (m, 1H); 3.60 (m, 2H); 4.08 (m, 2H); 4.60 (m, 1H); 6.0 (bs, 2H); 7.53 (s, 1H).
i) Preparation of
Into a 25 mL 1 neck round bottom flask was charged the product of Example 14, step h) (0.234 g, 0.394 mmol) dissolved in THF (1.7 mL). To this solution was added triflic acid (0.108 g) in H 2 O 180 mg. The mixture was stirred overnight at room temperature. To the reaction mixture was added saturated NaHCO 3 solution (10 mL), THF (5 mL), CH 2 Cl 2 (2 mL) and NaBH 4 (0.10 g). This mixture was stirred for 30 minutes. To the reaction mixture was added a 5% solution of KH 2 PO 4 (30 mL). This mixture was extracted with 2×15 ml of CH 2 Cl 2 . The organic layers were combined and dried over Na 2 SO 4 , filtered and concentrated in vacuo to a constant weight of 207 mg. This material was recrystallized from EtOAc (8 mL) and CH 3 CN (0.5 mL) affording 173 mg of the desired product.
300 MHz 1 H NMR (d6-DMSO) δ0.82 (t, 3H); 1.19 (m, 30H); 1.41 (m, 4H); 2.19 (t, 2H); 2.32 (m, 1H); 3.40 (m, 2H); 3.9 (m, 4H); 4.49 (m, 1H); 6.4 (bs, 2H); 7.61 (m, 1.5H); 9.55 (m, 0.5H).
EXAMPLE 15
Alternative Preparation of (R)-9-[4-(N-tert-butyloxycarbonyl-L-valyloxy)-2-(stearoyloxymethyl)butyl]guanine
(R)-9-[2-(Stearoyloxymethyl)-4-(t-butyldiphenylsilyloxy)butyl]guanine (45 g) and THF (950 ml) were combined in a 2 L flask. Then Boc-L-valine (3.22 g, 0.25 eq) was added, followed by tetrabutylammonium fluoride (1M in THF, 89.05 mL) over 10 minutes. The clear reaction mixture was stirred at room temperature for 2 hours and 50 minutes with monitoring of the reaction progress by TLC (90/10 CH 2 Cl 2 /MeOH).
To the reaction mixture was added Boc-L-valine (35.43 g, 2.75 eq), DCC (36.67 g, 2.75 eq) and dimethylaminopyridine (1.1 g, 0.15 eq) in THF (25 ml). The reaction mixture was stirred at room temperature for 24 hours. DCU was filtered off and washed with CH 2 Cl 2 . The filtrate was concentrated, and the residue was taken up in 2 litres of CH 2 CL 2 and washed with 2 L of ½ saturated sodium bicarbonate and brine solutions. On drying and evaporation, approximately 100 g of crude product was obtained. The material was purified by silica chromatography (6000 ml of silica) using 3% MeOH/CH 2 Cl 2 to 5% MeOH/CH 2 Cl 2 to obtain 38.22 mg of the desired product.
EXAMPLE 16
Alternative Preparation of (R)-9-[2-(stearoyloxymethyl)-4-(L-valyloxy) butyl]guanine
a) (R)-9-[2-Hydroxymethyl)-4-(t-butyldiphenylsilyloxymethyl)butyl]guanine
H2G (450.0 g, 1.78 mol) and N,N dimethylformamide (6.4 kg) were charged into a Bucchi evaporator and the mixture warmed to dissolve the solid. The solution was concentrated to dryness under vauum at no more than 90° C. The resulting powder was transferred to a 22 litre flask with stirrer, addition funnel and and temperature probe. N,N-dimethylformamide (1.7 kg) was added followed by pyridine (3.53 kg). The resulting suspension was cooled to −10° C. under nitrogen and stirred at −5±5° C. as t-butylchlorodiphenylsilane (684 g, 2.49 mol) was added dropwise. The resulting mixture was stirred at −5±5° C. until the reaction was complete (as monitored by TLC (10:1 methylene chloride/methanol) and HPLC (4.6×250 mm Zorbax RxC8 (5 micron); 60:40 acetonitrile-aq. NH 4 OAC (0.05M) at 1.5 ml/min; UV detection at 254 nm)). Water (16 kg) was added and the mixture was stirred for 30 minutes to precipitate the product, then the mixture was cooled to 0° C. for 30 minutes. The solid was isolated by filtration and the product cake was washed with cold water and sucked dry with air to provide the crude product as an off-white solid. The crude solid was taken up in pydridine (3 kg) and concentrated under vacuum at 60° C. to remove water. The dry solid residue was slurried with methanol (10 kg) at 60° C. for 1-2 hours and filtered while hot. The filtrate was concentrated under vacuum and the solid residue was refluxed with isopropyl acetate (7 kg) for 30 minutes. The mixture was cooled to 20° C. and filtered. The filter cake was dried under vacuum at 50° C. to provide the title compound as a white solid (555 g).
b) (R)-9-[2-(Stearoyloxymethyl)-4-(t-butyldiphenylsilyloxy)butyl]guanine
The product of Example 16, step a) (555 g, 1.113 mol) was charged to a 50 litre Buchi evaporator. Pyridine (2.7 kg) was added dropwise to dissolve the solid and the mixture was distilled to dryness under vacuum at 60° C. The residue was taken up in fresh pyridine (2.7 kg) and transferred to a 22 litre flask with stirrer, addition funnel and temperature probe. The solution was cooled to −5° C. under nitrogen. A solution of stearoyl chloride (440 g, 1.45 mol) in methylene chloride (1.5 kg) was added so as to maintain a temperature below 0° C. 4-(N,N-dimethylamino)pyridine (15 g, 0.12 mol) was added and the mixture was stirred at −5-0° C. for 2-4 hours until conversion was complete (as monitored by TLC (10:1 methylene chloride/methanol) and HPLC (4.6×250 mm Zorbax RxC8 (5 micron); 60:40 acetonitrile-aq. NH 4 OAc (0.05 M) at 1.5 ml/min; UV detection at 254 nm)). At the end of the reaction, acetonitrile (8.7 kg) was added and the mixture was stirred for not less than 15 minutes to precipitate the product. The slurry was cooled to 0° C. for 2 hours and the solid isolated by filtration and the filter cake washed with acetonitrile (2 kg). The desired product was obtained as a white solid (775 g).
c) (R)-9-[4-Hydroxy-2-(stearoyloxymethyl)butyl]guanine
A solution of the product of Example 16, step b) (765 g, 0.29 mol) in tetrahydrofuran (10 kg) was prepared in a reactor. A solution of tetra(n-butyl)arnmonium fluoride in tetrahydrofuran (1.7 kg of 1 M solution, 1.7 mol) was added and the resulting clear solution was stirred at 20±5° C. for 4 hours. Water (32 kg) was added and the resulting slurry was stirred for 1 hour and then cooled to 0° C. for 30 minutes. The precipitate was isolated by filtration and the filter cake was washed successively with water (10 kg) and acetonitrile (5 kg). After drying under vacuum at 25° C., 702 g of crude product was obtained. The crude product was dissolved in refluxing THF (4.2 kg) and water (160 g), then cooled to 40° C. and treated with methylene chloride (14.5 kg). The mixture was allowed to cool to 25±5° C. for 1 hour, then it was cooled to 5±5° C. for 1 hour to complete precipitation. The slightly off-white powder was isolated by filtration and dried under vacuum at 40° C. to yield the desired product (416 g).
d) (R)-9-[4-(N-Cbz-L-valyloxy)-2-(stearoyloxymethyl)butyl]guanine
A solution of N-Cbz-L-valine (169 g, 0.67 mol) in dry THF (750 ml) was prepared in a 2 litre flask with mechanical stirrer, thermometer and addition funnel. A solution of dicyclohexylcarbodiimide (69.3 g, 0.34 mol) in THF (250 ml) was added over 5 minutes and the resulting slurry was stirred at 20±5° C. for 2 hours. The slurry was filtered and the filter cake was washed with THF (300 ml). The filtrate and wash were charged to a 3 litre flask with stirrer and thermometer. The product of Example 16, step c) (116 g, 0.22 mol) was added as a solid, with a rinse of THF (250 ml). 4-(N,N-dimethylamino)pyridine (2.73 g, 0.022 mol) was added and the white slurry stirred at 20±5° C. Within 15 minutes, the solids were all dissolved and the reaction was complete within 1 hour (as determined by HPLC: 4.6×250 mm Zorbax RxC8 column; 85:15 acetonitrile—0.2% aq. HClO 4 at 1 ml/min.; UV detection at 254 nm; starting material elutes at 4.1 min. and product elutes at 5.9 min.). The reaction was quenched by addition of water (5 ml) and the solution was concentrated under vacuum to leave a light yellow semisolid. This was taken up in methanol (1.5 litres) and warmed to reflux for 30 minutes. The solution was cooled to 25° C. and the precipitate was removed by filtration. The filtrate was concentrated under vacuum to leave a viscous, pale yellow oil. Acetonitrile, (1 L) was added and the resulting white suspension was stirred at 20±5° C. for 90 minutes. The crude solid product was isolated by filtration, washed with acetonitrile (2×100 ml) and air-dried overnight to provide the desired product as a waxy, sticky solid (122 g). This was further purified by crystallization from ethyl acetate (500 ml) and drying under vacuum at 30° C. to provide the desired product as a white, waxy solid (104 g).
e) (R)-9-[4-(L-valyloxy)-2-(stearoyloxymethyl)butyl]guanine
A solution of the product of Example 16, step d), (77 g) in warm (40° C.) ethanol (2.3 L) was charged to an hydrogenation reactor with 5% Pd-C (15.4 g). The mixture was agitated at 40° C. under 40 psi hydrogen for 4 hours, evacuated and hydrogenated for an additional 4-10 hours. The catalyst was removed by filtration and the filtrate was concentrated under vacuum to provide a white solid. This was stirred with ethanol (385 ml) at 25° C. for 1 hour, then cooled to 0° C. and filtered. The filter cake was dried with air, then under vacuum at 35° C. to yield the title compound as a white powder (46 g).
EXAMPLE 17
(R)-9-[2-(L-Valyloxymethyl)-4-(stearoyloxy)butyl]guanine
a) (R)-9-[2-Hydroxymethyl-4-(stearoyloxy)butyl]guanine
H2G (506 mg; 2.0 mmol) was dissolved in dry N,N-dimethylformamide (40 ml) with pyridine (400 mg; 5.06 mmol) and 4-dimethylaminopyridine (60 mg; 0.49 mmol). Stearoyl chloride (1500 mg; 4.95 mmol) was added and the mixture kept overnight at room temperature. Most of the solvent was evaporated in vacuo, the residue stirred with 70 ml ethyl acetate and 70 ml water, and the solid filtered off, washed with ethyl acetate and water and dried to yield 680 mg of crude product. Column chromatography on silica gel (chloroform:methanol 15:1) gave pure title compound as a white solid.
1 H NMR (DMSO-d 6 ) δ: 0.86 (t, 3H); 1.25 (s, 28H); 1.51 (qui, 2H); 1.62 (m, 2H); 2.06 (m, 1H); 2.23 (t, 2H); 3.34 (d, 2H); 3.96 (ABX, 2H); 4.07 (dd, 2H); 6.30 (br s, 2H); 7.62 (s, 1H); 10.45 (s, 1H).
13 C NMR (DMSO-d 6 ) δ: 13,8 (C18); 22.0 (C17); 24.4 (C3); 27.7 (C3′); 28.4-28.8 (C4-6, C15); 28.9 (C7-14); 31.2 (C16); 33.5 (C2); 38.0 (C2′); 44.0 (C1′), 60.6/61.8 (C4′, C2″); 116.5 (guaC5); 137.7 (guaC7); 151.4 (guaC4); 153.5 (guaC2); 156.7 (guaC6); 172.7 (COO).
b) (R)-9-[2-(N-Boc-L-valyloxymethyl)-4-(stearoyloxy)butyl]guanine
A mixture of N-Boc-L-valine (528 mg; 2.1 mmol) and N,N′-dicyclohexyl carbodiimide (250 mg; 1.21 mg) in dichloromethane (20 ml) was stirred over night at room temperature, dicyclohexylurea filtered off and extracted with a small volume of dichloromethane, and the filtrate evaporated in vacuo to a small volume. (R)-9-[2-Hydroxymethyl-4-(stearoyloxy)butyl]guanine (340 mg; 0.654 mmol), 4-dimethylaminopyridine (25 mg; 0.205 mmol), and dry N,N-dimethylformamide (15 ml) were added and the mixture was stirred for 4 h at 50° C. under N 2 . The solvent was evaporated in vacuo to a small volume. Column chromatography on silica gel, then on aluminum oxide (ethyl acetate:methanol: water 15:2:1 as eluent) gave 185 mg (39%) pure title compound as a white solid.
1 H NMR (CHCl 3 ) δ: 0.85-1.0 (m, 9H) 18-CH 3 , CH(CH 3 ) 2 ; 1.25 (s, 28H) 4-17-CH 2 ; 1.44 (s, 9H) t-Bu; 1.60 (qui, 2H) 3-CH 2 ; 1.74 (qua, 2H) 3′-CH 2 ; 2.14 (m, 1H) 2′-CH; 2.29 (t, 2H) 2-CH 2 ; 2.41 (m,1H) CH(CH 3 ) 2 ; 4.1-4.3 (m, 6H) C1′-CH 2 , C2″-CH 2 , C4-CH 2 ; 5.4 (d, 1H) αCH; 6.6 (br s, 2H) guaNH 2 ; 7.73 (s, 1H) guaH8; 12.4 (br s).
13 C NMR (CHCl 3 ) δ: 13,9 (C18); 17,5/18.9 (2 Val CH 3 ); 22.4 (C17); 24.7 (C3); 28.1 (C3′); 28.9-29.3 (C4-6, C15); 29.4 (C7-14); 30.7 (Val βC); 31.7 (C16); 34.0 (C2); 35.9 (C2′); 43.9 (C1′); 58.7 (Val αC); 61.4/63.6 (C4′, C2″); 79.9 (CMe 3 ); 116.4 (guaC5); 137.9 (guaC7); 151.7 (guaC4); 153.7 (guaC2); 155.7 (CONH); 158.8 (guaC6); 172.1 (CHCOO); 173.5 (CH 2 COO).
c) (R)-9-[2-(L-Valyloxymethyl)-4-(stearoyloxy)butyl]guanine
Chilled trifluoroacetic acid (2.0 g) was added to (R)-9-[2-(N-Boc-L-valyloxymethyl)-4-(stearoyloxy)butyl]guanine (180 mg; 0.25 mmol) and the solution kept at room temperature for 1 h, evaporated to a small volume, and lyophilized repeatedly with dioxane until a white amorphous powder was obtained. The yield of title compound, obtained as the trifluoracetate salt, was quantitative.
1 H NMR (DMSO-d 6 ) δ: 0.87 (t, 3H) 18-CH 3 , 0.98 (dd, 6H) CH(CH 3 ) 2 ; 1.25 (s, 28H) 4-17-CH 2 ; 1.50 (qui, 2H) 3-CH 2 ; 1.68 (qua, 2H) 3-CH 2 2.19 (m, 1H) 2′-CH; 2.26 (t, 2H) 2-CH 2 ; 2.40 (m,1H) CH(CH 3 ) 2 ; 3.9-4.25 (m, 7H) C1′-CH 2 , C2″-CH 2 , C4-CH 2 , αCH; 6.5 (br s, 2H) guaNH 2 ; 7.79 (s, 1H) guaH8; 8.37 (br s, 3H) NH 3 + ; 10.73 (br s, 1H) guaNH.
13 C NMR (DMSO-d 6 ) δ: 14.2 (C18); 17.9/18.3 (2 Val CH 3 ); 22.3 (C17); 24.6 (C3); 27.7 (C3′); 28.7-29.1 (C4-6, C15); 29.2 (C7-14); 29.5 (Val βC); 31.5 (C16); 33.7 (C2); 35.0 (C2′); 44.1 (C1′); 57.6 (Val αC); 61.6/65.2 (C4′, C2″); 116.1 (guaC5); 116.3 (qua, J 290 Hz, CF 3 ); 137.9 (guaC7); 151.5 (guaC4); 154.0 (guaC2); 156.7 (guaC6);158.3 (qua, J 15 Hz, CF 3 COO) 169.1 (CHCOO); 173.1 (CH 2 COO).
EXAMPLE 18
Alternative Preparation of (R)-9-[2-hydroxymethyl-4-(stearoyloxy)butyl]guanine
H2G (7.60 g, 30 mmol) was heated to solution in dry DMF (200 ml). The solution was filtered to remove solid impurities, cooled to 20° C. (H2G cystallized) and stirred at that temperature during addition of pyridine (9.0 g, 114 mmol), 4-dimethylaminopyridine (0.46 g, 3.75 mmol) and then, slowly, stearoyl chloride (20.0 g, 66 mmol). Stirring was continued at room temperature overnight. Most of the solvent was then evaporated off in vacuo, the residue stirred with 200 ml ethyl acetate and 200 ml water and the solid filtered off, washed with ethyl acetate and water and dried to yield crude product. As an alternative to recrystallization, the crude product was briefly heated to almost boiling with 100 ml of ethyl acetate: methanol: water (15:2:1) and the suspension slowly cooled to 30° C. and filtered to leave most of the 2″ isomer in solution (the 2″ isomer would crystallize at lower temperature). The extraction procedure was repeated once more to yield, after drying in vacuo, 6.57 g (42%) of almost isomer free product.
EXAMPLE 19
Preparation of Crystalline (R)-9-[2-stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The product of Example 16, step c) (20.07 g, 32.5 mmol) was dissolved in absolute ethanol (400 ml) with heating, filtered, and further diluted with ethanol (117.5 ml). To this solution was added water (HPLC grade, 103.5 ml), and the mixture was allowed to cool to 35-40° C. After the mixture was cooled, water (HPLC grade, 931.5 ml) was added at a constant rate over 16 hours with efficient stirring. After all the water was added, stirring was continued for 4 hours at room temperature. The resulting precipitate was filtered through paper and dried under vacuum at room temperature to obtain the title compound as a white, free flowing crystalline powder (19.43 g, 97%), m pt 169-170° C.
EXAMPLE 20
9-R-(4-Hydroxy-2-(L-valyloxymethyl)butyl)guanine
a) To a solution of 9-R-(4-(tert-butyldiphenylsilyloxy)-2-(hydroxymethyl)butyl)guanine (695 mg, 1.5 mmole) in DMF (30 ml) were added N-Boc-L-Valine (488 mg, 2.25 mmole), 4-dimethylamino pyridine (30 mg, 0.25 mmole) and DCC (556 mg, 2.7 mmole). After 16 hr, the reaction was recharged with N-Boc-L-valine (244 mg) and DCC (278 mg), and was kept for an additional 5 hours. The reaction mixture was filtered through Celite and poured into sodium hydrogen carbonate aqueous solution, and then it was extracted with dichloromethane. The organic phase was evaporated and purified by silica gel column chromatography, giving 950 mg the N-protected monoamino acyl intermediate.
b) The above intermediate (520 mg, 0.78 mmole) was dissolved in THF (15 ml). To the solution was added hydrogen fluoride in pyridine (70%/30%, 0.34 ml). After two days, the solution was evaporated and coevaporated with toluene. Purification by silica gel column chromatography gave 311 mg of the protected monoamino acyl compound.
1 H-NMR (DMSO-d6): δ10.41(s, 1H), 7.59 (1H), 6.26 (br s, 2H), 4.32 (t, 1H), 3.95 (m, 5H), 3.46 (m, 2H), 2.41 (m, 1H), 2.06 (m, 1H), 1.45 (m, 2H), 1.39 (s, 9H), 0.90 (d, 6H).
c) The product of step b) (95 mg, 0.21 mmole) was treated with a mixture of trifluoroacetic acid (4 ml) and dichloromethane (6 ml) for 1 hr. The solution was evaporated and freeze-dried, give 125 mg of the unprotected monoaminoacyl product.
1 H-NMR (D 2 O): δ8.88 (s, 1H), 4.32 (m, 4H), 3.96 (d, 1H), 3.68 (m, 2H), 2.63 (m, 1H), 2.22 (m, 1H), 1,73 (m, 2H), 1.00 (m, 6H).
EXAMPLE 21
(R)-9-(2-Hydroxymethyl-4-(L-isoleucyloxy)butyl)guanine
a) To a solution of (R)-9-(2-hydroxymethyl-4-hydroxybutyl)guanine (2.53 g, 10 mmole) in DMF (250 ml) were added N-Boc-L-isoleucine(2.77 g, 12 mmole), 4-dimethylaminopyridine (61 mg, 0.6 nmnole) and DCC (3.7 g, 18 mmole). After reaction for 16 hr at 0° C., N-Boc-L-isoleucine (1.3 g) and DCC (1.8 g) were recharged, and the reaction was kept overnight at room temperature. The reaction mixture was filtered through Celite and the filtrate was evaporated and purified by silica gel column chromatography, giving 1.25 g of the N-protected monoamino acyl intermediate.
1 H-NMR (DMSO-d6): δ10.56 (s, 1H), 7.62 (s, 1H), 6.43 (s, 2H), 4.75 (t, 1H), 4.15-3.80 (m, 5H), 3.25 (m, 2H) 2.05 (m, 1H), 1.80-1-05 (m, 14H), 0.88 (m, 6H).
b) The intermediate from step a) (100 mg, 0.21 mmole) was treated with trifluoroacetic acid (3 m) and for 30 min at 0° C. The solution was evaporated and freeaze-dried, give the titled unprotected mono-aminoacyl product in quantitative yield.
1 H-NMR (DMSO-d6+D 2 O): δ8.72 (s, 1H), 4.15 (m, 4H), 3.90 (d, 1H), 3.42 (m, 2H), 2.09 (m, 1H), 1.83 (m, 1H), 1.61 (m, 2H), 1.15 (m, H), 0.77 (d, 3H), 0.71 (t, 3H).
EXAMPLE 22
(R)-9-[2-Hydroxymethyl-4-(L-valyloxy)butyl]guanine
The product of Example 1, step a) was deprotected with trifluoroaacetic acid in the same manner as Example 1, step c)
1 H-NMR (250 MHz, DMSO-d 6 ): δ1.04 (dd, 6H), 1.55-1.88 (m, 2H), 2.21 (m, 2H), 3.48 (m, 2H), 4.00 (m, 1H), 4.13 (m, 2H), 4.34 (t, 2H), 6.9 (br s, 2H), 8.21 (s, 1H), 8.5 (br s, 3H), 11.1 (br s, 1H).
EXAMPLE 23
(R)-9-[2-(L-Valyloxymethyl)-4-(valyloxy)butyl]guanine
a) (R)-9-[4-(N-Boc-L-valyloxy)-2-(N-Boc-L-valyloxymethyl)butyl]guanine
Application of the technique described in Example 1, step a), but using 2.7 eqs, 0.28 eqs, and 3.2 eqs of N-Boc-L-valine, DMAP, and DCC, respectively, resulted in the title compound.
1 H NMR (250 MHz, CHCl 3 ) δ: 0.95 (m, 12H), 1.42 (br s, 18H), 1.8 (m, 2H), 2.14 (m, 2H), 2.47 (m, 1H), 4.0-4.4 (m, 8H), 6.5 (br s, 2H), 7.67 (s, 1H).
b) (R)-9-[4-(L-Valyloxy)-2-(L-valyloxymethyl)butyl]guanine
The titled compound was obtained as the tris-trifluoroacetate salt from the intermediate of Example 20 step a) by deprotection in a manner analogous to Example 1 step c).
1 H NMR (250 MHz, D 2 O) δ: 1.0 (m, 12H), 1.89 (m, 2H), 2.29 (m, 2H), 2.62 (m, 1H), 4.02 (dd, 2H), 4.38 (m, 6H), 4.89 (br s, ca. 10H), 8.98 (s, 1H).
EXAMPLE 24
(R)-9-[4-hydroxy-2-(stearoyloxymethyl)butyl]guanine
The titled compound is prepared according to steps a) to c) of Example 7.
1 H NMR (250 MHz, DMSO-d 6 ): δ10.52 (s, 1H), 7.62 (s, 1H), 6.39 (s, 2H), 4.50 (t, 1H), 3.93 (m, 4H), 3.42 (m, 2H), 2.45 (m, 1H), 2.23 (t, 2H), 1.48 (m, 4H), 1.22 (s, 28H), 0.89 (t, 3H)
EXAMPLE 25
(R)-9-[2-Hydroxymethyl-4-(stearoyloxy)butyl]guanine
The titled compound is prepared by the procedure of Example 17, step a)
1 H NMR (DMSO-d 6 ) δ: 0.86 (t, 3H); 1.25 (s, 28H); 1.51 (qui, 2H); 1.62 (m, 2H); 2.06 (m, 1H); 2.23 (t, 2H); 3.34 (d, 2H); 3.96 (ABX, 2H); 4.07 (dd, 2H); 6.30 (br s, 2H); 7.62 (s, 1H); 10.45 (s, 1H).
EXAMPLE 26
Alternative Preparation of (R)-9-[2-stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
a) (R)-9-[4-N-benzyloxycarbonyl-L-valyloxy)-2-(hydroxymethyl)-butyl]guanine
Dry H2G (252 mg, 1 mmol), 4-dimethylaminopyridine (122 mg, 1 mmol) and N-Cbz-L-valine p-nitrophenyl ester (408 mg, 1.1 mmol) were dissolved in dry dimethyl formamide (16 ml). After stirring at 23° C. for 30 hours, the organic solvent was removed and the residue carefully chromatographed (silica, 2%-7% methanol/methylene chloride) to afford the desired product as a white solid (151 mg, 31%).
b) (R)-9-[4-N-benzyloxycarbonyl-L-valyloxy)-2-(stearoyloxymethyl)-butyl]guanine
A solution of stearoyl chloride (394 mg, 1.3 mmol) in dry methylene chloride (2 ml) was added slowly dropwise under nitrogen to a solution of the product of step a) (243 mg, 1 mmol) and 4-dimethylaminopyridine (20 mg) in dry pyridine (5 ml) at −5° C. The reaction mixture was stirred at that temperature for 12 hours. Methanol (5 ml) was added and the reaction stirred for 1 hour. After removal of the solvent, the residue was triturated with acetonitrile and chromatographed (silica, 0-5% methanol/methylene chloride) to afford the desired product (542 mg, 72%).
c) (R)-9-[2-stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
The product of step b) (490 mg, 1 mmol) was dissolved in methanol (30 ml) and 5% Pd/C (100 mg) added. A balloon filled with hydrogen was placed on top of the reaction vessel. After 6 hours at 23° C., TLC showed the absence of starting material. The reaction mixture was filtered through a 0.45 micron nylon membrane to remove the catalyst and the solvent was removed to afford the desired product as a white solid (350 mg, 99%) which was identical (spectral and analytical data) to Example 16.
EXAMPLE 27
Alternative Preparation of (R)-9-(4-hydroxy-2-(L-valyloxymethyl)butyl)guanine
(R)-9-(4-(L-valyloxy)-2-(L-valyloxymethyl)butyl)guanine from Example 23 step b) (100 mg, 0,126 mmole) was dissolved in 0.1 N NaOH aqueous solution (6.3 ml, 0.63 mmole) at room temperature. At intervals, an aliquot was taken and neutralized with 0.5 N trifluoroacetic acid. The aliquots were evaporated and analyzed by HPLC to monitor the progress of the reaction. After 4 hours, 0.5 N trifluoroacetic acid solution (1.26 ml, 0.63 mmole) was added to the solution and the reaction mixture was evaporated. The desired product was purified by HPLC, (YMC, 50×4.6 mm, gradient 0.1% TFA+0-50% 0.1% TFA in acetonitrile, in 20 minutes, UV detection at 254 nm. Yield: 13.6%
1 H-NMR (D 2 O): δ8.81 (s, 1H), 4.36 (m, 4H), 4.01 (d, 1H), 3.74 (m, 2H), 2.64 (m, 1H), 2.25 (m, 1H), 1.73 (m, 2H), 1.03 (dd, 6H).
EXAMPLE 28
Alternative Preparation of (R)-9-(2-hydroxymethyl-4-(L-valyloxy)butyl)guanine
HPLC separation of the reaction solution from Example 27 gave the titled compound in 29.2% yield.
1 H-NMR (DMSO-d 6 ): δ8.38 (s, 3H), 8.26 (s, 1H), 6.83 (br s, 2H), 4.23 (m, 2H), 4.06 (m, 2H), 3.91 (m, 1H), 3.40 (m, 2H), 2.19 (m, 2H), 1.8-1.40 (m, 2H), 0.95 (dd, 6H).
EXAMPLE 29
(R)-9-[2-stearoyloxymethyl)-4-(L-valyloxy)]butylguanine monohydrochloride
The product of Example 16, step d) (360 mg, 0.479 mmol) was dissolved in a mixture of methanol (10 ml) and ethyl acetate (10 ml). To the solution was added 10% Pd/C (100 mg) and 1N HCl (520 microlitres). The reaction mixture was stirred at room temperature for 2 hours under 1 atm. H 2 . The reaction mixture was filtered and the solvent evaporated from the filtrate to provide the desired product as a crystalline solid (300 mg).
Formulation Example A
Tablet Formulation
The following ingredients are screened through a 0.15 mm sieve and dry-mixed
10 g
(R)-9-[2-(stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
40 g
lactose
49 g
crystalline cellulose
1 g
magnesium stearate
A tabletting machine is used to compress the mixture to tablets containing 250 mg of active ingredient.
Formulation Example B
Enteric Coated Tablet
The tablets of Formulation Example A are spray coated in a tablet coater with a solution comprising
120
g
ethyl cellulose
30
g
propylene glycol
10
g
sorbitan monooleate
ad 1000
ml
aq. dist.
Formulation Example C
Controlled Release Formulation
50 g
(R)-9-[2-(stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
12 g
hydroxypropylmethylcellulose(Methocell K15)
4.5 g
lactose
are dry-mixed and granulated with an aqueous paste of povidone. Magnesium stearate (0.5 g) is added and the mixture compressed in a tabletting machine to 13 mm diameter tablets containing 500 mg active agent.
Formulation Example D
Soft Capsules
250 g
(R)-9-[2-(stearoyloxymethyl)-4-(L-valyloxy)butyl]guanine
100 g
lecithin
100 g
arachis oil
The compound of the invention is dispersed in the lecithin and arachis oil and filled into soft gelatin capsules.
Biology Example 1
Bioavailability Testing in Rats
The bioavailability of compounds of the invention were compared to the parent compound H2G and other H2G derivatives in a rat model. Compounds of the invention and comparative compounds were administered, per oral (by catheter into the stomach), to multiples of three individually weighed animals to give 0.1 mmol/kg of the dissolved prodrug in an aqueous (Example 4, 5, Comparative example 1-3, 5, 8), peanut oil (Comparative examples 4, 9, 10) or propylene glycol (Example 1-3, 6-12, 17, Comparative example 6, 7) vehicle dependent on the solubility of the test compound ingredient. The animals were fasted from 5 hours before to approximately 17 hours after administration and were maintained in metabolic cages. Urine was collected for the 24 hours following administration and frozen until analysis. H2G was analysed in the urine using the HPLC/UV assay of Stähle & Öberg, Antimicrob Agents Chemother. 36 No 2, 339-342 (1992), modified as follows: samples upon thawing are diluted 1:100 in aq dist H 2 O and filtered through an amicon filter with centrifugation at 3000 rpm for 10 minutes. Duplicate 30 μl samples are chromatographed on an HPLC column; Zorbax SB-C18; 75×4.6 mm; 3.5 micron; Mobile phase 0.05M NH 4 PO 4 , 3-4% methanol, pH 3.3-3.5; 0.5 ml/min; 254 nm, retention time for H2G at MeOH 4% and pH 3.33, ˜12.5 min. Bioavailability is calculated as the measured H2G recovery from each animal averaged over at least three animals and expressed as a percentage of the averaged 24 hour urinary H2G recovery from a group of 4 individually weighed rats respectively injected i.v jugularis with 0.1 mmol/kg H2G in a Ringer's buffer vehicle and analysed as above.
Comparative example 1 (H2G) was from the same batch as used for preparation of Examples 1 to 12. The preparation of Comparative example 2 (monoVal-H2G) and 3 (diVal-H2G) are shown in Examples 21 and 23. Comparative example 4 (distearoyl H2G) was prepared by di-esterification of unprotected H2G in comparable esterification conditions to step 2 of Example 1. Comparative examples 5 & 8 (Val/Ac H2G) were prepared analogously to Example 4 using acetic anhydride with relevant monovaline H2G. Comparative example 6 (Ala/stearoyl H2G) was prepared analogously to Example 6 using N-t-Boc-L-alanine in step 4. Comparative example 7 (Gly/decanoyl) was prepared analogously to Example 5 but using the step 1 intermediate made with N-t-Boc-L-glycine. The preparation of Comparative examples 9 and 10 is shown in Examples 24 and 25 respectively. The results appear on Table 2 overleaf:
TABLE 2
Compound
R 1
R 2
Bioavailability
Comparative example 1
hydrogen
hydrogen
8%
Comparative example 2
valyl
hydrogen
29%
Comparative example 3
valyl
valyl
36%
Example 1
valyl
stearoyl
56%
Comparative example 4
stearoyl
stearoyl
1%
Example 2
valyl
myristoyl
57%
Example 3
valyl
oleoyl
51%
Example 4
valyl
butyryl
45%
Comparative example 5
valyl
acetyl
11%
Example 5
valyl
decanoyl
48%
Example 6
valyl
docosanoyl
48%
Example 7
isoleucyl
stearoyl
53%
Example 8
isoleucyl
decanoyl
57%
Example 9
isoleucyl
myristoyl
49%
Example 10
valyl
4-acetylbutyryl
52%
Example 11
valyl
dodecanoyl
46%
Example 12
valyl
palmitoyl
58%
Example 17
stearoyl
valyl
52%
Comparative example 6
alanyl
stearoyl
23%
Comparative example 7
glycyl
decanoyl
25%
Comparative Example 8
acetyl
valyl
7%
Comparative Example 9
hydrogen
stearoyl
12%
Comparative Example 10
stearoyl
hydrogen
7%
Comparison of the bioavailabilities of the compounds of the invention with the comparative examples indicates that the particular combination of the fatty acids at R 1 /R 2 with the amino acids at R 1 /R 2 produces bioavailabilities significantly greater than the corresponding diamino acid ester or difatty acid ester. For example, in this model, the compound of Example 1 displays 55% better bioavailability than the corresponding divaline ester of Comparative example 3. The compound of Example 4 displays 25% better availability than the corresponding divaline ester.
It is also apparent, for instance from Comparative examples 5, 6 and 7 that only the specified fatty acids of this invention in combination with the specified amino acids produce these dramatic and unexpected increases in pharmacokinetic parameters.
Biology Example 2
Plasma Concentrations in Rats
A plasma concentration assay was done in male Sprague Dawley derived rats. The animals were fasted overnight prior to dosing but were permitted free access to water. Each of the compounds evaluated was prepared as a solution/suspension in propylene glycol at a concentration corresponding to 10 mg H2G /ml and shaken at room temperature for eight hours. Groups of rats (at least 4 rats in each group) received a 10 mg/kg (1 ml/kg) oral dose of each of the compounds; the dose was administered by gavage. At selected time points after dosing (0.25, 0.5, 1, 1.5, 2, 4, 6, 9, 12, 15, and 24 hours after dosing), heparinized blood samples (0.4 ml/sample) were obtained from a tail vein of each animal. The blood samples were immediately chilled in an ice bath. Within two hours of collection, the plasma was separated from the red cells by centrifugation and frozen till analysis. The components of interest were separated from the plasma proteins using acetonitrile precipitation. Following lyophilisation, and reconstitution, the plasma concentrations were determined by reverse phase HPLC with fluorescence detection. The oral uptake of H2G and other test compounds was determined by comparison of the H2G area under the curve derived from the oral dose compared to that obtained from a 10 mg/kg intravenous dose of H2G, administered to a separate group of rats. The results are depicted in Table 1B above.
Biology Example 3
Bioavailability in Monkeys
The compounds of Example 1 and Comparative example 3 (see Biology Example 1 above) were administered p.o. by gavage to cynomolgus monkeys. The solutions comprised:
Example 1
150 mg dissolved in 6.0 ml propylene glycol, corresponding to 25 mg/kg or 0.0295 mmol/kg.
Comparative Example 3
164 mg dissolved in 7.0 ml water, corresponding to 23.4 mg/kg or 0.0295 mmol/kg.
Blood samples were taken at 30 min, 1, 2, 3, 4, 6, 10 and 24 hours. Plasma was separated by centrifugation at 2500 rpm and the samples were inactivated at 54° C. for 20 minutes before being frozen pending analysis. Plasma H2G levels were monitored by the HPLC/UV assay of Example 30 above.
FIG. 1 depicts the plasma H2G recovery as a function of time. Although it is not possible to draw statistically significant conclusions from single animal trials, it appears that the animal receiving the compound of the invention experienced a somewhat more rapid and somewhat greater exposure to H2G than the animal which received an alternative prodrug of H2G.
Biology Example 4
Antiviral Activity
Herpes simplex virus-1 (HSV-1)-infected mouse serves as an animal model to determine the efficacy of antiviral agents in vivo. Mice inoculated intraperitoneally with HSV-1 at 1000 times the LD 50 were administered either with a formulation comprising the currently marketed anti-herpes agent acyclovir (21 and 83 mg/kg in a 2% propylene glycol in sterile water vehicle, three times daily, p.o.) or the compound of Example 29 (21 and 83 mg/kg in a 2% propylene glycol in sterile water vehicle, three times daily, p.o.) for 5 consecutive days beginning 5 hours after inoculation. The animals were assessed daily for deaths. The results are displayed in FIG. 2 which charts the survival rate against time. In the legend, the compound of the invention is denoted Ex.29 and acyclovir is denoted ACV. The percentage of mice surviving the HSV-1 infection was significantly greater following a given dose of the compound of the invention relative to an equivalent dose of acyclovir.
The foregoing is merely illustrative of the invention and is not intended to limit the invention to the disclosures made herein. Variations and changes which are obvious to one skilled in the art are intended to be within the scope and nature of the invention as defined in the appended claims
|
Methods and novel intermediates for the preparation of and the treatment with acyclic nucleoside derivatives of the formula:
where one of R 1 and R 2 is an amino acid acyl group and the other of R 1 and R 2 is a —C(O)C 3 -C 21 saturated or monounsaturated, optionally substituted alkyl and
R 3 is OH or H.
| 2
|
FIELD OF THE INVENTION
The present invention relates to apparatus for preparing food and, in particular, to the multipurpose kitchet apparatus called food processors in which a plurality of interchangeable rotary food preparing tools are removably mounted on a tool drive mount in a bowl, including a variety of tools such as cutting discs or blades, slicing discs, rasping discs, grating discs, grinding or chopping blades, etc., which are used for performing the operations of cutting, slicing, rasping, grating, pureeing, etc., of food items.
BACKGROUND OF THE INVENTION
There are food processors of the type broadly set forth above having a working bowl or vessel with a motor-driven tool-drive mount in the bowl on which various selected rotary tools can be engaged to be driven for performing various food processing operations, such as listed above, as may be desired by the user. A detachable cover is secured over the top of the bowl during use. This cover includes a hopper or feed tube which has a mouth that opens downwardly through the cover into the top of the bowl. The food items to be prepared are placed in this feed tube and then are manually pushed down through the feed tube into the bowl by means of a removable pusher member which is adapted to slide down in the manner of a plunger into this feed tube. For further information about this type of food preparing apparatus, the reader may refer to U.S. Pat. Nos. 3,892,365 to Verdun and 3,985,304 to Sontheimer.
The rotary tools in food processors are being driven by relatively powerful motor drive arrangements and have the capability of causing injury. For this reason, a mechanical interlock bowl-cover safety switch is conventionally incorporated into these units. This switch arrangement requires that the cover be firmly locked onto the bowl in normal position before the motor will start. This requirement is achieved by making the cover, which locks rotationally to the bowl, with a projection or member which causes the closing of the switch carried in the housing only when the cover is properly locked into its normal position on the bowl. Depending upon the type of food processor, this cover projection may actuate the switch directly or through an intermediate linkage.
Another safety feature is the provision of an upright food-receiving hopper having a feed passageway which extends down through the cover. This hopper is deliberately designed in terms of shape, moderate cross-sectional area of the food feed passageway and height to make it almost impossible for a normal adult inadvertently to insert a hand sufficiently far down into the hopper to touch the rotating tool located in the upper portion of the working bowl. In addition, the pusher is provided for feeding food items down into engagement with the food processing tool.
Such mechanically actuated switches require that a mechanical access port be provided through which a plunger or other projecting member can actuate the switch. This access port is usually covered by a recessed, flexible displaceable diaphragm for preventing food materials or liquids from entering the base housing. The user is faced with the need to keep the access port and the recessed surface of the diaphragm clean for aesthetic and sanitary reasons. Moreover, such a flexible, displaceable diaphragm may be subject to aging or deterioration over long periods of time, making it more difficult to clean or to operate.
Accordingly, it is an object of the present invention to provide a safety interlock for the bowl and cover, and in some cases for the food pusher as well, employing magnetic effects to prevent operation of the motor drive unless the components are properly mounted and firmly held in place and thereby avoiding the need for any mechanical access port in the base housing. Consequently, the food processor is neater in appearance and easier to clean and to maintain.
In employing magnetic effects to provide the desired safety interlock feature, we recognize that simple magnet arrangements are undesirable because of the widespread use of small magnets in many home kitchens. Such readily available magnets might be used inadvertently or intentionally to defeat a safety interlock based upon a simple scheme. Accordingly, we have provided various embodiments of the invention employing magnetic effects and each including discriminating means for increasing their discrimination against inadvertent or improper actuation by ordinary magnets.
SUMMARY
The invention is an improvement in an automatic food processor of the type including a relatively powerful electric motor drive mechanism within a base housing and having "ON" and "OFF" operating conditions for the motor drive. A working bowl is mountable on the housing and is adapted to have a rotatable tool removably installed on tool drive means in the bowl. This tool drive means is driven by the powerful motor in the base housing when the motor drive is operating. A removable cover for the bowl has a food-receiving hopper or feed tube with a passageway which extends down through the cover. A food pusher is manually insertable into the hopper for advancing food against a food processing tool in the working bowl. The improvement in one of its aspects utilizes magnetic means operatively associated with the cover and bowl which prevent the motor drive from operating to rotate the tool unless the bowl is located properly on the base housing and the cover is firmly locked or held on the bowl in normal position. The improvement in another of its aspects utilizes magnetic means in the food pusher, cover, and bowl for preventing the motor drive from operating to rotate the tool unless the bowl and cover are firmly mounted in place and the food pusher is inserted into the feed tube.
Among the advantages of this latter interlock are those resulting from the fact that the cross-sectional area of the food passageway in the feed tube can be made as large as may be desired, so that larger food items can be inserted whole into the food processor. As a result, the entire machine can now safely be scaled up to larger size for commercial and industrial applications, with corresponding enlargement of the cover and feed tube.
Each of the various interlock systems described advantageously employs magnetic effects and includes discriminating means for increasing their discrimination against inadvertent or improper actuation by ordinary magnets.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further objects, features, aspects and advantages thereof, will be more clearly understood from a consideration of the following description taken in conjunction with the accompanying drawings in which like reference numerals indicate like parts or corresponding elements throughout the various views.
FIG. 1 is a front perspective view of a food processor embodying the safety interlock method and apparatus of the present invention for preventing actuation of the tool drive unless two conditions have been met, namely, (1) the working bowl is mounted in proper position on the base housing, and (2) the cover is in proper position on the bowl. This view is seen from in front and above the food processor;
FIG. 2 is a schematic magnetic and electrical circuit diagram of the food processor of FIG. 1 for purposes of explanation of the ultrasonic frequency electromagnetic interlock;
FIG. 3 is a top plan view of the food processor shown in FIG. 1;
FIG. 4 is a front elevational view of portions of a food processor including a schematic magnetic and electrical circuit diagram of modified safety interlock method and apparatus similar to that shown in FIGS. 1, 2 and 3, except that in this modification actuation of the tool drive is prevented unless three conditions have been met, namely, the same two as above, plus (3) the food pusher is inserted into the feed tube in the cover. Part of FIG. 4 is shown in section;
FIG. 5 is a top plan view of the apparatus shown in FIG. 4 with the feed tube being shown in section;
FIG. 6 shows part of modified magnetically actuated control means for rendering the tool drive operative or inoperative, employing A.C. electromagnetic effects;
FIG. 7 shows the control means of FIG. 6 employed in the system of FIGS. 1, 2 and 3;
FIG. 8 shows the control means of FIG. 6 employed in the system of FIGS. 4 and 5;
FIG. 9 is a perspective view of a food processor employing a permanent magnet actuated safety interlock system, including discrimination against improper actuation by an ordinary permanent magnet;
FIGS. 10 through 12 illustrate another permanent magnet actuated safety interlock having discrimination against improper actuation by an ordinary permanent magnet;
FIG. 12 is a perspective view of the magnetic apparatus shown in FIGS. 10 and 11;
FIGS. 13 and 14 illustrate a presently preferred permanent magnet actuated safety interlock including magnetically coded permanent magnets for discriminating against improper actuation;
FIG. 15 is a partial sectional view as seen along the line 15--15 in FIG. 13;
FIG. 16 is a bottom plan view of a movable upper permanent magnet showing the pattern of its magnetic coding; and
FIG. 17 is a top plan view of a lower permanent magnet showing its magnetic coding pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning attention now to FIG. 1, a food processor referred to generally with the reference character 10, is illustrated having a base housing 12 with a removable working bowl 18 shown mounted thereon in operating position. The top of the bowl 18 is closed by a cover 20 which is arranged to be engaged in fastened or secured relationship in its normal operating position on the bowl 18, whenever the food processor 10 is to be in operation. Extending upwardly from the cover 20 is a food receiving hopper or feed tube 30 which opens downwardly through the cover 20. The feed tube 30 is designed to receive a food pusher 32 which is manually insertable in the manner of a plunger and is employed to push food items down into engagement with a rotating tool (not shown) mounted on tool mounting means (not shown) for rotation in the bowl 18.
As is more fully shown and described in the aforesaid Verdun patent, the housing 12 contains relatively powerful electric motor tool drive means 36 for driving tool mounting means which extend upwardly from the housing 12 into the interior of the working bowl 18. A variety of different types of food processing tools are provided which may be selectively mounted on such tool mounting means for rotation within the bowl 18. Since such food processing tools and the tool drive apparatus are conventional, one example of which is illustrated in said Verdun patent, they are not shown nor described in detail here.
Also, the Verdun patent shows one method of obtaining a securing engagement of the cover when it has been properly mounted on the bowl in the form of rim-mounted depending lugs 22 which upon a manual turning of the cover engage beneath a plurality of radial ledges 24 on the lip or rim 26 of the bowl 18 in the manner of a twist lock. Likewise, other suitable means may be used to secure or fasten the cover in place when properly positioned on the bowl such as are now being used on the various commercially available food processors.
Suitable fastening means 28, 29 are also provided for securing the bowl in proper position on the base 12. For example, there are shown lateral tenons 28 which engage in corresponding notches 29 provided in a skirt on the bottom of the bowl 18. Thus, the bowl is secured in position on the base by manually lowering and turning the bowl relative to the base for causing the tenons 28 to enter and engage within the respective notches 29. Other suitable bowl-securing means may be provided interengageable between the base 12 and bowl 18, such as are now being used on the various commercially available food processors. A handle 34 is provided on the bowl for convenience of the user.
Control levers or buttons 14 and 16 extend from the front of the base. The lever 14 turns "ON" and "OFF" the tool drive means 36, but this tool drive means will not actually operate unless the bowl and cover are properly positioned, as shown in FIGS. 1 and 2, as will be explained in detail further below. The lever 16 serves to "JOG" or "PULSE" the tool drive means 36 for producing brief momentary operation as may be desired by the user for particular food processing operations. Again, this lever 16 will not actually cause the tool drive means 36 to operate unless bowl and cover are in their proper positions. Such jogging or pulsing operation is known in the art and is not part of the present invention.
In order to prevent operation of the tool drive means 36 unless the bowl 18 and cover are both in their respective proper positions, there is provided first magnetic means 40 associated with the cover and with the bowl and second magnetic means 50 coupled with the control means 52. These first and second magnetic means serve for placing the tool drive means 36 in operative or inoperative condition. The control means 52 is connected by electrical leads 53 to a relay 54 which is included in the energizing circuit 59 of the tool drive means 36. Thus, this tool drive means 36 will not be operative until the relay 54 has been actuated into closed condition by the control 52.
The first magnetic means 40 and the second magnetic means 50 when they are positioned as shown in FIG. 2 define an essentially closed-loop magnetic circuit of very high magnetic permeability formed by elongated ferromagnetic members 41, 42, 43 and 51 having low hysteresis and low eddy current loss characteristics at ultrasonic frequencies. For example, these ferromagnetic members 41-43 and 51 may each comprise a bundle of numerous fine parallel wires of high quality, high frequency transformer iron which are electrically insulated one from another by individual varnish or enamel coating. Alternatively, these members 41-43 and 51 may each be formed of a ferromagnetic ceramic material, called ferrite, having low hysteresis and eddy current losses at ultrasonic frequencies. The magnetic member 41 has a broad U-shape and extends generally horizontally, being embedded in the front rim 52 of the plastic cover 20.
As seen in FIG. 3, this magnetic member 41 has a significant curvature being shaped concentric with the circular plan of the cover and it is longer than the width of the feed tube 30. The front rim 52 of the cover is thickened in the region containing the member 41 to provide sufficient plastic material for conveniently embedding this member.
The two straight magnetic members 42 and 43 extend vertically and parallel and are embedded in the wall of the bowl 18 in elongated bosses 54 and 55, respectively, which are symmetrically positioned on opposite sides of the handle 34. When the cover is in proper position on the bowl, the ends of the member 41 are aligned with and closely adjacent to the upper ends of the two vertical members 42 and 43. Thus, there is a highly permeable path for magnetic flux provided by the first magnetic means 40, which includes the ferromagnetic members 41, 42 and 43 in series with each other as seen in FIG. 2.
The second magnetic means 50 is in the base housing 12 and includes the ferromagnetic member 51, which has a broad U-shape defining a pair of spaced vertical parallel legs 57, and includes the primary and secondary windings 56 and 58 located on its two leg portions 57. The two leg portions 57 of the ferromagnetic member 51 are aligned with and closely adjacent to the lower ends of the two members 42 and 43 when the bowl 18 is in operating position on the base 12 for completing the closed-loop magnetic circuit as seen in FIG. 2.
A source 60 of high frequency alternating current (A.C.), for example, an oscillator, generates an alternating electrical current having a predetermined ultrasonic frequency, for example, a fixed frequency in the range from 30,000 Hertz to 70,000 Hertz. This oscillator 60 is connected to the primary winding 56 for inducing ultrasonic A.C. magnetic flux in the magnetic loop circuit 51, 41-43.
Thus, there is ultrasonic A.C. magnetic flux in the ferromagnetic loop 51, 41-43 which, in turn, induces an A.C. voltage of the same ultrasonic frequency in the secondary winding 58, which is connected to the control 52. The secondary winding 58 may be called a pick-up winding. The control 52 includes a solid state amplifier for amplifying the A.C. signal voltage induced in the secondary winding 58, and a narrow band-pass filter or other frequency discriminating means tuned to be responsive only to the predetermined frequency of the oscillator 60. Also, included in the control 52 is a rectifier and filter capacitor connected to the output of the amplifier for supplying direct current (D.C.) over the wires 53 to the relay 54. Therefore, the control 52 descriminates against all signals except a signal voltage of predetermined frequency from the oscillator 60, and will actuate the relay 54 for placing the tool drive 36 in operative condition only when the bowl and cover are in proper operating position.
If both the cover and bowl are not in their respective proper operating positions, then the high permeability magnetic circuit 51, 41-43 for the flux is not closed, resulting in a greatly increased magnetic reluctance, so that only an insignificant amount of the ultrasonic A.C. magnetic flux from the primary winding 56 couples with the secondary winding 58. Therefore, the control 52 does not actuate the relay 54, and the tool drive 36 remains inoperative.
The magnetic interlock method and apparatus shown in FIGS. 4 and 5 is similar to that as described for FIGS. 1, 2 and 3, except that the first magnetic means 40A is also associated with the feed tube 30 and with the plunger 32 as well as being associated with the bowl and cover. In addition to the ferromagnetic members 42 and 43 embedded in the wall of the bowl 18, as described above, there are a pair of upper ferromagnetic members 44 and 45 whose lower ends are aligned with and closely adjacent to the upper ends of the ferromagnetic members 42 and 43. These upper members 44 and 45 are embedded in elongated bosses 64 and 65, respectively, on the cover and extending up along opposite sides of the feed tube 30.
In order to complete the closed-loop magnetic circuit, there is a horizontally extending ferromagnetic member 46 embedded in the food pusher 32 in a location where it effectively bridges across between the upper ferromagnetic members 44 and 45 whenever the food pusher 32 is inserted into the feed tube 30. If the food pusher 32 is of solid construction, then this horizontal member 46 can extend straight across the pusher from one side to the other near the bottom of the pusher as apparently seen toward the right side of the pusher in FIG. 4.
In most instances the food pusher 32 is hollow, having a bottom, side walls and a top rim, thereby being generally of cup-shaped configuration. Consequently, the horizontal ferromagnetic member 46 is hoop-shaped, as seen in FIG. 5 and as shown at the left in FIG. 4, so that it is embedded in the side wall of the pusher near the bottom of the pusher.
Whenever the food pusher 32 has been inserted into the feed tube 30, with the bowl and cover in their proper operating positions, as seen in FIG. 4, then the closed-loop magnetic circuit is established so that the ultrasonic A.C. magnetic flux from the primary winding 56 couples with the secondary winding 58, causing the control 52 to actuate the relay 54 for placing the tool drive 36 in operative condition. Even when the food pusher is only slightly inserted into the feed tube, the horizontal ferromagnetic member effectively bridges across between the vertical members 44 and 45 in the wall of the feed tube as shown at 46' because the member 46 is close to the lower end of the food pusher.
If the bowl, cover, and food pusher are not all in their respective proper operating positions, there is only an insignificant amount of magnetic flux coupling with the secondary winding 58. Therefore, the control 52 does not actuate the relay 54, and the tool drive 36 remains inoperative.
In order to increase the sensitivity for distinguishing whether the ferromagnetic circuit is closed as shown in FIGS. 2 and 4, or whether it is open as a result of improper positioning of the food processor components, as described above, the second magnetic means 50A (FIG. 6) in the base housing 12 includes a ferromagnetic member 66 having a broad H-shape as seen in FIG. 6. Either the primary or secondary winding 56 or 58 is wound onto one of the vertical legs 67 with half of this winding being above and half being below the horizontal cross bar 68 of the H-shaped ferromagnetic core 66. The other winding 58 or 56 (secondary or primary, as the case may be) is placed on the horizontal cross bar 68 as far as possible from the leg 67 which contains the first winding. By virtue of the fact that the axes of the primary and secondary windings on the ferromagnetic core 66 are orthogonal to each other, there is normally a very small coefficient of coupling between these two windings, as indicated by the mutually uncoupled magnetic flux lines 70 (FIG. 6). However, whenever the magnetic circuit between the upper ends of the core legs 67 is completed by proper positioning of the components of the food processor, as shown in FIGS. 7 or 8, then a significant electromagnetic coupling is established between primary and secondary windings, as shown by the flux lines 70', so that the tool drive means is rendered operative.
It is to be understood that whichever winding is the primary winding in FIGS. 7 and 8 is energized by an oscillator (similar to the showing in FIGS. 2 and 4), while the secondary or pick-up winding is connected to a control as shown in FIGS. 2 and 4 for rendering the tool drive operative or inoperative.
In FIG. 9 the first magnetic means 40B associated with the cover 20 and bowl 18 includes a curved permanent magnet 72 embedded in the enlarged front rim 52 of the cover 20 and two vertical parallel ferromagnetic members 42 and 43 embedded in the walls of the bowl similar to those previously described. The second magnetic means 50B includes another permanent magnet 74 pivoted at 76 at its center to a clevis at the upper end of the actuating arm 78 of a tool drive control switch 82. This normally open control switch 82 is connected to the tool drive energizing circuit 59 (FIGS. 2 and 4) and renders the tool drive 36 operative only when this switch 82 is closed by depressing its actuating arm 78 against the spring force of the switch.
When the cover and bowl are in their proper operating positions the first permanent magnet 72 repels the second permanent magnet 74 for depressing the upwardly spring-biased actuating arm 78, thereby closing the control switch 82 for rendering the tool drive operative. By virtue of the fact that the magnet 74 is pivoted at 76, it does not depress the switch actuating arm 78 unless the downward acting repulsive forces exerted at its two ends are equal. Therefore, this pivot mounting 76 serves as discriminating means for preventing the switch 82 from being inadvertently or intentionally actuated by a kitchen magnet. Moreover, the two ends of the magnet 74 are relatively widely spaced, which further reduces the possibility of actuation of the switch by a kitchen magnet, which is usually of relatively small size.
In the interlock method and apparatus as shown in FIGS. 10-12, the bowl 18 is equipped with a vertically movable actuating rod 84 located within a vertical semicylindrical boss 86 formed on the wall of the bowl. This vertically movable rod 84 and the enclosing boss 86 are similar to those shown in the Verdun U.S. Pat. No. 3,892,365. Attached to the lower end of this rod 84 by a bracket 88 is a permanent magnet 72A. An enlarged socket 90 is provided at the lower end of the boss 86 for housing the magnet 72A. A spring 92 normally urges the rod 84 toward its upper position, as shown in FIG. 10.
When the cover 20 is placed on the rim 26 of the bowl 18 and is turned into its proper operating position, a cam 94 on the rim of the cover depresses the actuating rod 84, as shown in FIG. 11, thereby moving the magnet 72A down against the upper surface of the base housing 12 directly above a pivoted magnet 74. This pivoted magnet 74 is repelled by the downwardly moving magnet 74A. Thus, the switch actuating arm 78 is depressed for closing the normally-open control switch 82, thereby placing the tool drive means 36 in operative condition. The first magnet means 40C in FIGS. 10-12 includes the magnet 72A and its associated actuator rod 84.
Again, it is noted that the magnet 72A is pivoted at 76 at its center for discriminating against inadvertent or intentional actuation of the switch 82 by an ordinary kitchen magnet. As before, it is noted that the ends of the magnet 74 are relatively widely spaced from each other which makes the inadvertent or intentional actuation of the switch 82 by an ordinary magnet more difficult.
Furthermore, it is noted that the base housing 12 includes a circular turret or elevated platform shown dotted at 80 of a diameter slightly less than the diameter of the bowl 18. The lower skirt of the bowl 18 seats down around this raised platform. Such a raised platform is not shown in in any of the drawings, but the configuration of the top surface of the base housing 12, including a circular bowl-mounting platform, is clearly shown in said Verdun patent.
The two ends of the permanent magnet 74 (in FIGS. 10, 11 and also in FIG. 9) are positioned beneath the top of the housing 12 near to the periphery of this raised circular platform. Consequently, it is not possible for the opposite ends of an ordinary straight bar magnet to be placed simultaneously directly above the opposite ends of the magnet 74 because of interference with the curved periphery of the raised platform. As shown in FIG. 12, the magnet 72A is curved concentric with the periphery of the raised platform to provide clearance so that its opposite ends can be positioned directly above the opposite ends of the pivoted magnet 74 for depressing the latter magnet against the force of the spring means in the normally-open control switch 82.
It is to be noted that this condition of the raised platform interfering with simultaneous access by any straight magnet or bar to the regions on the base housing 12 directly above the opposite legs 57, 57 or 67, 67 in FIGS. 2, 4, 7 and 8 is also true, thereby providing further discrimination against inadvertent or intentional actuation of the tool drive control means, except by the intended proper positioning of the respective components of the food processor in their respective operating positions as described above.
In the preceding description, the cam 94 is described as being located on the rim of the cover 20. In an alternative arrangement which is now commercially available in the market, the cam 94 is located on a protective outer sleeve which slides down around the feed tube 30. This outer sleeve contains a movable food pusher which is captivated within the sleeve for assuring that the food pusher is located within the feed tube before the food processor is operated. Therefore, it is to be understood that the cam 94, as shown in FIGS. 10 and 11 may be located upon the cover or may be located upon such a protective feed-tube sleeve associated with the feed tube cover, as is indicated by the legend in FIG. 10.
Although the spring 92 in FIGS. 10 and 11 is shown near the upper end of the movable rod 84 for convenience of illustration, it is to be understood that this spring may be located lower down in the boss 86, for example, as shown in the Verdun patent.
In the interlock method and apparatus as shown in FIGS. 13 through 17, the bowl 18 is equipped with a vertically movable actuating rod 84 similar to that as described in connection with FIGS. 10 through 12. Attached by adhesive cement to the lower end of this rod 84 is a coded rubber magnet 100, the shape of which is shown in FIG. 16. As shown in FIG. 16, this rubber magnet 100 includes alternating stripes each approximately one-eighth of an inch wide of north, south, north, south polarity. Positioned beneath and closely adjacent to the top surface of the base housing 12 is another coded rubber magnet 102 of circular configuration cemented onto a soft iron disk 104. This ferromagnetic disk is soldered to the upper outer end of a movable actuating arm 78 of a tool drive control switch 82. This movable arm 78 is pivoted at 106 to a bracket 108 mounted upon the casing of the switch 82. The switch 82 is normally open and has an actuator button 110 which is spring-biased upwardly and is located beneath an elbow 112 of the arm 78 near the pivot 106. Thus, the arm 78 as an overall configuration of a lever of the second class, with the fulcrum being located at the pivot 106, thereby providing mechanical advantage for depressing the button 110 against the spring force of the switch 82. The switch 82 as shown is a small switch of the type commercially available under the designation "MicroSwitch", in which a relatively short downward stroke of the button 110 will close the contacts in this normally open switch.
FIG. 17 shows the alternating north, south, north, south polarity stripes in the coded rubber magnet 102. As shown in FIG. 14, when the cover 20 or the feed-tube sleeve, as described above, is turned into operating position relative to the bowl 18, the cam 94 depresses the actuating rod 84, thereby moving the coded magnet 100 down against the top surface of the base housing 12. By virtue of the fact that the coded magnetic polarity stripes 101 in the upper magnet 100 are oriented parallel with the corresponding magnetic polarity stripes 103 in the lower magnet 102, and the respective stripes of like polarity are positioned directly above the corresponding like-polarity stripes 103 in the lower magnet, the upper magnet 100 repels the lower magnet 102 causing the arm 78 to swing downwardly as shown in FIG. 14. Thus, the button 110 is depressed, and the contacts in the switch 82 become closed for completing the energization circuit 59 of the tool drive means 36 (FIGS. 2 and 4).
The coded striping 101 and 103 in the rubber magnets 100 and 102 serve as discriminating means for preventing inadvertent or intentional actuation of the switch 82 by an ordinary magnet. Such coded rubber magnets 100 and 102 are relatively powerful in spite of their thin configuration. The coded rubber magnet material is commercially available in sheet strip form, and the sheet can conveniently be cut and shaped with a penknife. The rubber magnet sheet is approximately one-eighth of an inch thick. The soft iron disk 104 is approximately one-sixteenth of an inch thick and effectively provides a high permeability medium directly below the lower magnet 102 for conducting magnetic flux, thereby increasing the effective strength of this lower magnet 102. Note that the magnets are chosen anti-symmetric (NSNS). Therefore, only at 0° (proper alignment) relative rotation of the top magnet with respect to the bottom magnet can the switch be actuated. If an attempt is made to place an ordinary magnet on the top surface of the base housing 12 above the lower magnet the result is to attract, not to repel, this lower magnet, and so the switch 82 is not closed, and the tool drive means 36 remains inoperative.
Advantageously, each of the embodiments of the present invention described above, enables the top surface of the base housing 12 to be smooth, without any aperture or access port as is provided in commercially available food processors currently on the market. This housing 12 is of plastic, which is premeable to magnetic flux, and therefore the magnetic flux will pass through it as described. This avoidance of an aperture or an access port in the upper surface of the base housing 12 provides an overall sleek, neat appearance and facilitates cleaning of the food processor, since there is no discontinuity in the surface in which food particles can become lodged.
It is to be noted that the energization circuit 59 (FIGS. 2, 4, 9-14) may serve to control the energization of the electric motor in the base housing 12 of the food processor for rendering the motor drive operative for driving a tool in the bowl 18. Alternatively, this energization circuit 59 may serve to control the operation of a clutch in the motor drive for rendering the tool drive operative for driving a tool in the bowl 18. In other words, the motor itself may be turned on by a different switch, and then a clutch must be actuated by the control means before the tool in the bowl 18 becomes driven by the motor. Therefore, the terms "control means" and "tool drive means" are intended to be interpreted sufficiently broadly to include either of these control arrangements for rendering the tool drive operative and inoperative.
It is also to be noted that in the embodiments of this invention which have been described, the second magnet means 50, 50A, 50B, 50C and the associated tool drive control means are located within the base housing 12 at a lower level than the bottom of the bowl 18. There are food processors in use today in which a motor control switch is located in an elevated position in an upstanding portion of the base housing 12 adjacent to the rim of the bowl 18 and the cover 20. It is to be understood that the second magnet means 50, 50A, 50B, 50C can be positioned in such an elevated for upstanding portion of the base housing, with an appropriate reconfiguration of the first magnet means 40, 40A, 40B, 40C for actuating the tool drive control means when the components, as described, are in their respective proper operating positions.
In FIG. 13 the plastic housing has a depending annular ridge 114 forming a wide shallow socket 116 on the under surface of the base housing 12 into which the lower magnet 102 fits with clearance. This socket 116 in effect steers the lower magnet 102 into a predetermined accurate position below the housing surface 12 in spite of moderate tolerance in movement of the outer end of the actuating arm 78.
There is another advantage in eliminating the aperture or access port in the base housing. In order to understand this advantage, it is helpful first to understand the operation of prior art food processors having such an access port. An actuating rod on the bowl as shown in said Verdun patent is caused to enter the access port for actuating a switch in the machine base below the port. This actuating rod becomes depressed into the port when the cover is twist-locked into operating position on the bowl. Therefore, the bowl must first be properly positioned on the base with the actuating rod directly aligned with the port before the cover can be twist-locked onto the bowl. An attempt to twist-lock the cover in operation position on the bowl before the bowl is placed on the machine base will cause the actuating rod to become depressed, and its downwardly projecting lower end will thereafter interfere with an attempt to mount the bowl on the machine base. Any of the interlock methods and apparatus as described herein enable either the bowl or the cover to be mounted first.
If desired by the user, the cover can be mounted on the bowl before the bowl is mounted upon the base 12. Therefore, the user has greater flexibility in the procedures of handling the bowl and cover components of the food processor, because an actuating rod does not need to be aligned with an access port before it is depreseed.
As shown at the right in FIGS. 16 and 17, the magnetic polarity stripes 101 and 103 in the upper and lower permanent magnets 100 and 102 all extend in a direction perpendicular to a vertical plane tangent to the circular cylindrical wall of the bowl 18 in the region where the upper magnet 100 is located. Thus, the orientation of these magnetic stripes is perpendicular to the twist-lock turning movement applied by the user to the bowl in engaging the bowl notches 29 on the tenons 28. Therefore, the orientation of these magnetic stripes also provides discrimination for assuring that the bowl has been fully turned into its proper operating position on the base, because only then will like-polarity stripes on the upper magnet be directly aligned with and registered with like-polarity stripes on the lower magnet for exerting a powerful repelling force for depressing the switch actuating arm 78 as shown in FIG. 14.
Since other changes and modifications varied to fit particular food processor operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the examples chosen for purposes of illustration, and includes all changes and modifications which do not constitute a departure from the true spirit and scope of this invention as defined by the following claims and equivalents thereof.
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Safety interlock method and apparatus employing magnetic effects for food processors having a base enclosing a motor drive, working bowl detachably mountable on the base for receiving various rotatable tools removably installable on drive means in the bowl, with removable cover for the bowl. Such food processors normally include a hopper or feed tube on the cover with manually operated pusher for feeding food items down it to the rotating tool. The safety interlock in one embodiment prevents actuation of the drive to prevent tool rotation unless two conditions are met: (1) the working bowl is in proper position and (2) the cover is in proper position. The safety interlock in another embodiment prevents actuation of the motor drive unless three conditions are met: (1) bowl in proper position, (2) cover in proper position, and (3) food pusher is inserted into the feed tube. If there is a relatively large feed tube, the user is thus prevented by the inserted food pusher from inadvertently inserting a hand or foreign object into it. By virtue of this latter interlock, the feed tube can safely be made of larger cross-sectional area so that larger food items can be inserted whole. Moreover, the entire size of working bowl, cover and feed tube can be proportionately enlarged for providing a larger overall machine. The various interlock systems employ magnetic effects advantageously in ways for increasing discrimination against inadvertent actuation by ordinary magnets.
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FIELD OF THE INVENTION
The present invention relates to a connector, and more particularly to a connector for glass. With the connector, glass is combined to be a revolving door, a paravent or a casement.
BACKGROUND OF THE INVENTION
Glass is largely used in doors or screens and all these applications of glass required special designed connectors. Each of these connectors is designed to have only one special application, that is, a specially designed connector applies only to a specific function. There is no room of substitution of these connectors. Therefore, users will have to prepare a lot of different connectors for different applications. Furthermore, these connectors are complex in structure and difficult in mounting. As a consequence, the cost for these connectors is high.
To overcome the shortcomings, the present invention intends to provide an improved glass connector to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
The primary objective of the invention is to provide a connector for glass. The connector is simple in structure and easy to be implemented.
In order to accomplish the foregoing objective, the connector of the present invention has a main post and a secondary post securely connected to the main post. The main post is adapted to be connected a top hinge and a bottom hinge of a glass door, a revolving door, a casement or a paravent.
Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the connector of the present invention;
FIG. 2 is an exploded perspective view of the connector in FIG. 1;
FIG. 3 is a schematic view of the connector, wherein the connector is implemented to secure a glass door;
FIG. 4 is a perspective view showing that two connectors are mounted to secure a glass door;
FIG. 5 is an exploded perspective view of another embodiment of the connector of the present invention;
FIG. 6 is a schematic view of the connector in FIG. 5, wherein the connector is used to secure a glass door with two layers of glasses;
FIG. 7 is an exploded perspective view of still another embodiment of the connector of the present invention;
FIG. 8 is a schematic view of the connector in FIG. 7, wherein the connector is used to secure a paravent;
FIG. 9 is an exploded perspective view of the main post; and
FIG. 10 is a schematic view of the connector in FIG. 9, wherein the connector is used to adapt to a different type of hinge of a glass door.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1, 2 and 3 , the connector 1 in accordance with the present invention has a main post 11 and a secondary post 12 .
The main post 11 has a bottom hole 111 defined in one end of the main post 11 to adapt to a hinge 32 of a glass sheet 2 . A side hole 112 is defined in a periphery of the main post 11 . A top hole 114 is defined in another end of the main post 11 to threadingly receive therein a bolt 113 .
The secondary post 12 has a connecting end 120 with a plan face 121 formed on a periphery of the secondary post 12 and at least one (two are shown in this preferred embodiment) securing unit 122 secured to the periphery of the secondary post 12 . Each securing unit 122 includes a first connector 1221 , a second connector 1222 and a securing bolt 1223 . The securing bolt 1223 extends through the second and first connector 1221 , 1222 so as to threadingly engage with a threaded hole 1220 in the periphery of the secondary post 12 .
When the connector in FIG. 1 is implemented to secure glass sheet (as shown in FIG. 3 ), two main posts 11 are used to respectively engage with a top hinge 31 and a bottom hinge 32 of the glass sheet 2 by inserting the top and bottom hinges 32 of the glass sheet 2 into the bottom holes 111 . The connecting end 120 is inserted into the side hole 112 and the bolt 113 is threadingly inserted into the top hole 114 to engage with the plan face 121 so as to secure the secondary post 12 in the main post 11 . Then the first connector 1221 of the at least one securing unit 122 is first attach to the periphery of the secondary post 12 and the glass sheet 2 attach to the first connector 1221 with holes 21 in the glass sheet 2 aligned with holes (not numbered) in the first connector 1221 . Thereafter, the securing bolt 1223 extends through the second connector 1222 , the holes 21 , the first connector 1221 and into the threaded hole 1220 to thereby secure the glass sheet 2 with the connector 1 of the present invention.
With reference to FIG. 4, when the glass sheet is a glass door 3 , with the connector 1 of the present invention, the glass door is able to securely and smoothly pivot about the top and bottom hinges 31 , 32 .
With reference to FIGS. 5 and 6, a second preferred embodiment of the present invention is shown. The connector as shown has two pairs of securing units 122 on the secondary post 12 . The two pairs of securing units 122 are correspondingly formed on the secondary post 12 . That is, each securing unit 122 has another securing unit 122 close by and still another securing unit 122 on the opposite side of the secondary post 12 . With the arrangement of the connector 2 of the present invention, two glass sheets 2 are able to be simultaneously secured by the connector 2 so that the user is able to work on the two-layer glass door 3 to increase attractions.
With reference to FIGS. 7 and 8, the connector of the present invention has two secondary posts 12 each having at least one (two are shown in this embodiment) securing unit 122 . Each at least one securing unit 122 on one secondary post 12 may be formed on the same side as another on the other secondary post 12 so that the connector 1 is able to function as a joint to secure two glass sheets 2 .
With reference to FIGS. 9 and 10, still another preferred embodiment of the present invention is shown. The connector of this embodiment has an auxiliary seat 13 with a flange 131 , a truncated conical bottom 132 securely formed on a side of the flange 131 and a channel 1311 defined to communicate with the bottom hole 111 of the main post 11 . The truncated conical bottom 132 is able to be received in the bottom hole 111 and secured in the bottom hole 111 by a bolt 14 extending through the periphery of the main post 11 . Due to the conical shape of the truncated conical bottom 132 , the bolt 14 is able to securely retain the auxiliary seat 13 in the bottom hole 111 . After the auxiliary seat 13 is secured in the bottom hole 111 in the main post 11 , the shape of the channel 1311 is able to be designed to any shape to adapt to the top or bottom hinge 31 , 32 , as shown in FIGS. 9A and 9B, wherein the shape of the channel 1311 may be a round or a square one. Again, an extension 133 may be formed on top of the flange 131 to cope with a nut like cap 4 so as to be received in the bottom hinge 32 of the glass sheet 2 .
Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A connector for a piece of glass has a main post and a secondary post securely connected to the main post. The main post is adapted to be connected a top hinge and a bottom hinge of a glass door, a revolving door, a casement or a paravent. The secondary post is able to secure the piece of glass.
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TECHNICAL FIELD
[0001] This invention relates generally to the field of sharing application programs and, more specifically, to the optimization of the transmission of data from a shared application to a shadow computer system.
BACKGROUND OF THE INVENTION
[0002] The modem workplace is increasingly reliant on the use of networks. A network is a group of computer systems and associated devices that are connected by communications facilities. A network enables the transfer of electronic information between computer systems. Typically, each of the computer systems has local applications which may be invoked at that computer system. The local applications may receive input from a user at that computer system. Also, a local application displays output at that computer system.
[0003] It is useful for a user to be able to share an application invoked at a host computer system with another user at a shadow computer system. For example, sharing an application which generates a word processing document may assist an editor who is working with a writer to publish a document. In particular, the editor may wish to edit the document at the host computer system, while the writer views the document at the shadow computer system. In this manner, the writer may also provide input to the shared application and modify the document based on the editor's comments. Immediately, the editor may review this revised document. In addition, sharing an application may be useful for diagnostic testing by a technical person upon receiving questions from a user. For example, if the user has found that an application is not working properly, then the user may desire to share the application with the technical person. Then, the technical person can attempt to solve the problem, receiving input from the user describing the problem as needed.
[0004] Some conventional computer systems allow a user at a host computer system to share an application with a user at a shadow computer system. These conventional computer systems typically display the output of the shared application within a shadow window that is contained within a top-level window. The top-level window is created and controlled by the program that coordinates the sharing of the application. Unfortunately, because the shadow window is not a top-level window, the shadow window may not be minimized or maximized under the control of the operating system.
[0005] In addition, these conventional systems typically do not negotiate control of the shared application. Instead, either user may input data to the shared application, and all data is passed in to the application in the order it is entered. Moreover, typically, a user who is sharing an application may either view the application or control it (i.e., provide input to it). Conventional systems do not enable a user who is sharing an application to use non-shared applications. It may be useful, however, for a user to be able to use a non-shared application and still be able to view a shared application.
[0006] Also, various computer systems within a network may have differing display resolutions. For example, some computer systems may have a display resolution of 1024 by 768 pixels and other computer systems may have a display resolution of 640 by 480. Thus, it would be useful when sharing an application to accommodate the different display resolutions.
[0007] Furthermore, since the user of a shared application at the shadow computer system actually views the output in real time, it is important that the speed of transmission of the output data from the host to the shadow computer systems be optimized.
SUMMARY OF THE INVENTION
[0008] An aspect of the present invention is a Share System that provides a method for transmitting display orders (output data) from a host computer system to a shadow computer such that display orders whose visible effect is nullified by a subsequent display order is not transmitted. The Share System executes on both the host and shadow computer systems. The Share System that executes on the host computer system, receives a group of display orders. For each of the received display orders, the Share System determines whether the effect of the display order on the display would be visible after performing all of the display orders. When the effect of the display order on the display would be visible, the Share System transmits the display order to the shadow computer system such that the shadow computer system does not receive display orders that would have no visible effect after performing all of the display orders.
[0009] In another aspect of the present invention, the Share System provides a method for transmitting pixel data from a first computer system to a second computer system. The pixel data has a high pixel depth. The first computer system has a first translator for translating pixel data from the high pixel depth to a low pixel depth. The second computer system has a second translator for translating from the high pixel depth to a low pixel depth. The second computer system also has a display device for displaying pixel data in the low pixel depth. The Share System determines whether the first translator or the second translator performs a more accurate translation of the high pixel depth to the low pixel depth. When it is determined that the first translator performs a more accurate translation, the Share System translates the pixel data using the first translator from the high pixel depth to the low pixel depth and sends the pixel data in the low pixel depth from the first computer system to the second computer system. Upon receiving the sent pixel data in the low pixel depth at the second computer system, the Share System displays the pixel data in the low pixel depth. When it is determined that the second translator performs a more accurate translation, the Share System sends the pixel data in the high pixel depth from the first computer system to the second computer system. Upon receiving the sent pixel data in the high pixel depth at the second computer, the Share System translates the pixel data using the second translator from the high pixel depth to the low pixel depth and displays the pixel data in the low pixel depth.
[0010] In another aspect of the present invention, the Share System provides a method for transmitting data output from a first computer system to a second computer system. Under control of the second computer system, the Share System sends to the first computer system an identification of each font supported by the second computer system. Under control of the first computer system, the Share System receives the sent identifications of each font supported by the second computer system, receives a request to display text data in a specified font, and checks the received identifications to determine whether the second computer supports the specified font. When it is determined that the second computer system supports the specified font, the Share System sends the text data along with an identification of the specified font to the second computer system. When it is determined that the second computer system does not support the specified font, the Share System generates a bitmap representation of the text data in the specified font and sends the generated bitmap representation of the text data to the second computer program. Under control of the second computer system, the Share System upon receiving the sent text data and the identification of the specified font, displays the text data in the specified font, and upon receiving the sent bitmap representation of the text data, displays the bitmap representation.
[0011] In another aspect of the present invention, the Share System provides a method for transmitting representations of bitmaps from a first computer system to a second computer system. The Share System caches bitmaps that are sent twice from the first to the second computer system. After caching a bitmap, the Share System sends an indication of the bitmap that is cached, rather than the bitmap itself.
[0012] In another aspect of the present invention, the Share System provides a method in a computer system for compressing a bitmap. The bitmap is organized into rows with a number of bits. The Share System first outputs a run-length encoding of the first row of data. For each row of the bitmap except for the first row, the Share System generates an interim row with the number of bits by setting the bit value of each bit in the interim row to the exclusive-OR of a corresponding bit in the row and of a corresponding bit in a previous row, and outputs a run-length encoding of the interim row of data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram of a computer system on which the Share System executes.
[0014] FIG. 2 is a diagram illustrating the sharing of an application program under control of the Share System.
[0015] FIG. 3 is a block diagram of the architecture of the Share System executing on both the host and shadow computer systems.
[0016] FIG. 4 is a block diagram illustrating the components of the controlling tasks
[0017] FIG. 5 is a flow diagram of a template for the intercept GDI functions.
[0018] FIG. 6 is a flow diagram of a template for the share GDI functions.
[0019] FIG. 7 is a flow diagram of the Update Sender portion of the Update Sender/Receiver component.
[0020] FIG. 8 is a flow diagram of the Update Receiver portion of the Update Sender/Receiver component.
[0021] FIG. 9A is a block diagram illustrating the order queue and the screen list.
[0022] FIGS. 9B through 9J illustrate examples of optimizing order and screen list entries.
[0023] FIG. 10 is a flow diagram of the Output GDI routine.
[0024] FIG. 11 is a flow diagram of the Queue Order routine.
[0025] FIG. 12 is a flow diagram of the Setup New Order routine.
[0026] FIG. 13 is a flow diagram of the Get Starting Point routine.
[0027] FIG. 14 is a flow diagram of the Spoil Orders routine.
[0028] FIG. 15 is a flow diagram of the Store Screen Data routine.
[0029] FIG. 16 is a flow diagram of the Forced Merge routine.
[0030] FIG. 17 is a flow diagram of the Adjust routine.
[0031] FIG. 18 is a flow diagram of the Spoil Orders With Screen Data routine.
[0032] FIG. 19 is a flow diagram of the Transmit Output Data routine.
[0033] FIG. 20 is a flow diagram of the Send Order Entry routine.
[0034] FIGS. 21A-21D illustrate the order encoding process of the Share System.
[0035] FIG. 22 is a flow diagram of the Encode Order routine.
[0036] FIG. 23 is a flow diagram of the Send Bitmap routine.
[0037] FIG. 24 is a flow diagram of the Should Cache routine.
[0038] FIGS. 24A-24C illustrate differential encoding of screen data.
[0039] FIG. 25 is a flow diagram of the Encode Bitmap routine.
[0040] FIG. 26 is a flow diagram of the XOR Screen Data routine.
[0041] FIG. 27 is a flow diagram of the Encode Runs routine.
[0042] FIG. 28 is a flow diagram of the Idle Mode Encoding routine.
[0043] FIG. 29 is a flow diagram of the Background Run Encoding routine.
[0044] FIG. 30 is a flow diagram of the Foreground Run Encoding routine.
[0045] FIG. 31 is a flow diagram of the Dithered Run Encoding routine.
[0046] FIG. 32 is a flow diagram of the Foreground-Background Image Encoding routine.
[0047] FIG. 33 is a flow diagram of the Receive Font List routine.
[0048] FIG. 34 is a flow diagram of the Font Match routine.
[0049] FIG. 35 is a flow diagram of the Process Pixel Depth Message routine.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIG. 1 is a block diagram of a computer system on which the Share System executes. The computer system includes a central processing unit (CPU) 102 , a memory 104 , input devices 114 , and an output device 116 . The input devices are preferably a keyboard and a mouse, and the output device is preferably a display device, such as a CRT. The CPU, memory, input devices, and output device are interconnected by bus 118 . The memory contains application programs 108 , the Share System 106 , and an operating system 110 . In a preferred embodiment, the operating system is Windows of Microsoft Corporation. The architecture of the Windows operating system is fully described in “Programming Windows 3.1” by Charles Petzold, Microsoft Press, 1992, which is hereby incorporated by reference.
[0051] FIG. 2 is a diagram illustrating the sharing of an application program under control of the Share System. The host computer system 210 includes a keyboard 211 , a mouse 212 , and a display 213 . The display 213 shows the host window 214 for the application program that is being shared (the “shared application”). In this example, the application program entitled “WORD” is being shared and is executing on the host computer system. The data of the shared application output is being displayed in a host window 214 . The Share System intercepts the output data of the shared application that is directed to the host window 214 . The Share System transmits the intercepted output data to the shadow computer system 220 . The Share System also forwards the intercepted output data to the operating system of the host computer system to be displayed in a normal manner within host window 214 . The shadow computer system includes a keyboard 221 , a mouse 222 , and a display 223 . When the shadow computer system receives the intercepted output data, the Share System of the shadow computer system creates a shadow window 224 that corresponds to the host window 214 and that is registered with the operating system of the shadow computer system. The Share System then forwards the intercepted output data to operating system of the shadow computer system for display in the shadow window 224 . Thus, all output data of the shared application is displayed on both the host and shadow computer systems.
[0052] In addition, the Share System allows a user of either the host computer system or the shadow computer system to input data to the shared application. A user inputs data by first “taking control” of the shared application. For example, a user of the shadow computer system can click a mouse button to take control of the shared application. The user can then enter data using keyboard 221 . The Share System of the shadow computer system intercepts the input data and transmits the input data to the Share System of the host computer system. The Share System of the host computer system forwards intercepted input data to the operating system of the host computer system, which sends the input data to shared application for processing as if the input data had been entered on keyboard 211 . When the shared application outputs data to host window 214 in response to receiving the input data, the Share System of the host computer system intercepts the output data and transmits the intercepted output data to the Share System of the host computer system, which updates shadow window 224 as described above. Similarly, when a user of the host computer system takes control and inputs data through keyboard 211 or mouse 212 , the Share System of the host computer system forwards the input data to the operating system of the host computer system, which sends the input data to the shared application for processing as normal. Thus, to a user of the shadow computer system, the shared application looks as though it is executing on the shadow computer system.
[0053] FIG. 3 is a block diagram of the architecture of the Share System executing on both the host and shadow computer systems. The function of the Share System is divided into three tasks that execute on the host computer system and two tasks that execute on the shadow computer system. On the host computer system, the first task corresponds to the execution of the shared application 301 , the second task corresponds to the execution of a controlling task 302 , and the third task corresponds to the execution of a network transport task 303 . When the Share System is initially installed on the host computer system, the Share System inserts various hooks in the operating system to allow the Share System to intercept input and output data and to forward intercepted data to the operating system.
[0054] In the following, an overview of aspects of the preferred operating system is described that relate to the installation of the hooks. In the described embodiment, the hooks are installed on a computer system operating under the control of the Windows operating system. Other operating systems typically provide mechanism for intercepting input and output data. Thus, one skilled in the art would appreciate that the principles of the present invention can be used in conjunction with differing operating systems. The Windows operating system provides a standard graphical device interface (GDI) layer, which is used by applications to output data to display devices, and a standard device driver (DD) layer, which is used to handle device interrupts. The standard GDI layer provides various functions that can be called by an application program to output data to a display device. For example, the standard GDI layer may provide a function for displaying a specified string of text at a specified display location in a specified font. The standard GDI layer is typically linked at run time into the address space of each application program that calls its functions. The standard DD layer provides various device drivers to handle interrupts and to forward input data to the operating system.
[0055] To intercept output data, the Share System installs an intercept GDI layer 301 B in place of the standard GDI layer 301 C provided by the operating system. The intercept GDI layer provides an intercept function for each function of the standard GDI layer. Each intercept function has a prototype that is identical to the prototype of the corresponding standard function. In this way, a shared application 301 A (actually all applications whether shared or not) is linked to the intercept GDI layer when the application is loaded, rather than the standard GDI layer. Thus, all calls directed to the standard GDI layer are actually calls to the intercept GDI layer. The called intercept GDI function either calls to the corresponding standard GDI function or calls a share GDI layer 301 D provided by the Share System. The share GDI layer contains a function for each function of the standard GDI layer that the Share System needs to intercept. (The Share System would not need to intercept a GDI function that only returns status information.) The share GDI functions store data describing the called GDI function and its parameters in an intercept storage area 302 A. The share GDI function also invokes the corresponding standard GDI function to the output data to the host window.
[0056] Periodically, the controlling task 302 receives control. The controlling task retrieves the data stored on the intercept storage area and packets the data for transmission to the shadow computer system. The packeted data is forwarded to the network transport task 303 . The network transport task 303 then transmits the packeted data to the shadow computer system 310 . The network transport task 313 of the shadow computer system receives the packeted data and forwards it to the controlling task 312 of the shadow computer system, which unpackets the data and controls the displaying of the output data in the shadow window.
[0057] To support displaying the output data, the shadow computer system maintains a shadow bitmap 312 A. The shadow bitmap contains an in memory copy of the shared window of the host computer system. All updates to the host window are reflected in both the shadow bitmap and the shadow window. The shadow bitmap is used for handling “paint” messages received from the operating system of the shadow computer system. The operating system sends a paint message to a window (via a window procedure for the window) whenever a portion of the window that was previously obscured and has now become visible. The window is responsible for repainting the now visible portion. Thus, whenever a paint message is received by the shadow window, the shadow window retrieves the output data for the repaint from the shadow bitmap. Thus, when the controlling task receives output data it stores the data in the shadow bitmap and notifies the operating system that the displayed shadow window (or a portion of it) is no longer valid. The operating then generates a “paint” message that is sent to the shadow window. When the shadow window receives the paint message, the shadow window is updated.
[0058] The Share System installs an intercept DD layer 315 A to intercept calls from the standard DD layer 315 to the operating system. When a user of the shadow computer system inputs data for the shared application, the standard device driver for the input device is executed which calls the intercept DD layer. The intercept device driver stores the input data into a local queue and forwards the interrupt to the operating system to process the input data as normal by generating a message to send to the shadow window describing the input data. The controlling task intercepts all messages generated by the operating system that are directed to an application program. When a message is intercepted that is directed to the shadow window, the controlling task 312 retrieves the corresponding input data from the local queue that caused the intercepted message to be generated. The controlling task then packets the input data and forwards the packeted input data to the network transport task 313 . The network transport task then transmits the packeted input data to the network transport task 303 of the host computer system. The network transport task 303 forwards those packeted input data to the controller task 302 of the host computer system. The controlling task stores the input data in a remote queue 307 . The controlling task 302 retrieves the input data from the remote queue 307 forwards the input data to the operating system. The operating system then generates messages corresponding to the input data and sends the messages to the host window. In this way, the shared application treats input data entered on the shadow computer system as if they were generated locally at the host computer system.
[0059] FIG. 4 is a block diagram illustrating the components of the controlling tasks. The controlling tasks contain several components: a packet router, update sender/receiver, input manager, desktop scroller, shadow window presenter, control arbitrator, active window coordinator, and shared window list manager. Since the Share System on both the host computer system and the shadow computer system have the same components, the computer systems can function as both a host computer system and a shared computer system simultaneously. That is, a computer system can be executing a shared application and displaying a shadow window of another shared application program that is executing on a another computer system. The network transport task receives network messages and forwards the message to the packet router. The packet router processes messages relating to input and output data by invoking the appropriate other components to handle the messages. The patent application U.S. patent application Ser. No. ______, entitled “Method and System for Sharing Applications Between a Host Computer System and a Shadow Computer System,” which was filed concurrently with the present application describes these components in more detail, and is hereby incorporated by reference.
[0060] FIG. 5 is a flow diagram of a template for the intercept GDI functions. For each function of the standard GDI layer, the intercept GDI layer contains a corresponding function with the same prototype. The intercept GDI functions either invoke the corresponding share GDI function or standard GDI function. If the Share System needs to intercept the GDI function, then the intercept GDI function invokes the share GDI function passing the parameters it was passed. Otherwise, the intercept GDI function invokes the standard GDI function passing the parameter it was passed. The intercept GDI function then returns.
[0061] FIG. 6 is a flow diagram of a template for the share GDI functions. The share GDI functions store output data in the intercept storage area in the form of “orders” or “screen data” and call the corresponding standard GDI function to send the output data to the host window as normal. In step 601 , the share GDI function invokes the corresponding standard GDI function passing the parameters that it was passed. In step 602 , if the GDI function is being invoked by a shared application, then the function continues at step 603 , else the function returns. Recall that since the intercept GDI layer replaces the standard GDI layer all applications are linked into the intercept GDI layer whether shared or not. In step 603 , the share GDI function calls the Output GDI routine, which stores output data in the intercept storage area and returns.
[0062] FIG. 7 is a flow diagram of the Update Sender portion of the Update Sender/Receiver component. The controlling task receives control periodically and invokes the Update Sender. The Update Sender retrieves the output data from the intercept storage area, prepares the output data for transmission, and forwards the prepared output data to the network transport layer for transmission to the shadow computer system. The Update Sender ensures that the last output data was transmitted to the network by the network transport layer. Thus, the Share System ensures that the intercept storage area is not flushed too quickly so that the data can be optimized before transmission. In step 701 , if an acknowledgment has been received for the last output data transmitted, then the Update Sender continues at step 702 , else the Update Sender returns. In step 702 , if there is output data in the intercept storage area to transmit, then the Update Sender continues at step 703 , else the Update Sender returns. In step 703 , the Update Sender invokes the Transmit Output Data routine and returns. The Transmit Output Data routine prepares the output data by compressing and encoding the output data before transmitting to the shadow computer system.
[0063] FIG. 8 is a flow diagram of the Update Receiver portion of the Update Sender/Receiver component. The controlling task receives control periodically and the packet router calls the Update Receiver when output data is received. In step 801 , the Update Receiver calls the Receive Output Data routine to retrieve the output data received by the network transport task of the shadow computer system. The Receive Output Data routine decodes and decompresses the transmitted output data. In step 802 , the Update Receiver stores the output data in the shadow bitmap. In step 803 , the Update Receiver notifies the operating system that a portion of the Shadow window is invalid and returns.
[heading-0064] Storing Intercepted Output Data
[0065] The Share System, upon intercepting a GDI function, stores the output data representing the GDI function and its parameters in the intercept storage area. The Share System translates the GDI function call to either “orders” or “screen data” that represent the GDI function call. An order represents an output data request, such as, to display a specified text string at a specified display location in a specified font. Screen data represents a bitmap within the host window. The intercept storage area contains an order queue for queuing the orders and a screen list for storing references to the screen data in the host window. Each GDI function call is translated into corresponding orders to be performed by the shadow computer system. If the shadow computer system cannot support the orders corresponding to a GDI function call or if the GDI function call is too complex, then the output data corresponding to the GDI function call is represented by screen data. The screen data represents that portion of the host window that is affected by the GDI function call. For example, if the shadow computer system does not support the same font as specified in a GDI function call to display text, then the Share System translates the GDI function call to a reference to screen data and stores the reference in the screen list If the shadow computer system does support the font, then an order is placed in the order queue.
[0066] FIG. 9A is a block diagram illustrating the order queue and the screen list. The order queue 9 A 10 contains order entries 9 A 11 , 9 A 12 , and 9 A 13 that represent orders that have not yet been transmitted to the shadow computer system. Each entry in the order queue contains an order field, a set of spoil flags, and the coordinates of the bounding rectangle affected by the order. The order field is subdivided into an order type and various subfields. The order type indicates the type of the order to be performed (e.g., display text). The subfields are the parameters for the order. For example, the parameters for display text order would include a pointer to the text to display, the location at which to display the text, and an indication of the font in which to display the text.
[0067] The screen list 9 A 20 contains an entry 9 A 21 , 9 A 22 , and 9 A 23 for each screen data that is not yet transmitted to the shadow computer system. The screen list entries contain the coordinates of the screen data within the display bitmap.
[0068] Before adding entries to either the order queue or the screen list, the Share System attempts to optimize the data stored in the entries so as to minimize data transmission. For example, if screen data added to the screen list completely encompasses screen data already in the screen list then the screen list entry corresponding to the encompassed screen data is removed from the screen list. An order or screen data that has not yet been transmitted and whose visual effect is completely overwritten by a subsequent GDI function call is referred to as “spoiled.” Similarly, if screen data already in the screen list would be partially overlapped, then the overlapped portion can be removed from the screen data.
[0069] FIGS. 9B through 9J illustrate examples of optimizing order entries and screen list entries. FIG. 9B illustrates the optimization of screen list entries that are partially overlapping. The rectangles in the solid lines indicate screen data currently in the screen list, and the rectangles in the dashed lines indicate screen data to be added to the screen list. Screen data 9 B 01 represents screen data currently in the screen list, and screen data 9 B 02 represents screen data to be added to the screen list. Screen data 9 B 01 is partially overlapped by screen data 9 B 02 . To optimize the transmission of screen data 9 B 01 and 9 B 02 , the Share System adjusts the screen list entry for screen data 9 B 01 to that shown by screen data 9 B 03 , and adjusts screen data 9 B 02 to that shown by screen data 9 B 04 . The Share System then adds a screen list entry for screen data 9 B 04 . As a result, no screen data that is overlapped is transmitted to the shadow computer system. Alternatively, the Share System could have added a screen list and entry for 9 B 02 in its entirety, and truncated the screen list entry for the screen data 9 B 01 . Screen data 9 B 05 also represents screen data currently in the screen list, and screen data 9 B 06 represents screen data to be added to the screen list. Screen data 9 B 05 is partially overlapped by screen data 9 B 06 . To optimize the transmission, the Share System divides screen data 9 B 06 into screen data 9 B 08 A and 9 B 08 B, which are portions that do not overlap screen data 9 B 05 . Alternatively, the Share System could transmit screen data 9 B 06 in its entirety and divide screen data 9 B 05 into the non-overlapped portions.
[0070] FIGS. 9C through 9J illustrate further optimizations performed by the Share System. The optimizations included removing spoiled orders, that is, orders that are completely overwritten by subsequent orders or completely within screen data in the screen list. In FIG. 9C , the bitmap 9 C 01 represents a 50×30 pixel host window. The screen data within the bounding rectangle 9 C 02 is to be transmitted to the shadow computer system. Thus, the screen list contains an entry with the coordinates for the bounding rectangle 9 C 02 . FIG. 9D illustrates that a GDI function to display the letter “A” has been called. The letter “A” is stored in the bitmap 9 C 01 in the bounding rectangle 9 C 03 . The order queue contains an entry corresponding to the letter “A”.
[0071] FIG. 9E shows the bitmap 9 C 01 after the letter “B” has been stored in bounding rectangle 9 C 04 . The order queue is shown with an order entry corresponding to the letter “B”. FIG. 9F illustrates when a non-opaque GDI function overwrites bounding rectangle 9 C 04 . The letter “S” is stored in non-opaque mode within bounding rectangle 9 C 05 . Although the bounding rectangle 9 C 05 completely encompasses bounding rectangle 9 C 04 , the order entry corresponding to the bounding rectangle 9 C 04 is left in the order queue because its visual effect is merged with that of bounding rectangle 9 C 05 , rather than overwritten FIG. 9G illustrates when a GDI function in opaque mode overwrites a bounding rectangle for an order entry. In this example, the GDI function is to fill in a rectangle in a solid color. The bounding rectangle 9 C 06 completely overwrites bounding rectangles 9 C 04 and 9 C 05 . The Share System detects that the order entries corresponding to bounding rectangles 9 C 04 and 9 C 05 are therefore spoiled, and removes them from the order queue. The Share System then stores an order entry representing the bounding rectangle 9 C 06 in the order queue. FIG. 9H illustrates when screen data overwrites the effect of an order entry. In this example, an order entry corresponding to the bounding rectangle 9 C 07 is placed in the screen list. The bounding rectangle completely overwrites the bounding rectangle 9 C 03 . Thus, the order entry corresponding to the bounding rectangle 9 C 03 is removed from the order queue. FIG. 9I illustrates when screen data overlaps other screen data in the screen list In this example, bounding rectangle 9 C 08 completely overlaps bounding rectangle 9 C 06 and partially overlaps bounding rectangle 9 C 07 . The Share System stores an entry in the screen list corresponding to bounding rectangle 9 C 08 , removes the screen list entry for bounding rectangle 9 C 06 , and adjusts the screen list entry for bounding rectangle 9 C 07 to not include the portion of the bounding rectangle 9 C 07 that is partially overlapped by bounding rectangle 9 C 08 . FIG. 9J illustrates screen data that completely overlaps all the other screen data on the screen list and all the orders. All entries are removed from both the order queue and screen list, and a screen list entry for bounding rectangle 9 C 09 is added.
[0072] FIG. 10 is a flow diagram of the Output GDI routine. The Output GDI routine is called by the share GDI function to store orders or screen data that corresponds to the GDI function and its parameters in the intercept storage area. In step 1001 , if the intercepted GDI function would result in no effect in the host window, then the Output GDI routine returns, else the Output GDI routine continues at step 1002 . An intercepted GDI function would have no effect if, for example, text to be output is a null string or the rectangle to display has all corners that coincide. In step 1002 , if the intercepted GDI function is executable as an order on the shadow computer system, then the Output GDI routine queues the order in step 1003 by calling the Queue Order routine, else the Output GDI routine stores the effect of the intercepted GDI function as screen data in step 1004 by invoking the Store Screen Data routine. If the order queue is full, the Output GDI routine preferably calls the Store Screen Data routine regardless as to whether the intercepted GDI function is executable as an order on the shadow computer system. Thus, the screen list acts as an overflow for the order queue. The screen list typically cannot become full because the area of bounding rectangle of an existing screen list entry can be increased to encompass the entire host window. The order queue can become full if the shared application outputs a large volume of data rapidly or because the shadow host computer cannot receive anymore transmissions (e.g., its buffers are full). The Output GDI routine then returns.
[0073] FIGS. 11-14 are flow diagrams describing the function of queuing an order. FIG. 11 is a flow diagram of the Queue Order routine. The Order Queue routine initializes a new order entry, determines if the new order entry would spoil any order entries currently on the order queue, removes any spoiled entries, and adds the new order entry to the order queue. In step 1101 , the routine invokes the Setup New Order routine to create a new order and to return a new order entry. In step 1102 , if the order queue is empty, then the routine continues at step 1105 , else the routine continues at step 1103 . In step 1103 , the Queue Order routine invokes the Get Starting Point routine to determine at which order entry within the order queue to start checking for the spoiled orders. In step 1104 , the. Queue Order routine invokes the Spoil Order routine to locate and remove any spoiled orders. In step 1105 , the routine adds the new order entry to the order queue and returns.
[0074] FIG. 12 is a flow diagram of the Setup New Order routine. The Setup New Order routine creates an order entry and sets the order field, the spoil flags, and the bounding rectangle. The spoil flags contain three flags: spoiler, spoilable, and blocker. The spoiler flag indicates that the order would completely overwrite all data within the bounding rectangle. The spoilable flag indicates that this order can be overwritten by subsequent orders. The blocker flag indicates that this order relies on the effect of a previous order (e.g., a screen to screen copy). Thus, any order previous to an order with a blocker flag set cannot necessarily be removed from the order queue. In step 1201 , the Setup New Order routine allocates a new order entry. In step 1202 , the routine sets the bounding rectangle for the new order entry. In step 1203 , if the new order entry fully overwrites (i.e., an opaque overwrite) the bounding rectangle, then the routine sets the spoiler flag to TRUE in step 1204 . In step 1205 , if the new order entry can safely be overwritten by a subsequent order, then the routine sets the spoilable flag to TRUE in step 1206 . In step 1207 , if the new order entry relies on the effect of a previous order, then the routine sets the blocker flag to TRUE. The Setup New Order routine then returns.
[0075] FIG. 13 is a flow diagram of the Get Starting Point routine. The Get Starting Point routine determines which is the most recent order entry placed in the order queue that does not have its blocker flag set to TRUE. The only orders that can be safely removed are those orders which are subsequent to the last order with its blocker flag set to TRUE. In step 1301 , the Get Starting Point routine selects the last (newest) order entry placed in the order queue. In step 1302 , if the order queue is empty, then the routine returns an indication that the order queue is empty, else the routine continues at step 1303 . In step 1303 , if the selected order entry is a blocker (i.e., has its blocker flag set to TRUE), then the routine returns the previous order entry selected, else the routine continues at step 1304 . In step 1304 , if all the order entries have already been selected, then the start of the order queue is reached and the routine returns the first (oldest) order entry in the order queue, else the routine continues at step 1305 . In step 1305 , the Get Starting Point routine selects the next order entry in the order queue and loops to step 1303 .
[0076] FIG. 14 is a flow diagram of the Spoil Orders routine. The Spoil Orders routine is passed a reference to the queue entry at which to start checking for spoiled orders. The Spoil Orders routine checks each newer order entry to determine if it spoiled and, if so, removes the order entry from the order queue. In step 1401 , if the end of the order queue has been reached, then the routine returns, else the routine continues at step 1402 . In step 1402 , if the bounding rectangle of the new order entry completely overwrites the bounding rectangle of the selected order entry, then the routine continues at step 1403 , else the routine continues at step 1404 . In step 1403 , the Spoil Orders routine removes the selected order from the order queue. In step 1404 , the Spoil Orders routine selects the next newer order in the order queue and loops to step 1401 .
[0077] FIGS. 15-18 are flow diagrams illustrating storing screen data in the screen list. FIG. 15 is a flow diagram of the Store Screen Data routine. The Store Screen Data routine determines whether the new screen data can be merged with other screen data in the screen list. Next, the Store Screen Data routine determines whether any of the screen list entries need to be adjusted to remove overlapping areas of the host window. Finally, the Store Screen Data routine determines whether any orders entries are spoiled by the screen data. In step 1501 , the Store Screen Data routine creates a new screen list entry. In step 1502 , the routine initializes the bounding rectangle to refer to the screen data in the host window. In step 1503 , if the screen list is already full, then the routine invokes the Forced Merge routine in step 1504 , else the routine continues at step 1505 . The Forced Merge routine merges the new screen data with the screen data of a screen list entry. That is, the bounding rectangle of the new screen data is adjusted to encompass the bounding rectangle of that screen list entry. That screen list entry is then removed from the screen list to make room for the new screen list entry. In step 1505 , the Store Screen Data routine selects the first screen list entry. In step 1506 , if the end of the screen list is reached, then the routine continues at step 1513 , else the routine continues at step 1507 . In step 1507 , if the new screen data overlaps the screen data of the selected screen list entry, then the routine continues at step 1509 , else the routine selects the next screen list entry and loops to step 1506 . In step 1509 , the Store Screen Data routine invokes the Adjust routine. The Adjust routine divides the overlapping screen data in an attempt to prevent transmission of redundant screen data. In step 1510 , if the Adjust routine results in the new screen data being completely merged with screen data already in the screen list, then the routine returns, else the routine continues at step 1511 . In step 1511 , if there was a change in the bounding rectangle of the new screen list entry, then the routine loops to step 1505 to continue the processing at the start of the order queue, else the routine continues at step 1512 . In step 1512 , if the end of the screen list has been reached, then the routine continues at step 1513 , else the routine continues at step 1508 . In step 1513 , the Store Screen Data routine adds the new screen list entry to the screen list. In step 1514 , the Store Screen Data routine invokes the Spoil Orders With Screen Data routine and returns. The Spoil Orders With Screen Data routine checks if the new screen data spoils any order entries.
[0078] FIG. 16 is a flow diagram of the Forced Merge routine. The Forced Merge routine is invoked when the screen list is full, and it selects which screen list entry to merge with the new screen list entry and removes the selected screen list entry from the screen list. The Forced Merge routine selects the screen list entry that when merged with the new screen list entry results in an area of the bounding rectangle that is the smallest. In step 1601 , the Forced Merge routine selects the first screen list entry. In step 1602 , the Forced Merge routine initializes a loop for finding the smallest merged bounding rectangle that results from merging each of the screen list entries with the new screen list entry. In step 1602 , the smallest bounding rectangle area found so far is initialized to the area of the shadow window and the merge-with screen list entry is set to point to the first screen list entry. At the end of the processing, the merge-with screen list entry points to the screen list entry that when merged with the new screen list entry results in the smallest merged bounding rectangle. In step 1603 , the Forced Merge routine calculates the area of the bounding rectangle that would result if the selected screen list entry was merged with the new screen list entry. In step 1604 , if the calculated area is less than the smallest bounding rectangle area found so far, then the routine continues at step 1605 , else the routine continues at step 1606 . In step 1605 , the Forced Merge routine sets the smallest bounding rectangle area found so far to the calculated area and saves a pointer to the selected screen list entry as the merge-with screen list entry. In step 1606 , the Forced Merge routine selects the next screen list entry. In step 1607 , if all the screen list entries have already been selected, then the routine continues at step 1608 , else the routine loops to step 1603 . In step 1608 , the Forced Merge routine merges the merge-with screen list entry into the new screen list entry. In step 1609 , the Forced Merge routine removes the merge-with screen list entry from the screen list and returns.
[0079] FIG. 17 is a flow diagram of the Adjust routine. The Adjust routine adjusts the new screen data or the screen data already in the screen list to remove overlap. In step 1701 , if the new screen data overlaps and splits the selected screen data into two portions, then the routine continues at step 1702 , else the routine continues at step 1705 . In step 1702 , the Adjust routine removes the selected screen list entry from the screen list. In steps 1703 and 1704 , the Adjust routine recursively calls the Store Screen Data routine to add back into the screen list each non-overlapped portion of the selected screen data and then returns. In step 1705 , if the new screen data fully overlaps the selected screen data, then the routine continues at step 1706 , else the routine continues at step 1707 . In step 1706 , the Adjust routine removes the selected screen list entry and returns. In step 1707 , if either the new screen data or the selected screen data can be adjusted to remove the overlap, then the routine in step 1708 removes the overlap. The Adjust routine then returns.
[0080] FIG. 18 is a flow diagram of the Spoil Orders With Screen Data routine. The Spoil Orders With Screen Data routine creates an order entry with a bounding rectangle corresponding to the new screen data and checks for which order entries that created order would spoil. In step 1801 , the routine creates an order entry with the same bounding rectangle as the new screen data. In step 1802 , the routine invokes the Get Starting Point routine. In step 1803 , the routine invokes the Spoil Orders routine and returns.
[heading-0081] Transmitting Output Data
[0082] FIG. 19 is a flow diagram of the Transmit Output Data routine. The Transmit Output Data routine is invoked to transmit orders and screen data from the host computer system to the shadow computer system. In a preferred embodiment, multiple orders and screen data are stored in a single network packet to improve network performance. Also, large areas of screen data may not fit into a single packet and are thus stored in multiple packets. In step 1901 , the Transmit Output Data routine removes the next order entry from the order queue. In step 1902 , the routine invokes the Send Order Entry routine, which encodes the order and transmits the order to the shadow computer system. In step 1903 , if the order was sent successfully, then the routine continues at step 1905 , else the routine re-queues the order in step 1904 and returns. An order might not be sent successfully if the shadow computer system indicates that it has no space to store the order. In step 1905 , if the order queue is empty, then the routine continues at step 1907 to send the screen data, else the routine loops to step 1901 to send the next order. In step 1907 , the Transmit Output Data routine removes the next screen data from the screen list. In step 1908 , the routine invokes the Encode Bitmap routine to encode the screen data and then sends the encoded screen data. In step 1909 , if the screen data was sent successfully, then the routine continues at step 1910 , else the routine adds the screen list entry back into the screen list and returns. In step 1910 , if the screen list is empty, then the routine returns, else the routine loops to step 1907 to process the next screen list entry.
[0083] FIG. 20 is a flow diagram of the Send Order Entry routine. In steps 2001 , the Send Order Entry routine encodes the order. In step 2002 , the routine sends the encoded order and returns a flag indicating whether the order was sent successfully.
[0084] FIGS. 21A-21D illustrate the order encoding process of the Share System. The Share System maintains an order encoding table 2101 on the host computer system, and an order encoding table 2102 on the shadow computer system. As described above, an order is encoded as an order type and various fields. Rather than transmitting the order type and each of the fields each time an order is transmitted, the Share System transmits the order type along with an indication of which fields have changed since the last transmission of an order of that type and along with only the fields that have changed. For example, if the text string transmitted in the last text string order is the same as the next text string order, then only a flag indicating that the text strings are the same is sent with the next order, rather than the text. string itself The order encoding tables 2101 and 2102 contain an entry for each type of order that has been transmitted along with the field values that were last transmitted with that order type. For example, the last order with a type of 2 that was transmitted had the field values of D, E, and F. The orders 2105 , 2104 , and 2103 represent the next three orders to be transmitted.
[0085] FIG. 21B illustrates the transmission of order 2105 to the shadow computer system. Since the order type of order 2105 is 1 and since the values for the second and third fields B and C correspond to the same values that were sent in the last order of that type, the encoded order 2106 contains an indication of the order type, a series of change flags which indicate that only the first field is changed, and the changed field value L. When the shadow computer system receives the encoded order 2106 , the shadow computer system regenerates the order by removing the flags and adding the received values stored in its order encoding table, and updates the order encoding table as shown in FIG. 21C .
[0086] FIG. 21C illustrates the order encoding of order 2104 . In this example, the second and third field are changed, but the first field is the same as for the last transmission of that order type. FIG. 21D illustrates the order encoding for order 2103 . In this example, all the order fields are the same as the order fields for the last order of type 3 . Thus, only the order type, along with the three flags indicating that the fields are the same as the last order of that type, are transmitted to the shadow computer system.
[0087] FIG. 22 is a flow diagram of the Encode Order routine. The Encode Order routine uses the order encoding table to encode the order to be transmitted. The code is encoded into an encoded message. In step 2201 , the Encode Order routine stores the order type in the encoded message. In step 2202 , the Encode Order routine selects the next field in the order. In step FB 03 , if all fields for the order have already been selected, then the routine continues at step 2209 , else the routine continues at step 2204 . In step 2204 , the Encode Order routine retrieves the values stored in the order encoding table for this order type for the selected field. In step 2205 , if the value of the retrieved field and the selected field are equal, then the routine sets the corresponding flag to 0 in step 2206 and loops to step 2202 , else the routine continues at step 2207 . In step 2207 , the Encode Order routine sets the flag corresponding to a selected field to 1 . In step 2208 , the routine writes the value of the selected field to the encoded message and updates the order encoding table and loops to step 2202 . In step 2209 , the routine invokes the Send Bitmap routine for any bitmap that is part of the order and returns.
[0088] FIG. 23 is a flow diagram of the Send Bitmap routine. To minimize the amount of screen data that is transmitted, the Share System uses a caching technique and an encoding technique to send a bitmap that is part of an order. The same encoding technique is used to encode screen data. The Share System maintains a caching table on both the host computer system and the shadow computer system. When the same bitmap is sent twice to the shadow computer system, the Share System of the host computer system sends a notification to cache the bitmap along with the bitmap. The shadow computer system, when it receives the caching notification, stores the bitmap in its cache table. The host computer system also stores an identification (such as a handle to the memory block in which the bitmap is stored) of the bitmap in its caching table, which is kept in parallel with the cache table of the shadow computer system. The next time the same bitmap is to be sent to the shadow computer system, the Share System sends an identification of the screen data within the cache table, rather than the bitmap itself. The shadow computer system uses the identification to retrieve the bitmap from its cache table. The Share System also encodes the bitmaps it transmits using a compression technique that contains differential encoding and run-length encoding as described below in detail. In step 2301 , the routine invokes the Should Cache routine to determine whether the bitmap should be cached. In step 2302 , if the bitmap should be cached, then the routine continues at step 2305 , else the routine continues at step 2303 . In step 2303 , the Send Bitmap routine invokes the Encode Bitmap routine. In step 2304 , the Send Bitmap routine sends the encoded bitmap to the shadow system and returns. In step 2305 , if the bitmap is already in the cache table, then the routine sends the index into the cache table to the shadow computer system in step 2306 and returns. In step 2307 , if the bitmap is in the candidate list, then the routine continues at step 2308 , else the routine continues at step 2311 . The candidate list contains a list of identification of the bitmaps that have been sent only once to the shadow computer system. If the bitmap in the candidate list or cache table is changed or deleted, then the Share System intercepts the GDI function that alters the bitmap, and removes the bitmap from the candidate list and cache table. In step 2308 , the Send Bitmap routine removes the bit from the candidate list and places the bitmap in the cache table. In step 2309 , the routine encodes the bitmap. In step 2310 , the Send Bitmap routine sends the encodedbitmap, and a notification to cache the bitmap to the shadow computer system and returns. In step 2311 , the Send Data routine adds the bitmap to the candidate list. In step 2312 , the routine encodes the bitmap. In step 2313 , the Send Data routine sends the encoded bitmap to the shadow computer system and returns.
[0089] FIG. 24 is a flow diagram of the Should Cache routine. The routine determines whether bitmap should be cached. In step 2401 , if the number of bits per pixel (“pixel depth”) of the bitmap is equal to 1, then the routine returns an indication that the bitmap should not be cached, else the routine continues at step 2403 . In step 2403 , if the bitmap is too large to be cached or the GDI function to generate the bit involves a complex mapping operation, then the routine returns an indication that the screen data should not be cached, else the routine returns an indication that the bitmap should be cached.
[heading-0090] Screen Data Encoding
[0091] The Share System encodes (compresses) screen data (and bitmaps) that is transmitted from a host computer system to the shadow computer system. The encoding is a combination of differential encoding and run-length encoding. Each row of the screen data is differentially encoded with respect to the previous row. After differentially encoding a row, the row is then run-length encoded.
[0092] FIG. 24A is a diagram illustrating sample screen data to be encoded. The screen data represents a 30×24 rectangle of pixels with a pixel depth of four. Thus, each pixel can be one of 16 different colors. The screen data as shown contains six different colors. The outline section 24 A 01 is in the color black; the center “plus” section 24 A 02 is in the color white; and the rectangular sections 24 A 03 - 24 A 06 are in the color 1 , color 2 , color 3 , and color 4 , respectively.
[0093] FIG. 24B illustrates a hexa-decimal representation of the colors of the screen data. The color black is represented by the hexa-decimal value 0 , the color white is represented by the hexa-decimal value f, the color one is represented by the hexa-decimal value a, the color 2 is represented by the hexa-decimal color b, the color 3 is represented by the hexa-decimal value c, and the color 4 is represented by the hexa-decimal value d.
[0094] FIG. 24C is a diagram illustrating the results of differentially encoding the rows. To differentially encode the rows, the Share System performs an exclusive-OR logical operation on each row of the screen data. The exclusive-OR logical operation identifies which bit values are different between one row and the next row. The result of the exclusive-OR is a 1 if the values are different and is a 0 if the values are the same. Row 24 C 01 is represented by color values of all 0 s. The first row is output without performing any exclusive-OR operation. The second row 24 C 02 is the result of exclusive-OR of each pixel of the first row 24 C 01 and the second row 24 C 02 . Since the pixel values in the first row 24 C 01 and the second row 24 C 02 are the sane, the result of the exclusive-OR is row 24 C 02 with all pixel values set to 0. Row 24 C 03 is the result of the exclusive-OR of row 24 C 02 and row 24 C 03 . Since row 24 C 02 is all 0s, the result of the exclusive-OR identifies those bits that were set to 1 in row 24 C 03 . Thus, the result is the same as the value row 24 C 03 . Row 24 C 04 represents the exclusive-OR of rows 24 C 03 and 24 C 04 . Since rows 24 C 03 and 24 C 04 have the same color values, the exclusive-OR is a value 0, as shown in row 24 C 0 . Similarly, since rows 24 C 04 through 24 C 11 are the same as each previous row, each of the results is a row of all 0s, as shown in rows 24 C 05 - 24 C 11 . Row 24 C 12 is the result of the exclusive-OR of each pixel of row 24 C 11 with the corresponding pixel of row 24 C 12 . The Share System continues in a similar manner to differently encode the remaining rows of the screen data.
[0095] As shown in FIG. 24B , the result of the is that the differentially encoder is the screen data transferred to have long run of 0s. Thus, each row can be compressed using run-length encoding.
[0096] The Share System encodes the pixels in the following formats:
1. Background run 2. Foreground run 3. Dithered run 4. Foreground/Background image 5. Color Image
[0102] The background run format is used to encode a run of pixels with the value of 0. The foreground run format is used to encode a run of pixels that have a non-zero value. The dithered run format is used to encode a run of pixels that alternate between two values. The foreground/background image format is used to encode a run of pixels that have only the value 0 and one non-zero value. The color image format is used to encode a run of pixels that do not fit into one of the other formats. Each of the formats, except for the dither run format, have a short form and a long form. The short form is used to encode shorter runs and the long form is used to encode longer runs. Table 1 illustrates the runlength encoding of the Share System.
TABLE 1 Background Run Foreground Run Dithered Run Foreground-Background Image Color Image Mega Background Run Mega Foreground Run Mega Foreground- Background Image Mega Color Image Set Foreground Color
[0103] The Share System uses a variable length prefix code to indicate the type of run being encoded. For example, the prefix code of 0 indicates a background run. A prefix code of 1001 indicates a foreground, a prefix code of 10000000 indicates a dithered run, and so on, as shown in Table 1. A background run is encoded in one byte, and indicates a run of pixel values of 0 with a length of up to 127. The foreground run is a one-byte code that indicates a run of up to 15 pixels of the foreground color are being encoded. The current foreground color is established by a one-byte format with the prefix code 1000 followed by the pixel value. The mega (long) background run is encoded in two bytes and encodes runs of the background color of lengths from 128 to 32K (256*128). The length field indicates the number runs of 128. The mega (long) foreground run is encoded in two bytes and used to encodes runs of the foreground color of lengths from 16 to 4K (256*16). The dithered run is encoded in three bytes and encodes alternating pixel values. The length of the dithered run can be up to 512 pixels, as indicated in the second byte, and the colors in the dithered run are represented by the values in the third byte. The remaining formats are encoded as illustrated in Table 1.
[0104] FIG. 25 is a flow diagram of the Encode Bitmap routine. In step 2501 , the Encode Bitmap routine invokes the XOR Screen Data routine, which generates temporary screen data that contains the exclusive-OR of each pixel in each row of the screen data with the corresponding pixel in the previous row. In step 2502 , the Encode Bitmap routine invokes the Encode Runs routine, which encodes the temporary screen data and returns.
[0105] FIG. 26 is a flow diagram of the XOR Screen Data routine. In step 2601 , the XOR Screen Data routine initializes variables for looping through the screen data. The temporary screen data is stored as simply a sequence of pixel values. The variable curRow points to the current row, and the variable curCol points to the current column in the screen data. Each column is one pixel wide. In step 2602 , the XOR Screen Data routine increments the current column to point to the next column. In step 2603 , if the current column is greater than the number of columns in a row, then the routine continues at step 2604 , else the routine continues at step 2605 . In step 2604 , the XOR Screen Data routine selects the first column of the next row. In step 2605 , if the current row is greater than the number of rows of screen data, then the routine returns, else the routine continues at step 2606 . In step 2606 , if the current row selected is 0 , then the routine continues at step 2607 , else the routine continues at step 2608 . In step 2607 , the XOR Screen Data routine copies the first row of screen data to the temporary screen data without performing any exclusive-OR. In step 2608 , the XOR Screen Data routine sets the next pixel value in the temporary Screen data to the exclusive-OR of the currently selected pixel with the corresponding pixel in the previous row. The XOR Screen Data loops to step 2602 to select the next column.
[0106] FIG. 27 is a flow diagram of the Encode Runs routine. In a preferred embodiment, the encode runs routine is implemented as a state machine. The modes (states) of the machine are: idle, background run, foreground run, dithered run, foreground-background image, and color image. The idle mode indicates that the routine is determining what type of run to encode next. The background run mode indicates that a background run is to be encoded, the foreground run mode indicates that a foreground run is to be encoded, and so on. In step 2701 , the Encode Runs routine initializes the index into the temporary screen data, the variable max (which indicates the number of pixels in the temporary screen data), the foreground color to hexadecimal value f, and the mode to idle. In steps 2702 - 2716 , the Encode Runs routine loops, executing the state machine. In step 2702 , if the index into temporary screen data is greater than the maximum number of pixels, then the routine returns, else the routine continues at step 2703 . In step 2703 , if the index into the temporary screen data is within eight of the maximum number of pixels, then the routine continues at step 2710 , else the routine continues at step 2704 . In step 2703 A, the Encode Runs routine invokes the Finish Encoding routine to complete the encoding of the screen data. In steps 2704 - 2708 , the Encode Runs routine determines the current mode and invokes the corresponding routine to process that mode in steps 2711 - 2716 . After the return from the routine to process the mode, the Encode Runs routine loops to step 2702 .
[0107] FIG. 28 is a flow diagram of the Idle Mode Encoding routine. The Idle Mode Encoding routine looks at the next eight pixels in the temporary screen data to determine the mode to enter. If all eight pixels are black (a 0 pixel value), then the routine enters the background run mode. If all eight pixels are of one color, then the routine enters the foreground run mode. If all the colors are black and one other color, then the routine enters the foreground-background run. If all the pixels alternate between two colors, then the routine enters the dithered run mode. Otherwise, the Idle Mode Encoding routine enters the color image mode. In step 2801 , the idle mode encoding routine selects the next eight pixels. In step 2802 , if all the selected pixels are black, then the routine continues at step 2803 , else the routine continues at step 2804 . In step 2803 , the Idle Mode Encoding routine sets the mode to background run, saves the position of the start of the run, increments the current index into temporary screen data to point to the next set of eight pixels, and returns. In step 2804 , if all the selected pixels are one color, the routine continues at step 2805 , else the routine continues at 2808 . In step 2805 , if the color of the selected pixels equals the current foreground color, then the routine continues at step 2806 , else the routine resets the foreground color in step 2807 , and then continues at step 2806 . In step 2806 , the Idle Mode Encoding routine sets the mode to foreground run, saves the position of the start of the run, and increments the current index and returns. In step 2808 , if all the selected pixels are either black and one other color, then the routine continues at step 2809 , else the routine continues at step 2812 . In step 2809 , if the current foreground color is not equal to the other color, then the routine resets the foreground color in step 2811 and continues at step 2810 . In step 2810 , the Idle Mode Encoding routine sets the mode to foreground-background run, saves the start of the run, increments the current index, and returns. In step 2812 , if the selected pixels alternate between two colors, then the routine continues at step 2813 , else the routine continues at step 2814 . In step 2813 , the Idle Mode Encoding routine sets the start of the run, increments the current index, sets the first and second colors, and returns. In step 2814 , the Idle Mode Encoding routine sets the mode to color image and sets the start of the run, and returns.
[0108] FIG. 29 is a flow diagram of the Background Run Encoding routine. In step 2901 , if the next eight pixels in the temporary screen data are all set to the background color, then the routine increments the current index in step 2902 and returns, else the routine continues at step 2903 . In steps 2903 and 2904 , the Background Run Encoding routine determines how many of the next eight pixels are the background color. In step 2905 , the Background Run Encoding routine outputs the run in either background run format, or the mega background run format (depending on the length of the run) sets the mode to idle, and returns. At any point, if the maximum number of pixels in the run exceeds the maximum possible length for mega background run, the routine outputs the mega background run and then continues.
[0109] FIG. 30 is a flow diagram of the Foreground Run Encoding routine. The routine is analogous to the Background Run Encoding routine, except that in 3005 , if the foreground color has changed, then before outputting the run, the Foreground Run Encoding routine outputs a change in foreground color.
[0110] FIG. 31 is a flow diagram of the Dithered Run Encoding routine. The Dithered Run Encoding routine is analogous to the Background Run Encoding routine. However, the test for determining whether the run is being extended is whether the next pixels alternate between color 1 and color 2 .
[0111] FIG. 32 is a flow diagram of the Foreground-Background Image encoding routine. In step 3201 , if the next eight pixels are all of the background and foreground colors, then the routine continues at step 3202 , else the routine continues at step 3203 . In step 3202 , the Foreground-Background image encoding routine advances the current index past the next eight pixels and returns. In step 3203 , the foreground-background image Encoding Routine Outputs the run, sets the mode to idle, and returns.
[0112] The Color Image Encoding routine and the Finished Encoding routine are not shown in a flow diagram. The Color Image Encoding routine determines whether the color image mode is ending and outputs the color image run, and returns. The Finished Encoding Routine determines whether the run for the current mode can be extended or not. If the run for the current mode can be extended, it is extended. Any remaining pixels are simply encoded as a color image and the routine returns.
[heading-0113] Font Matching
[0114] The Share System preferably ensures that the shadow window displays an exact replica of the data in the host window. Typically, the GDI functions are translated to codes that are sent to the shadow computer system. However, a problem may occur with GDI function that specify text is to be output in a particular font. The problem occurs when the shadow computer system does not support a font that is supported by the host computer system. For example, if the host computer system supports a font with variable width characters, such as Times Roman, and the shadow computer system only supports fixed width fonts, then any text output by the shadow computer system may be a different length than the text output on the host computer system, resulting in a different appearance in the shadow window.
[0115] To solve this problem, the Share System of the host computer system, upon initialization, determines which fonts the shadow computer system supports. If both the host and shadow computer systems support the font specified in a GDI function, then the host computer system translates GDI function to an order that uses the font. If, however, the shadow computer system cannot support that font, then the host computer system generates a screen list entry, rather than an order entry. The screen list entry references the bounding rectangle of the host window that will be used to extract the screen data that results from the rendering of the data in the font. In this way, the Share System minimizes data transmission by transmitting text data as an order when the font is supported, but transmits screen data to ensure that the shadow window is visually consistent with the host window when the font is not supported.
[0116] FIG. 33 is a flow diagram of the Receive Font List routine. The Receive Font List routine is executed by the controlling task whenever a font list message is received at the host computer system from the shadow computer system. The Receive Font List routine stores the font list information which is used to determine whether a certain font is supported. The font list is transmitted as a message with a list of font descriptions. In step 3301 , the Receive Font List routine selects the next font description in the message starting with the first font description. In step 3302 , if all the font descriptions have already been selected, then the routine returns, else the routine continues at step 3303 . In step 3303 , the Receive Font List routine adds the selected font description to the list of font descriptions and loops to step 3301 to select the next font description.
[0117] FIG. 34 is a flow diagram of the Font Match routine. The Font Match routine is invoked to determine whether the shadow computer system supports a font specified in a GDI function. Since the font descriptions may be sent in a series of messages asynchronously, it may take a considerable time to determine all the supported font of the shadow system initially. Consequently, all GDI function that specify a font are converted to screen data until a message indicating the font is received. In this way, the application sharing can proceed even though all the supported fonts have not yet been identified. Alternatively, the Share System encodes all output specifying a font as screen data until all the font descriptions have been received. In step 3401 , the Font Match routine selects the next font description from the list of shadow fonts, starting with the first. In step 3402 , if all the font descriptions have already been selected, then the routine returns a false value, else the routine continues at step 3403 . In step 3403 , if the selected font description matches the font description of the desired font, then the font match routine returns a value true, else the routine loops to step 3401 to select the next font description. A font description contains a name, size, and checksum for the font. Thus, font descriptions match, when the name, size, and checksums match. A checksum of a font is used as a double-check to ensure that a font supported by the host computer system is the same as a font supported by the shadow computer system. Any of well-known checksum techniques can be used to generate the checksum, the checksum is generated on the definition of the font, which may include generating the checksum from each bitmap for each character in the font. Alternatively, the checksum can be generated based on the height and width of each character in the font since the Share System is concerned primarily about those characteristics.
[heading-0118] Pixel Depth
[0119] The Share System selects a pixel depth for transmission of bitmap data that preferably tends to maximize the quality of the data displayed on the shadow window. Typically, a low resolution display device has a translator associated with it that translates from a high pixel depth to one low pixel depth of the display device. Such translators associated with the low resolution device tend to be optimized to ensure that the low resolution data is an accurate representation of the high resolution data. Conversely, those computer systems with high resolution display devices may not have translators that accurately translate from the high resolution to the low resolution. Consequently, to enhance the quality of the display in the shadow window, when the shadow computer system supports a lower resolution display device than the host computer system, the Share System preferably transmits screen data in the high pixel depth to the shadow computer system. The shadow computer system then translates the screen data from the high pixel depth to the low pixel. Although this technique increases the amount of transmission time of screen data, the resulting displayed data more accurately represents the data displayed in the host computer system.
[0120] Upon connection of computer systems, one computer system supplies a list of pixel depths that it supports, along with the pixel depth of its display device. The pixel depth of the display device is the resolution of the display device. Upon receipt of the information, the Share System determines the pixel depth that is common to both the computer systems that is closest to the lowest display pixel depth and uses that as the transmission pixel depth. If however, the transmission pixel depth is 4 and both computer systems support a pixel depth of 8 , then a transmission depth of 8 is used.
[0121] FIG. 35 is a flow diagram of the Process Pixel Depth Message routine. The Process Pixel Depth Message routine is invoked by the controlling task when the computer system receives a message containing the pixel depth information from the other computer system. In step 3501 , the Process Pixel Depth Message routine retrieves the message that contains the display pixel depth of the computer system and the supported pixel depths of the computer system. In step 3502 , the routine sets the transmission depth to that commonly supported pixel depth that is closest to the shadow display depth. In step 3503 , if the display pixel depth is less than the display pixel depth of the computer system, then the routine continues at step 3504 , else the routine returns. In step 3504 , if the selected transmission depth equals 4 and both computer systems support a pixel depth of 8 , then the transmission pixel depth is set to 8 in step 3505 . The Process Pixel Depth Message routine then returns.
[0122] Although the present invention has been described in terms of a preferred embodiment, it is not intended that the invention be limited by this embodiment. Modifications within the spirit of the present invention will be apparent to those skilled in the art. The scope of the present invention is defined in the claims that follow.
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A method and system for compressing bitmap data in a system for sharing an application running on a host computer with a remote computer, wherein the shared application's screen output is simultaneously displayed on both computers. Simultaneous display of screen output is achieved by efficiently transmitting display data between the host computer and the remote computer. When a font used by the host computer for displaying text is not available on the remote computer, the host computer sends a bitmap representation of the text for display, rather than the text itself. Bitmap representations are cached by the remote computer, so that the same bitmap representation need not be repeatedly transmitted from the host computer to the remote computer. Bitmap representations are compressed by the host computer prior to transmission, transmitted, then decompressed by the computer.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/652,426, filed Aug. 31, 2000 which is a division of U.S. patent application Ser. No. 08/977,251, filed Nov. 24, 1997, now U.S. Pat. No. 6,126,847 issued Oct. 3, 2000.
BACKGROUND OF THE INVENTION
The present invention relates to a process for selectively etching one or more oxide layers on a surface of a substrate, and more particularly, to such a process in semiconductor device fabrication to etch silicon oxides.
In the manufacture of semiconductor devices, oxides of silicon are used in many different forms and for different applications. Dense, thermally grown or chemically deposited oxides may find use as dielectric films and insulating layers. Typical of such oxides is the class of tetraethylorthosilicate (TEOS) derived oxides.
Other less dense forms of silicon oxides are also used in semiconductor device fabrication where planarized insulating layers are desired. Examples of these types of oxides include doped oxides such as phosphosilicate glass (PSG), borosilicate glass (BSG), borophosphosilicate glass (BPSG), and boron or phosphorous-doped TEOS. Spin-on glass (SOG) is another porous oxide which is used, especially where planarization is desired.
Many semiconductor manufacturing processes require selective etching to remove one form of silicon oxide (typically a more porous form such as BPSG) in preference to another silicon oxide (typically a dense form such as TEOS) or other material (such as silicon). Where there is a desire for selective etching of different forms of silicon oxides, typically hydrogen fluoride (HF) is used as the primary etchant. However, wet etching using aqueous solutions of HF is not very selective, etching both dense and more porous forms of silicon oxides at similar rates. The art has moved to the use of vapor phase HF etching processes to achieve greater selectivity.
For example, Bergman, U.S. Pat. Nos. 5,235,995, 5,238,500, and 5,332,445 teaches a vapor etch process using a homogeneous mix of HF and water vapor as the etchant gas. Grant et al, U.S. Pat. Nos. 5,234,540 and 5,439,553, teach a vapor phase etching process using HF and an alcohol or organic acid. Mehta, U.S. Pat. No. 5,635,102, teaches a selective etching process which exposes the silicon oxides to alternating pulses of HF gas and inert gas causing selective etching of a porous silicon oxide layer (BPSG) in preference to a dense silicon oxide layer (TEOS). However, while such processes may be selective, some have resulted in an undesirable non-uniform etching of the oxide layers.
One example of a semiconductor fabrication process which requires selective etching of different silicon oxides is the formation of stacked capacitor structures to be used in storage devices such as high-density dynamic random access memories (DRAMs). Such structures are formed using a large silicon wafer as a substrate. Fabrication of these devices requires not only a highly selective etching process, but also one which uniformly etches the oxide layers across the surface of the wafer.
Accordingly, there remains a need in this art for an etching process for oxides having differing densities which is not only highly selective, but also produces uniform etches.
SUMMARY OF THE INVENTION
The present invention meets that need by providing a process for etching oxides having differing densities which is not only highly selective, but which also produces uniform etches. In accordance with one aspect of the present invention, a process is provided and includes the steps of providing an oxide layer on a surface of a substrate, exposing the oxide layer to a liquid comprising a halide-containing species, and exposing the oxide layer to a gas phase comprising a halide-containing species. Preferably, halide-containing species is selected from the group consisting of HF, NF 3 , CIF 3 , and F 2 . In a preferred embodiment of the invention, the halide-containing species comprises HF, and the gas phase includes an alcohol.
The process of the present invention desirably is used to selectively etch a substrate surface in which the surface of the substrate includes on a first portion thereof a first silicon oxide and on a second portion thereof a second silicon oxide, with the first silicon oxide being relatively more dense than the second silicon oxide. In this manner, the steps of exposing the oxide to a liquid comprising a halide-containing species and exposing the oxide to a gas phase comprising a halide-containing species causes the second silicon oxide to selectively etch at a rate greater than the etch rate of the first silicon oxide. In a preferred embodiment, the first silicon oxide comprises a tetraethylorthosilicate derived oxide and the second silicon oxide comprises borophosphosilicate glass. The process of the invention is particularly useful where the second silicon oxide overlies the first silicon oxide, and the first silicon oxide acts as an etch stop layer.
In accordance with another aspect of the invention, a process for etching a layer of a silicon oxide on a substrate is provided and comprises the steps of providing a silicon oxide layer on the surface of a substrate, exposing the silicon oxide layer to a liquid comprising an aqueous solution of hydrofluoric acid, and exposing the silicon oxide layer to a gas phase comprising hydrofluoric acid vapor. In a preferred form, the gas phase includes an alcohol such as methanol to promote a uniform etch.
In this embodiment of the invention, the surface of the substrate preferably includes on a first portion thereof a first silicon oxide and on a second portion thereof a second silicon oxide, with the first silicon oxide being relatively more dense than the second silicon oxide. The steps of exposing the oxide to a liquid comprising an aqueous solution of hydrofluoric acid and exposing the oxide to a gas phase comprising hydrofluoric acid vapor causes the second silicon oxide to selectively etch at a rate greater than the etch rate of the first silicon oxide. Preferably, the first silicon oxide comprises a tetraethylorthosilicate derived oxide and the second silicon oxide comprises borophosphosilicate glass. Where the second silicon oxide overlies the first silicon oxide, the first silicon oxide acts as an etch stop layer.
The process of the present invention finds use in the fabrication of semiconductor devices. In one embodiment, a process for forming hemispherical grain silicon is provided and comprised the steps of forming a polysilicon or amorphous silicon layer on a substrate and exposing the layer to a gas phase comprising a halide-containing species for a time sufficient to remove any oxides thereon. Then, without exposing the layer to oxygen or an oxygen-containing gas, the layer is annealed at an elevated temperature to transform the polysilicon or amorphous silicon into hemispherical grain silicon. Preferably, the halide-containing species is selected from the group consisting of HF, NF 3 , CIF 3 , and F 2 . In a preferred form, the halide-containing species comprises HF, and the gas phase includes an alcohol. The annealing step is carried out at an elevated temperature of above about 200° C.
In a preferred embodiment of the invention, the process is used to form a capacitor storage cell on a semiconductor substrate and comprises the steps of forming a first layer of a silicon oxide on the surface of the substrate and then forming a second layer of a silicon oxide on the first layer of silicon oxide, with the first silicon oxide being relatively more dense than the second silicon oxide. An opening is formed into the first and second silicon oxide layers, and a polysilicon or amorphous silicon container structure is formed having generally vertically-oriented side walls in the opening. At least a portion of the second silicon oxide layer is selectively removed by exposing the second silicon oxide layer to a liquid comprising a halide-containing species. The remainder of the second silicon oxide layer is removed by exposing the second layer to a gas phase comprising a halide-containing species, thereby exposing the side walls of the container structure. Without exposing the substrate to oxygen or an oxygen-containing gas, the container walls are annealed at an elevated temperature to transform the polysilicon or amorphous silicon into hemispherical grain silicon. The hemispherical grain silicon walls are conductively doped to form capacitor plates, and a capacitor dielectric layer is formed over the capacitor plates. Finally, a second conductive silicon layer is formed over the capacitor dielectric layer to complete the structure.
Accordingly, it is a feature of the present invention to provide a process for etching oxides having differing densities which is not only highly selective, but which also produces uniform etches. This, and other features and advantages of the present invention, will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, in cross-section, depicting the beginning stages of the fabrication of a capacitor storage cell using the process of the present invention;
FIG. 2 is a side view, in cross-section, of the storage container cell of FIG. 1 after subjecting the cell to a first selective etch;
FIG. 3 is a side view, in cross-section, of the storage container cell of FIG. 2 after subjecting the container to seeding and anneal steps to form HSG silicon;
FIG. 4 is a side view, in cross-section, of another embodiment of the invention depicting the beginning stages of the fabrication of a capacitor storage cell using the process of the present invention;
FIG. 5 is a side view, in cross-section, of the storage container cell of FIG. 4 after subjecting the cell to selective etching and anneal steps to form HSG silicon;
FIG. 6 is a side view, in cross section, depicting a completed DRAM container storage cell.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to a process for selectively etching oxide layers on a surface of a substrate, and preferably to fabrication processes for semiconductor devices including steps of selective etching of silicon oxide layers. As used herein, the term “substrate” means any material with sufficient load bearing capability and internal strength to withstand the application of additional layers of material. Included within this definition are metals, ceramics, plastics, glass, and quartz. Also included within this definition are silicon structures including silicon wafers; silicon structures in the process of fabrication; and silicon wafers in the process of fabrication. The term “fabrication” means the process of forming patterns on a substrate using photolithography techniques. The term “opening” includes vias, trenches, grooves, contact holes, and the like in a substrate.
Referring now to FIG. 1, the selective etching process of the present invention is described with respect to the formation of a capacitor storage cell on a semiconductor substrate. However, it will be apparent to those skilled in this art that the process of the present invention may be used in the fabrication of other semiconductor devices. As shown, a starting substrate 10 has deposited thereon a first silicon oxide layer 12 . First oxide layer 12 may be chemically deposited or thermally grown and preferably comprises a tetraethylorthosilicate (TEOS) derived oxide. A second oxide layer 14 is deposited onto and overlies first layer 12 . Preferably second oxide layer 14 is a less dense form of silicon oxide such as, for example, doped oxides such as phosphosilicate glass (PSG), borosilicate glass (BSG), borophosphosilicate glass (BPSG), boron or phosphorous-doped TEOS, and spin-on glass (SOG). Typically, first oxide layer 12 has a thickness of from about 1500 to about 3000 Å, preferably about 2300 Å, and second oxide layer 14 has a thickness of from about 9000 to about 11,000 Å, preferably about 10,000 Å.
After the layers have been planarized, an opening is formed therein to provide access to substrate 10 . The opening may be formed by techniques which are conventional in the art and which may include masking and etching steps. A container structure 16 is then formed within the opening, again using techniques which are conventional in this art. Preferably, container 16 is formed of either polycrystalline silicon (polysilicon) or amorphous silicon. Container structure 16 includes generally vertically upstanding side walls 17 and a base 18 .
Referring now to FIG. 2, the structure of FIG. 1 is subjected to a wet etch step at temperatures ranging from ambient up to about 100° C. using an etchant containing a halide species. Preferably, the etchant is hydrofluoric acid in water, diluted either in a water to HF ratio of 10:1 or 100:1. Such an etchant rapidly etches the second silicon oxide layer 14 . Generally, it is desired to rapidly etch approximately 75-90%, and most preferably 80%, of the thickness of second oxide layer 14 using the wet etchant. Typically, where second layer 14 is BPSG having a thickness of approximately 10,000 Å, the wet etch will remove approximately 8000 Å in 5 minutes (10:1 at about 4.3 Å/sec) or 40 minutes (100:1 at about 0.5 Å/sec). After etching, the substrate is rinsed in deionized water to remove all remaining traces of the etchant.
Referring now to FIG. 3, a thin layer of a native oxide 19 (approximately 20-50 Å thick) grows over the container walls due to exposure of the substrate to air after the initial wet etching step. Substrate 10 is then subjected to a second vapor etch in an enclosed chamber. A suitable enclosed etching chamber is described in Grant et al, U.S. Pat. No. 5,234,540, the disclosure of which is incorporated by reference herein. In this etching step of the process, the substrate is exposed to a gas phase etchant comprising a halide-containing species. Preferably, the gas phase etchant is HF vapor, a mixture of HF with an alcohol such as methanol, or a mixture of HF with acetic acid. HF vapor preferentially and selectively etches the less dense second oxide layer 14 as well as the native oxide coating 19 to completely remove those layers while etching little of the more dense first oxide layer 12 . While a mixture of HF with acetic acid enhances the rate of etching of the BPSG second layer (6.7 Å/sec with acetic acid versus 3.0 Å/sec without acetic acid), it has been found that the HF/acetic acid may cause non-uniform etching near container side walls 17 . For that reason, it is not preferred. HF alone or in a mixture with an alcohol such as methanol has been found to provide both selectivity as well as highly uniform etching of the native oxide and second oxide layers. The HF vapor etches BPSG/thermal oxide layers with a selectivity of greater than 100, and etches BPSG/TEOS with a selectivity of greater than 20.
After removal of the native oxide and remainder of the second oxide layer using the vapor etch, substrate 10 is subjected to an annealing step to transform the surfaces of the polysilicon or amorphous silicon container walls 17 and base 18 into HSG silicon as depicted in FIG. 3 . To avoid the possibility of any further native oxide forming on the surface of the container walls, the substrate is protected from exposure to oxygen or an oxygen-containing atmosphere. This may be accomplished by conducting the vapor etch procedure in a first sealed chamber followed by transfer of the substrate to a second sealed chamber such as a rapid thermal chemical vapor deposition (RTCVD) chamber in a clustered tool. Using a clustered tool permits the vapor etch and subsequent transformation to HSG silicon to be carried out in a controlled environment. This technique combines final BPSG and native oxide etching and avoids the need for a further native oxide cleaning step prior to HSG transformation.
While there are many processes in the prior art which may be used to form the HSG silicon, a preferred process is that taught in commonly-assigned Weimer et al, U.S. Pat. No. 5,634,974, the disclosure of which is incorporated herein by reference. Weimer et al teach a process in which the container structure is first seeded using a hydride gas as a seeding material and is carried out at a temperature of from between about 100° C. to about 1000° C. and at a pressure of less than about 200 Torr. The seeded structure is then subjected to an annealing step at a temperature of from about 200° C. to about 15000° and at a pressure of 1×10 −8 Torr to 1 atm. The annealing step transforms the relatively smooth container walls of the structure into a roughened surface structure as depicted in FIG. 3 . Of course, those skilled in the art will recognize that other methods may be utilized to convert the container walls to a roughened HSG structure.
In another embodiment of the invention, the process is utilized to fabricate a capacitor storage cell on a semiconductor substrate. Referring to FIGS. 4-6, a starting substrate 20 is processed in a conventional manner to provide a diffusion region 24 therein located between word lines 21 . A planarized insulating layer of a first, dense silicon oxide 22 , preferably a thermally grown or chemically deposited tetraethylorthosilicate (TEOS) is provided over the substrate, diffusion region and word lines. A second, less dense silicon oxide is then formed over first layer 22 and also planarized. The second silicon oxide layer is preferably selected from the group consisting of phosphosilicate glass (PSG), borosilicate glass (BSG), borophosphosilicate glass (BPSG), boron or phosphorous-doped TEOS, and spin-on glass (SOG). An opening is formed in the silicon oxide layers to provide access to diffusion region 24 . A container structure 23 is then formed in the opening to make contact with diffusion region 24 . Preferably, the container is formed of either polysilicon or amorphous silicon.
In FIG. 4, a partially fabricated structure is depicted in which the second silicon oxide layer has already been etched away leaving container structure 23 with walls extending generally vertically from the structure. As described above, the etching procedure includes a first wet etch followed by a vapor etch in a seal chamber. The structure of FIG. 4 is then transferred, preferably in a clustered tool arrangement, directly from the etch chamber into a RTCVD chamber.
There, as shown in FIG. 5, structure 23 is subjected to the seeding and annealing steps described previously. This results in the transformation of the relatively smooth silicon surface of container walls 23 into a roughened surface of HSG silicon. The roughened HSG surface is conductively doped, either before or after the anneal step, to form a storage node cell plate of a DRAM storage cell.
Referring now to FIG. 6, the DRAM storage cell is completed by forming cell dielectric layer 41 over structure 23 , followed by the formation of a second cell plate 42 which is typically a conductively-doped polysilicon or metal-based layer. The structure 23 may then be further processed by fabrication procedures which are conventional in this art.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the methods and apparatus disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims.
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A process for etching oxides having differing densities which is not only highly selective, but which also produces uniform etches is provided and includes the steps of providing an oxide layer on a surface of a substrate, exposing the oxide layer to a liquid comprising a halide-containing species, and exposing the oxide layer to a gas phase comprising a halide-containing species. The process desirably is used to selectively etch a substrate surface in which the surface of the substrate includes on a first portion thereof a first silicon oxide and on a second portion thereof a second silicon oxide, with the first silicon oxide being relatively more dense than the second silicon oxide, such as, for example, a process which forms a capacitor storage cell on a semiconductor substrate.
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BACKGROUND
The invention relates to a Surface Mounted Device (SMD) soldering apparatus. For mounting the components on the upside wiring the so-called reflow soldering is used. The soldering spots are provided with solder paste--preferably by means of respective handling apparatuses--, and the board is provided with the components, preferably also by means of handling apparatuses. Thereafter the component-carrying circuit board (hereinafter "board") is heated, preferably by heat radiation, up to the soldering temperature. The heating is usually implemented in three temperature steps. In a first step, heating up to about 100° C. in order to remove solvents in the solder paste. In a second step, the board is heated to a temperature little below the solder melting temperature in an attempt to bring the entire board to substantially uniform temperature. In a third step, the solder is molten.
Known SMD reflow soldering installations are designed as tunnel furnaces through which the boards are continuously conveyed.
The known installations have some weaknesses.
Some SMD components, in particular semiconductor circuits, are conceived such that they support the melting temperature of the solder over a short time interval. Consequently, the third temperature step should be as short as possible. On the other hand, however, melting of all solder spots must be assured. With the known installations, several trials will have to be executed for a certain type of circuit in order to adjust the parameters properly. Nevertheless, the number of rejects is high, and repairs, if at all possible, require considerable effort.
It is a matter of course that such conveyer soldering installations are conceived for mass production because the high trial and reject rate would not be economically feasible for production of individual boards or a small series of boards.
A third drawback of the known installations is their conceptual basis to heat the entire board as uniformly as possible up to the melting point of the solder. This forces the designer to distribute the components in a similarly uniform pattern on the board surface regardless of their functional interaction and with a resulting disadvantageous wiring.
SUMMARY
It is the object of the present invention to eliminate or at least to reduce at least some of the drawbacks of the prior art mentioned above.
According to a first aspect, the invention provides not to determine the soldering parameters (temperature-time-control) by trial and error but that the very melting of the solder is monitored so that immediately thereafter heating may be stopped. To do so, preferably the phenomenon is utilized that the solder paste which is stump-grey below the melting point will radically change its reflectance upon melting, this being detectable by means of, for example a video camera.
This also removes the obstacle for utilizing SMD technique with individual boards or small series of boards so that instead of a conveyer furnace an apparatus may be used for single boards. In this apparatus, the three temperature-time-processes are successively implemented. In accordance with a further aspect of the invention, however, such apparatus may be modified for larger series in that it is preceded by a tunnel conveyer furnace wherein the first two heating steps are implemented while the supplemented apparatus will implement only the last, terminating step. It will be understood that the conveying will then not be continuous but occur in steps.
The fact that the board during soldering is stationary will facilitate application of a third aspect of the present invention. According thereto, a device is provided which permits to mask select areas of a board over selected time intervals so that other areas having higher heat absorption (e.g. heat sinks) are heated over a longer time period. In this way, the designer is free from the restrictions mentioned above.
A preferred embodiment of the invention will be explained hereunder with reference to the accompanying drawings. The illustrations are schematic to a large extent in order to show essential details.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the entire installation.
FIG. 2 is a plan view of the installation shown in FIG. 1.
FIG. 3 illustrates in an enlarged scale the individual apparatus of the installation shown in FIG. 1 and 2.
FIG. 4 is a side view seen in direction of arrow "4" in FIG. 3.
FIG. 5 illustrates the diaphragm device of the monitoring unit.
DETAILED DESCRIPTION
The installation according to FIG. 1 comprises the end stage apparatus 10 and the preceding tunnel furnace 12 through which the device-carrying boards pass in a stepwise manner in direction of arrows 14. A transfer station 16, illustrated in open state, is provided between the two units which transfer station permits to insert device-carrying boards directly into the end stage apparatus with tunnel furnace 12 being switched off (or not being present); the control of the end stage apparatus is such that it performs either heating, beginning with the intermediate temperature level (produced by the tunnel furnace) until the solder melts or, alternatively, permits heating to proceed through all three temperature levels. Adjacent the exit side of end stage apparatus 10 there is a supplemental housing 18 the function of which will be later described.
In the drawings, radiation heaters 20 are indicated which preferably are medium wave infra-red radiators. Such radiators are available in commerce, have little thermal inertia and may be controlled e.g. via a phase clipping circuit in order to control the temperature. The design of such control does not cause any problems for an expert and does not form part of the present invention.
On top of the heating chamber 22 the end stage apparatus has an intermediate housing 24 housing the monitoring camera 25, and on top thereof a display screen monitor 26 is disposed.
The design of the end stage apparatus 10 is shown in greater detail in FIGS. 3 to 5. The monitoring camera which may be a video camera available on the market for observation purposes or the like is directed vertically downward aiming at the board supported by a frame-like carrier 28 and transported by a chain conveyer. The output signal of the camera is supplied to monitor 26. The camera lens system is intentionally not focussed at the board surface, so that the image "seen" by it will appear in a misfocussed manner on the monitor; as such cameras normally have a brightness servosystem the monitor screen will at first display a substantially uniform grey surface. As soon as the solder melts, however, the solder droplets will reflect a substantial amount of visible light into the camera lens system, and an image similar to a shooting star will appear on the monitor screen. This is the signal for the operator to switch off the heaters and/or to transport the board out of the chamber 22 and to subject it to cooling by means of a blower.
It will be understood that the operator may be replaced with an image recognition system, or that the monitor is not required and instead the video output signals of the camera are directly processed.
As shown in the drawings, the camera must "look" between two juxtaposed radiators. Thus, it can recognize only a portion of the board if the full width of the apparatus is used. To permit observation of all board areas, camera 25 is mounted on a carriage 30 which, by means of a handle 32, is displaceable into three positions defined by notches 34. Carriage 30, in turn, is mounted on a slider 36 which is displaceable orthogonal with respect to the carriage movement by means of handle 32 between three stop positions. Each of the nine stop positions is associated with a sight opening 38 in a diaphragm 40. Finally, the assembly consisting of the upper radiators, their frame 42, diaphragm 40 and the camera with its notch system slidingly displaceable along rails 44, so that all points of the board may be brought into the sight field of the camera without aiming the camera directly at a radiator.
It will be understood that the camera could be mounted laterally, the images being projected into its lens system by means of mirrors which, if desired, are moveable. It will further be understood that the camera could be replaced with a row sensor combined with a rotating polygonal mirror or the like. Finally, it will be understood that the manual displacement of the camera may be facilitated by motor drives.
In FIG. 3 the conveyer chains 50 for the boards are indicated. Two additional pairs of chains 52, 54 extend through the supplemental housing 18 into the interior of the heating chamber. They may be reciprocatingly driven by a driving motor, not shown. A mask carrier 56 is suspended on these chain pairs, the mask carrier being displaceable from a position out of the heating chamber thereinto by means of the chain pairs and lowerable on a board in order to mask selected areas thereof against radiation from above over a predetermined time interval. This, of course, makes sense only during the soldering period because previously a uniform warm-up of all portions of a board is attempted. The mask, made of e.g. aluminum film, is simply cut for the respective board.
It will be understood that other mechanisms are conceivable for displacement of the mask carrier, such as linkages and the like.
The housings of the apparatus are preferably double-walled and compulsorily cooled by means of blower device 60 and suction device 62. The cooling air flow is indicated in FIG. 4 by arrows 64. The camera has its own cooling blower 66.
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In the attachment of surface mounted devices, melting of solder is monitored so that immediately thereafter heating may be stopped. The solder paste, which is stump-grey below the melting point, will radically change its reflectance upon melting, this being detectable by means of a video camera.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. 119(e) of United States Provisional Application No. 61/152,407, filed Feb. 13, 2009, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a padded head rest and, more particularly, to a padded head rest with a support structure allowing air flow.
[0004] 2. Discussion of the Background Art
[0005] Head and neck support pillows are known. For example, U.S. Pat. No. 5,095,569 to Glenn discloses a face-down pillow having a wedge shape and U.S. Pat. No. 5,546,619 to Braun discloses a head support designed to enable a user to rest upon his or her stomach. However, the face-down pillow of Glenn is cumbersome and lacks simple, compact design, and the head support of Braun has a rigid, horseshoe design that does not allow for compact storage and does not support the entire perimeter of the face.
[0006] Therefore, it can be appreciated that there exists a need for a new and improved head and neck support device.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes disadvantages of the prior art by providing a head and neck support device having a simple, easy-to-manufacture design with no rigid structure and fully supporting a user's head while allowing the user to breath comfortably. Some advantages achieved by various embodiments of the invention include providing a user with the ability to rest comfortably on the user's stomach without a massage table. Another advantage is the ability to inflate and deflate the head and neck support device and the associated extreme portability and ability to compactly store the head and neck support device in a deflated position. In addition, the closed-loop shape of the head and neck support device provides support for the entire perimeter of a user's face. Further, airflow grooves provide air circulation for inhalation and exhalation comfort. The simple design using reliable materials also provides durability. Plus, the head and neck support device can also be used for sun tanning to rest comfortably while preventing uneven facial tanning.
[0008] An aspect of the invention is a head and neck support device comprising a closed loop-shaped support pillow. The closed loop-shaped support pillow includes a rounded opening in the center of the support pillow extending through the support pillow from the top of the support pillow, and one or more airflow grooves extending along the base of the support pillow from outside the support pillow to the rounded opening in the center of the support pillow. The head and neck support device does not include a rigid base, does not include a rigid platform, and does not include rigid legs. The head and neck support device may include a closed loop-shaped main body in which the rounded opening is formed in the center thereof, and a plurality of supports extending from the main body. The one or more airflow grooves may be a plurality of airflow grooves extending along the base of the support pillow and formed between the plurality of supports extending from the main body. The head and neck support device may further comprise a support pillow cover covering at least a top surface of the main body and an inner side surface of the main body that forms the rounded opening in the center of the support pillow. The support pillow cover may include a plurality of sets of straps, each set of straps including an inner strap and an outer strap that are capable of being connected around the main body and through one of the plurality of airflow grooves to attach the support pillow cover to the support pillow. The support pillow may be configured to support a user's head while the user's face is inserted in the rounded opening. The closed loop-shaped support pillow may have a closed, circular loop shape. The support pillow may be inflatable and may comprise an air inflate nipple configured to allow a user to reversibly inflate and deflate the support pillow. The support pillow may be made of a polyvinyl chloride (PVC) material. The head and neck support device may further comprise a support pillow cover covering at least a top surface of the support pillow. The support pillow cover may additionally cover a portion of an outer side surface of the support pillow but may not cover any of the one or more airflow grooves. The portion of the support pillow cover that covers the portion of the outer side surface of the support pillow may include a pocket which is capable of holding an MP3 player. The support pillow cover may include a fragrance pocket. The support pillow cover may additionally cover at least a portion of an inner side surface of the support pillow that forms the rounded opening in the center of the support pillow without covering any of the one or more airflow grooves. The support pillow cover may include a fragrance pocket in a portion of the support pillow cover that covers the inner side surface of the support pillow. The support pillow cover may be made of a terrycloth material. The support pillow cover may include a plurality of straps to non-permanently secure the support pillow cover to the support pillow. The plurality of straps may include a plurality of sets of straps, each set of straps including an outer strap and a corresponding inner strap that non-permanently attach to secure the support pillow cover to the support pillow. At least one of the straps may include a fragrance pocket.
[0009] Another aspect of the invention is a support pillow cover for covering a support pillow having no rigid structure. The support pillow cover comprises a top fabric portion for covering a top surface of the support pillow, an inner fabric portion for covering an inner side surface of the support pillow that forms a rounded opening through the support pillow, an outer fabric portion for covering an outer side surface of the support pillow, and a plurality of straps capable of non-permanently securing the support pillow cover to the support pillow. The support pillow cover does not interfere with airflow through airflow grooves located at the base of the support pillow. The outer fabric portion may include a pocket in which an MP3 player is capable of being inserted, and the support pillow cover may include a fragrance pocket in which a fragrance strip is capable of being inserted.
[0010] Other features and advantages of the invention will become apparent to those of skill in the art upon reviewing the following detailed description of the preferred embodiments and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate a preferred embodiment of the present invention and, together with the detailed description, further serve to explain the principles of the invention and to enable a person skilled in the art to make and use the invention. In the drawings, like reference numbers are used to indicate identical or functionally similar elements.
[0012] FIG. 1 is an applied view showing the head and neck support device according to an embodiment of the present invention.
[0013] FIG. 2 is a side view showing the head and neck support device according to an embodiment of the present invention.
[0014] FIG. 3 is an exploded view of the head and neck support device according to an embodiment of the present invention
[0015] FIG. 4 is an airflow view showing air flow to and from the head and neck support device according to an embodiment of the present invention.
[0016] FIG. 5 is an applied view showing the bottom and side of the head and neck support device according to another embodiment of the present invention.
[0017] FIG. 6 is a side view showing the support pillow of the head and neck support device according to the other embodiment of the present invention.
[0018] FIG. 7 is a bottom view showing the support pillow of the head and neck support device according to the other embodiment of the present invention.
[0019] FIG. 8 is bottom view showing the support pillow cover of the head and neck support device according to the other embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] A head and neck support device 100 according to an embodiment of the present invention is shown in FIGS. 1-4 . The device 100 includes a support pillow 101 and a support pillow cover 102 . The support pillow 101 has a closed-loop shape with a rounded opening 104 formed through the center of support pillow 101 . Support pillow 101 includes a plurality of airflow grooves 106 extending along a base 101 d of support pillow 101 from outside of support pillow 101 to opening 104 . The plurality of airflow grooves 106 allow air to flow into and out of opening 104 .
[0021] Head and neck support device 100 does not include a rigid base or rigid platform and does not include rigid legs. Head and neck support device 100 may be completely constructed of a polyvinyl chloride (PVC) material. The support pillow 101 may be completely inflatable. To enable support pillow 101 to be inflated and deflated, support pillow 101 may include an air valve 107 .
[0022] The support pillow cover 102 includes a fabric cover 108 and straps 109 . Fabric cover 108 covers top surface 101 a of support pillow 101 . Fabric cover 108 may also include one or both of an inner portion covering at least a portion of inner side surface 101 b and an outer portion 108 b covering at least a portion of outer side surface 101 c of support pillow 101 . No portion of fabric cover 108 covers any of the plurality of airflow grooves 106 . The portions of fabric cover 108 may be separate pieces of fabric sown together or may simply be portions of a single piece of fabric. Fabric cover 108 may be made of terrycloth. Outer portion 108 b of fabric cover 108 may include a pocket configured to hold an MP3 player.
[0023] Straps 109 enable support pillow cover 102 to be attached to support pillow 101 . Straps 109 may enable support pillow cover 102 to be removably attached to the support pillow 101 . Straps 109 may include sets of straps 109 , where each set of straps 109 includes an inner strap 109 a and an outer strap 109 b. The support pillow cover 102 may be attached to support pillow 101 by connecting each inner strap 109 a to a corresponding outer strap 109 b. Inner strap 109 a may be connected to a corresponding outer strap 109 b by tying the corresponding inner and outer straps 109 a and 109 b together or through the use of buttons, hook and loop fastening strips (e.g., VELCRO) or any suitable connecting element at the ends of the inner and outer straps 109 a and 109 b. Each inner strap 109 a may be connected to a corresponding outer strap 109 b around the base 101 d of support pillow 101 to attach the support pillow cover 102 to the support pillow 101 . One strap may include a fragrance pocket 111 in which a fragrance, such as a scented oil on a fragrance pad, may be inserted. Alternatively, fragrance pocket 111 may hang from support pillow cover 102 into the rounded opening 104 or may be located on inner portion of fabric cover 208 , which covers inner side surface 101 b of support pillow 101 .
[0024] In operation, head and neck support device 100 supports a user's head and enables a user to comfortably rest upon his or her stomach. Support pillow cover 102 removably attaches to support pillow 101 by connecting each inner strap 109 a to a corresponding outer strap 109 b . Support pillow 101 supports a user's head while the user's face is inserted in the rounded opening 104 . The user's head rests comfortably on fabric cover 108 of the attached support pillow cover 102 while the user's face is inserted in rounded opening 104 and supported by support pillow 101 . While the user's face is inserted in the rounded opening 104 , the airflow grooves 106 allow air circulation to rounded opening 104 from outside the head and neck support device 100 for inhalation and exhalation comfort. Fragrance pocket 111 enables insertion of a fragrance for an aromatherapy effect and added comfort to the user. Because the head and neck support device 100 has no rigid structure and support pillow 101 may be inflated and deflated, the user may deflate support pillow 101 for portability and/or compact storage of head and neck support device 100 .
[0025] A head and neck support device 200 according to an embodiment of the present invention is shown in FIGS. 5-8 . The device 200 includes a support pillow 201 and a support pillow cover 202 .
[0026] Support pillow 201 includes a main body 203 having a closed-loop shape with a rounded opening 204 formed through the center of the main body 203 . Support pillow 201 also includes a plurality of extensions 205 extending from the main body 203 . The plurality of extensions 205 form a plurality of airflow grooves 206 between the plurality of extensions 205 . The plurality of airflow grooves 206 extend along a base 203 d of the main body 203 from outside of support pillow 201 to the opening 204 . The plurality of airflow grooves 206 allow air to flow between the plurality of extensions 205 to the opening 204 .
[0027] Head and neck support device 200 does not include a rigid base or rigid platform and does not include rigid legs. Head and neck support device 200 may be completely constructed of a polyvinyl chloride (PVC) material. The main body 203 and plurality of extensions 205 of support pillow 201 may be completely inflatable. To enable the main body 203 and plurality of extensions 205 to be inflated and deflated, support pillow 201 may include an air valve 207 .
[0028] The support pillow cover 202 includes a fabric cover 208 and straps 209 . Fabric cover 208 includes a central portion 208 a, an inner portion 208 b and an outer portion 208 c that cover top surface 203 a, inner side surface 203 b and outer side surface 203 c of main body 203 , respectively. The central, inner and outer portions 208 a - 208 c of fabric cover 208 may be separate pieces of fabric sown together or may simply be portions of a single piece of fabric. Fabric cover 208 does not cover any of the plurality of airflow grooves 206 . Fabric cover 208 may be made of terrycloth. Outer portion 208 c of fabric cover 208 may include pocket 210 configured to hold an MP3 player.
[0029] Straps 209 enable support pillow cover 202 to be attached to support pillow 201 . Straps 209 may enable support pillow cover 202 to be removably attached to the support pillow 201 . Straps 209 may include sets of straps 209 , where each set of straps 209 includes an inner strap 209 a and an outer strap 209 b. The support pillow cover 202 may be attached to support pillow 201 by connecting each inner strap 209 a to a corresponding outer strap 209 b. Inner strap 209 a may be connected to a corresponding outer strap 209 b by tying the inner and outer straps 209 a and 209 b together or through the use of buttons, hook and loop fastening strips (e.g., VELCRO) or any suitable connecting element at the ends of the inner and outer straps 209 a and 209 b. Each set of straps 209 may correspond to one of plurality of airflow grooves 206 , and each inner strap 209 a may be connected to a corresponding outer strap 209 b through the corresponding airflow groove 206 . One strap may include a fragrance pocket 211 in which a fragrance, such as a scented oil on a fragrance pad, may be inserted. Alternatively, fragrance pocket 211 may be located on inner portion 208 b of fabric cover 208 .
[0030] In operation, head and neck support device 200 supports a user's head and enables a user to comfortably rest upon his or her stomach. Support pillow cover 202 removably attaches to support pillow 201 by connecting each inner strap 209 a to a corresponding outer strap 209 b.
[0031] Because the straps 209 are connected through the airflow grooves 206 between the plurality of extensions 205 , the straps 209 are held in place between the extensions 205 . Support pillow 201 supports a user's head while the user's face is inserted in the rounded opening 204 . The user's head rests comfortably on fabric cover 208 of the attached support pillow cover 202 while the user's face is inserted in rounded opening 204 and supported by support pillow 201 . While the user's face is inserted in the rounded opening 204 , the airflow grooves 206 formed between extensions 205 allow air circulation to rounded opening 204 from outside the head and neck support device 200 for inhalation and exhalation comfort. Pocket 210 enables an MP3 player to be conveniently held so that a user may listen to soothing music while comfortably relaxing. Fragrance pocket 211 enables insertion of a fragrance for an aromatherapy effect and added comfort to the user. Because the head and neck support device 200 has no rigid structure and support pillow 201 may be inflated and deflated, the user may deflate support pillow 201 for portability and/or compact storage of head and neck support device 200 .
[0032] While the invention has been particularly taught and described with reference to certain preferred embodiments, those versed in the art will appreciate that modifications in form and detail may be made without departing from the spirit and scope of the invention. For example, although the support pillows 101 and 201 were described as being completely constructed of a PVC material, any suitable material or combination of materials may alternatively be used. Also, although support pillow covers 102 and 202 were described as including a fabric cover 108 or 208 that may be made of terrycloth, it is not necessary that the fabric cover 108 or 208 be made of terrycloth and any suitable soft fabric or material or combination of fabrics or materials that would be comfortable to a user's face may alternatively be used.
[0033] Further, support pillow 101 was shown as including three airflow grooves 106 , but it is not necessary that the number of the plurality of airflow grooves 106 be equal to three. Similarly, main body 203 was shown as being supported by four extensions 205 forming four airflow grooves 206 , but it is not necessary that the number of the plurality of extensions 205 and the number of the plurality airflow grooves 206 be equal to four. In addition, head and neck support device 100 was described as having a plurality of airflow grooves 105 , but the head and neck support device 100 may instead have a single airflow groove 105 . Similarly, head and neck support device 200 was described as having a plurality of extensions 204 and a plurality of airflow channels 205 , but the head and neck support device 200 may instead have a single U-shaped extension forming a single airflow channel 205 .
[0034] Also, although the support pillow covers 102 and 104 were described as having an MP3 pocket 110 or 210 and a fragrance pocket 111 or 211 , neither of the of the pockets are necessary, and the support pillow covers 102 and 104 may have one or neither of the pockets. As yet another alternative, support pillow covers 102 and 104 may have pockets in addition to the MP3 and fragrance pockets described.
[0035] These and other modifications of the present invention are intended to be within the scope of the appended claims.
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A new and improved head and neck support pillow which enables a user to comfortably rest upon his or her stomach. The support pillow is circular with a hole in the center of the pillow which allows the user to insert his or her face. The support pillow also has air holes at the base of the pillow which allows air flow to and from the face for inhalation and exhalation comfort. The support pillow may be completely constructed of PVC plastic with an air valve. The support pillow may be completely inflatable. The support pillow may also be accompanied with a terrycloth or similar fabric cloth which rests on the top of the support pillow for added comfort and is tied to the support pillow around the bottom base of the support pillow. A pocket may be sown in the pillow cover to allow insertion of a fragrance which would give the user an aroma therapy effect and added comfort to the user. A pocket may be sown on the pillow cover that is capable of holding an MP3 player.
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This application claims the benefit of Provisional application Ser. No. 60/016,861 filed May 3, 1996.
BACKGROUND OF THE INVENTION
This invention relates to a series of novel indazole analogs that are selective inhibitors of phosphodiesterase (PDE) type IV and the production of tumor necrosis factor (TNF), and as such are useful in the treatment of asthma, arthritis, bronchitis, chronic obstructive airway disease, psoriasis, allergic rhinitis, dermatitis, and other inflammatory diseases, AIDS, septic shock and other diseases involving the production of TNF. This invention also relates to a method of using such compounds in the treatment of the foregoing diseases in mammals, especially humans, and to pharmaceutical compositions containing such compounds.
Since the recognition that cyclic adenosine phosphate (AMP) is an intracellular second messenger, E. W. Sutherland, and T. W. Rall, Pharmacol. Rev., 12, 265, (1960), inhibition of the phosphodiesterases has been a target for modulation and, accordingly, therapeutic intervention in a range of disease processes. More recently, distinct classes of PDE have been recognized, J. A. Beavo et al., TiPS, 11, 150, (1990), and their selective inhibition has led to improved drug therapy, C. D. Nicholson, M. S. Hahid, TiPS, 12, 19, (1991). More particularly, it has been recognized that inhibition of PDE type IV can lead to inhibition of inflammatory mediator release, M. W. Verghese et al., J. Mol. Cell Cardiol., 12 (Suppl. II), S 61, (1989) and airway smooth muscle relaxation (T. J. Torphy in “Directions for New Anti-Asthma Drugs,” eds S. R. O'Donnell and C. G. A. Persson, 1988, 37 Birkhauser-Verlag). Thus, compounds that inhibit PDE type IV, but which have poor activity against other PDE types, would inhibit the release of inflammatory mediators and relax airway smooth muscle without causing cardiovascular effects or antiplatelet effects.
TNF is recognized to be involved in many infectious and auto-immune diseases, W. Friers, FEBS Letters, 285, 199, (1991). Furthermore, it has been shown that TNF is the prime mediator of the inflammatory response seen in sepsis and septic shock, C. E. Spooner et al Clinical Immunology and Immunopathology, 62, S11, (1992).
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula I
and to pharmaceutically acceptable salts thereof, wherein:
R is hydrogen, C 1 -C 6 alkyl, —(CH 2 ) n (C 3 -C 7 cycloalkyl) wherein n is 0 to 2, (C 1 -C 6 alkoxy)C 1 -C 6 alkyl, C 2 -C 6 alkenyl, —(CH 2 ) n (C 3 -C 9 heterocyclyl) wherein n is 0 to 2, or —(Z′) b (Z″) c (C 6 -C 10 aryl) wherein b and c are independently 0 or 1, Z′ is C 1 -C 6 alkylene or C 2 -C 6 alkenylene, and Z″ is O, S, SO 2 , or NR 9 , and wherein said alkyl, alkenyl, alkoxyalkyl, heterocyclyl, and aryl moieties of said R groups are optionally substituted by one or more substituents independently selected from halo, hydroxy, C 1 -C 5 alkyl, C 2 -C 5 alkenyl, C 1 -C 5 alkoxy, C 3 -C 6 cycloalkoxy, trifluoromethyl, nitro, CO 2 -R 9 , C(O)NR 9 R 10 , NR 9 R 10 and SO 2 NR 9 R 10 ;
R 1 is hydrogen, C 1 -C 7 alkyl, C 2 -C 3 alkenyl, phenyl, C 3 -C 7 cycloalkyl, or (C 3 -C 7 cycloalkyl)C 1 -C 2 alkyl, wherein said alkyl, alkenyl and phenyl R 1 groups are optionally substituted with up to 3 substituents independently selected from the group consisting of methyl, ethyl, trifluoromethyl, and halo;
R 2 a and R 2 b are independently selected from the group consisting essentially of hydrogen and hereinafter recited substituents, provided that one, but not both of R 2 a and R 2 b must be independently selected as hydrogen, wherein said substituents comprise:
wherein the dashed lines in formulas (Ia) and (Ib) independently and optionally represent a single or double bond, provided that in formula (Ia) both dashed lines cannot both represent double bonds at the same time;
m is 0 to 4;
R 3 is H, halo, cyano, C 2 -C 4 alkynyl optionally mono-substituted by phenyl, pyridyl or pyrimidinyl; C 1 -C 4 alkyl optionally substituted by one or more halogens; —CH 2 NHC(O)C(O)NH 2 , cyclopropyl optionally substituted by R 11 , R 17 , CH 2 OR 9 , NR 9 R 10 , CH 2 NR 9 R 10 , CO 2 R 9 , C(O)NR 9 R 10 , C°CR 11 , C(Z)H or —CH═CR 11 R 11 ; provided that R 3 is absent when the dashed line in formula (Ia) attached to the ring carbon atom to which R 3 is attached represents a double bond;
R 4 is H, R 6 , C(Y)R 14 , CO 2 R 14 , C(Y)NR 17 R 14 , CN, C(NR 17 )NR 17 R 14 , C(NOR 9 )R 14 , C(O)NR 9 NR 9 C(O)R 9 , C(O)NR 9 NR 17 R 14 , C(NOR 14 )R 9 , C(NR 9 )NR 17 R 14 , C(NR 14 )NR 9 R 10 , C(NCN)NR 17 R 14 , C(NCN)S(C 1 -C 4 alkyl), CR 9 R 10 OR 14 , CR 9 R 10 SR 14 , CR 9 R 10 S(O) n R 15 wherein n is 0 to 2, CR 9 R 10 NR 14 R 17 , CR 9 R 10 NR 17 SO 2 R 15 , CR 9 R 10 NR 17 C(Y)R 14 , CR 9 R 10 NR 17 CO 2 R 15 , CR 9 R 10 NR 17 C(Y)NR 17 R 14 , CR 9 R 10 NR 17 C(NCN)NR 17 R 14 , CR 9 R 10 NR 17 C(CR 9 NO 2 )S(C 1 -C 4 alkyl), CR 9 R 10 CO 2 R 15 , CR 9 R 10 C(Y)NR 17 R 14 , CR 9 R 10 C(NR 17 )NR 17 R 14 , CR 9 R 10 CN, CR 9 R 10 C(NOR 10 )R 14 , CR 9 R 10 C(NOR 14 )R 10 , CR 9 R 10 NR 17 C(NR 17 )S(C 1 -C 4 alkyl), CR 9 R 10 NR 17 C(NR 17 )NR 17 R 14 , CR 9 R 10 NR 17 C(O)C(O)NR 17 R 14 , CR 9 R 10 NR 17 O(O)C(O)OR 14 , tetrazolyl, thiazolyl, imidazolyl, imidazolidinyl, pyrazolyl, thiazolidinyl, oxazolyl, oxazolidinyl, triazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, CR 9 R 10 (tetrazolyl), CR 9 R 10 (thiazolyl), CR 9 R 10 (imidazolyl), CR 9 R 10 (imidazolidinyl), CR 9 R 10 (pyrazolyl), CR 9 R 10 (thiazolidinyl), CR 9 R 10 (oxazolyl), CR 9 R 10 (oxazolidinyl), CR 9 R 10 (triazolyl), CR 9 R 10 (isoxazolyl), CR 9 R 10 (oxadiazolyl), CR 9 R 10 (thiadiazolyl), CR 9 R 10 (morpholinyl), CR 9 R 10 (piperidinyl), CR 9 R 10 (piperazinyl), or CR 9 R 10 (pyrrolyl), wherein said heterocyclic groups and moieties for said R 4 substituents are optionally substituted by one or more R 14 substituents;
R 5 is R 9 , OR 9 , —CH 2 OR 9 , cyano, C(O)R 9 , CO 2 R 9 , C(O)NR 9 R 10 , or NR 9 R 10 , provided that R 5 is absent when the dashed line in formula (Ia) represents a double bond;
or R 4 and R 5 are taken together to form ═O or ═R 8 ;
or R 5 is hydrogen and R 4 is OR 14 , SR 14 , S(O) n R 15 wherein n is 0 to 2, SO 2 NR 17 R 14 , NR 17 R 14 , NR 14 C(O)R 9 , NR 17 C(Y)R 14 , NR 17 C(O)OR 15 , NR 17 C(Y)NR 17 R 14 , NR 17 SO 2 NR 17 R 14 , NR 17 C(NCN)NR 17 R 14 , NR 17 SO 2 R 15 , NR 17 C(CR 9 NO 2 )NR 17 R 14 , NR 17 C(NCN)S(C 1 -C 4 alkyl), NR 17 C(CR 9 NO 2 )S(C 1 -C 4 alkyl), NR 17 C(NR 17 )NR 17 R 14 , NR 17 C(O)C(O)NR 17 R 14 , or NR 17 C(O)C(O)OR 14 ;
R 6 is independently selected from methyl and ethyl optionally substituted by one or more halogens;
R 7 is OR 14 , SR 14 , SO 2 NR 17 R 14 , NR 17 R 14 , NR 14 C(O)R 9 , NR 17 C(Y)R 14 , NR 17 C(O)OR 15 , S(O) n R 12 wherein n is 0 to 2, OS(O) 2 R 12 , OR 12 , OC(O)NR 13 R 12 , OC(O)R 13 , OCO 2 R 13 , O(CR 12 R 13 ) m OR 12 wherein m is 0 to 2, CR 9 R 10 OR 14 , CR 9 R 10 NR 17 R 14 , C(Y)R 14 , CO 2 R 14 , C(Y)NR 17 R 14 , CN, C(NR 17 )NR 17 R 14 , C(NOR 9 )R 14 , C(O)NR 9 NR 9 C(O)R 9 , C(O)NR 9 NR 17 R 14 , C(NOR 14 )R 9 , C(NR 9 )NR 17 R 14 , C(NR 14 )NR 9 R 10 , C(NCN)NR 17 R 14 , C(NCN)S(C 1 -C 4 alkyl), tetrazolyl, thiazolyl, imidazolyl, imidazolidinyl, pyrazolyl, thiazolidinyl, oxazolyl, oxazolidinyl, triazolyl, isoxazolyl, oxadiazolyl, or thiadiazolyl, wherein said heterocyclic groups are optionally substituted by one or more R 14 substituents;
R 8 is —NR 15 , —NCR 9 R 10 (C 2 -C 6 alkenyl), —NOR 14 , —NOR 19 , —NOCR 9 R 10 (C 2 -C 6 alkenyl), —NNR 9 R 14 , —NNR 9 R 19 , —NCN, —NNR 9 C(Y)NR 9 R 14 , —C(CN) 2 , —CR 14 CN, —CR 14 CO 2 R 9 , —CR 14 C(O)NR 9 R 14 , —C(CN)NO 2 , —C(CN)CO 2 (C 1 -C 4 alkyl), —C(CN)OCO 2 (C 1 -C 4 alkyl), —C(CN)(C 1 -C 4 alkyl), —C(CN)C(O)NR 9 R 14 , 2-(1,3-dithiane), 2-(1,3-dithiolane), dimethylthio ketal, diethylthio ketal, 2-(1,3-dioxolane), 2-(1,3-dioxane), 2-(1,3-oxathiolane), dimethyl ketal or diethyl ketal;
R 9 and R 10 are independently hydrogen or C 1 -C 4 alkyl optionally substituted by up to three fluorines;
R 11 is independently fluoro or R 10 ;
R 12 is C 1 -C 6 alkyl, C 2 -C 3 alkenyl, C 3 -C 7 cycloalkyl, (C 3 -C 7 cycloalkyl)C 1 -C 2 alkyl, C 5 -C 10 aryl, or C 3 -C 9 heterocyclyl, wherein said R 12 groups are optionally substituted with up to 3 substituents independently selected from the group consisting of methyl, ethyl, trifluoromethyl, and halo;
R 13 is hydrogen or R 12 ;
R 14 is hydrogen or R 15 , or when R 14 and R 17 are as NR 17 R 14 then R 17 and R 14 can be taken together with the nitrogen to form a 5 to 7 membered ring optionally containing at least one additional heteroatom selected from O, N and S;
R 15 is C 1 -C 6 alkyl or —(CR 9 R 10 ) n R 16 wherein n is 0 to 2 and R 16 and said C 1 -C 6 alkyl are optionally substituted by one or more substituents independently selected from halo, nitro, cyano, NR 10 R 17 , C(O)R 9 , OR 9 , C(O)NR 10 R 17 , OC(O)NR 10 R 17 , NR 17 C(O)NR 17 R 10 , NR 17 C(O)R 10 , NR 17 C(O)O(C 1 -C 4 alkyl), C(NR 17 )NR 17 R 10 , C(NCN)NR 17 R 10 , C(NCN)S(C 1 -C 4 alkyl), NR 17 C(NCN)S(C 1 -C 4 alkyl), NR 17 C(NCN)NR 17 R 10 , NR 17 SO 2 (C 1 -C 4 alkyl), S(O) n (C 1 -C 4 alkyl) wherein n is 0 to 2, NR 17 C(O)C(O)NR 17 R 10 , NR 17 C(O)C(O)R 17 , thiazolyl, imidazolyl, oxazolyl, pyrazolyl, triazolyl, tetrazolyl, or C 1 -C 2 alkyl optionally substituted with one to three fluorines;
R 16 is C 3 -C 7 cycloalkyl, pyridyl, pyrimidyl, pyrazolyl, imidazolyl, triazolyl, pyrrolyl, piperazinyl, piperidinyl, morpholinyl, furanyl, thienyl, thiazolyl, quinolinyl, naphthyl, or phenyl;
R 17 is OR 9 or R 10 ;
R 18 is H, C(Y)R 14 , CO 2 R 14 , C(Y)NR 17 R 14 , CN, C(NR 17 )NR 17 R 14 , C(NOR 9 )R 14 , C(O)NR 9 NR 9 C(O)R 9 , C(O)NR 9 NR 17 R 14 , C(NOR 14 )R 9 , C(NR 9 )NR 17 R 14 , C(NR 14 )NR 9 R 10 , C(NCN)NR 17 R 14 , C(NCN)S(C 1 -C 4 alkyl), CR 9 R 10 OR 14 , CR 9 R 10 SR 14 , CR 9 R 10 S(O) n R 15 wherein n is 0 to 2, CR 9 R 10 NR 14 R 17 , CR 9 R 10 NR 17 SO 2 R 15 , CR 9 R 10 NR 17 C(Y)R 14 , CR 9 R 10 NR 17 CO 2 R 15 , CR 9 R 10 NR 17 C(Y)NR 17 R 14 , CR 9 R 10 NR 17 C(NCN)NR 17 R 14 , CR 9 R 10 NR 17 C(CR 9 NO 2 )S(C 1 -C 4 alkyl), tetrazolyl, thiazolyl, imidazolyl, imidazolidinyl, pyrazolyl, thiazolidinyl, oxazolyl, oxazolidinyl, triazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, wherein said heterocyclic groups are optionally substituted by one or more R 14 substituents;
R 19 is —C(O)R 14 , —C(O)NR 9 R 14 , —S(O) 2 R 15 , or —S(O) 2 NR 9 R 14 ;
Y is O or S; and,
Z is O, NR 17 , NCN, C(—CN) 2 , CR 9 CN, CR 9 NO 2 , CR 9 CO 2 R 9 , CR 9 C(O)NR 9 R 10 , C(—CN)CO 2 (C 1 -C 4 alkyl) or C(—CN)C(O)NR 9 R 10 .
R 2 a and R 2 b are defined hereinabove as being a member independently selected from the group consisting essentially of hydrogen and thereafter recited substituents, provided that one, but not both of R 2 a and R 2 b must be independently selected as hydrogen. Thus, only one of R 2 a or R 2 b is present, and they both have the same definition. As such, they define the stereoisomers of the compounds of formula I, i.e., for any given compound of formula I, one stereoisomer will be defined by R 2 a while the other stereoisomer will be defined by R 2 b . Both groups of stereoisomers are contemplated to have the same type of biological activity, i.e., PDE4 inhibition, and are therefore considered to be useful in the same methods of therapeutic treatment as herein described. There may be some difference in the level of biological activity resulting from the variations in conformation presented to the receptor(s) involved by each group of stereoisomers, or by differences in the pharmacodynamics of the stereoisomers. However, such differences in the degree of activity, rather than in the kind of activity present, permit the conclusion that a single invention is involved.
The invention also relates to compounds of formulas X, XVI, and XIX, which are intermediates that are useful in the preparation of compounds of formula I:
wherein R and R 1 are defined as indicated above for the compound of formula I.
The term “halo”, as used herein, unless otherwise indicated, means fluoro, chloro, bromo or iodo. Preferred halo groups are fluoro, chloro and bromo.
The term “alkyl”, as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight or branched moieties.
The term “alkoxy”, as used herein, unless otherwise indicated, includes O-alkyl groups wherein “alkyl” is defined above.
The term “alkenyl”, as used herein, unless otherwise indicated, includes unsaturated alkyl groups having one or more double bonds wherein “alkyl” is defined above.
The term “cycloalkyl”, as used herein, unless otherwise indicated, includes saturated monovalent cyclo hydrocarbon radicals including cyclobutyl, cyclopentyl and cycloheptyl.
The term “aryl”, as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen, such as phenyl or naphthyl.
The term “heterocyclyl”, as used herein, unless otherwise indicated, includes aromatic and non-aromatic heterocyclic groups containing one or more heteroatoms each selected from O, S and N. The heterocyclic groups include benzo-fused ring systems and ring systems substituted with an oxo moiety. With reference to the R 4 substituent of formula Ia, the C 3 -C 9 heterocyclic group can be attached to the C 1 -C 6 alkyl group by a nitrogen or, preferably, a carbon atom. An example of a C 3 heterocyclic group is thiazolyl, and an example of a C 9 heterocyclic group is quinolinyl. Examples of non-aromatic heterocyclic groups are pyrrolidinyl, piperidino, morpholino, thiomorpholino and piperazinyl. Examples of aromatic heterocyclic groups are pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, furyl, thienyl, isoxazolyl and thiazolyl. Heterocyclic groups having a fused benzene ring include benzimidazolyl.
Where heterocyclic groups are specifically recited or covered as substituents for the compound of formula I, it is understood that all suitable isomers of such heterocyclic groups are intended. Thus, for example, in the definition of the substituent R 4 , the term “thiazolyl” includes 2-, 4- or 5-thiazolyl; the term “imidazolyl” includes 2-, 4- or 5-imidazolyl; the term “pyrazolyl” includes 3-, 4- or 5-pyrazolyl; the term “oxazolyl” includes 2-, 4- or 5-oxazolyl; the term “isoxazolyl” includes 3-, 4- or 5-isoxazolyl, and so on. Likewise, in the definition of substituent R 16 , the term “pyridyl” includes 2-, 3- or 4-pyridyl.
Preferred compounds of formula I include those wherein R 2 is a group of the formula (Ia) wherein R 3 and R 5 are cis as follows:
Other preferred compounds of formula I include those wherein R 2 is a group of the formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond and R 3 and R 4 are cis.
Other preferred compounds of formula I include those wherein R is cyclohexyl, cyclopentyl, cyclobutyl, methylenecyclopropyl, isopropyl, phenyl or 4-fluoro-phenyl.
Other preferred compounds of formula I include those wherein R 1 is C 1 -C 2 alkyl optionally substituted by up to three fluorines, and, more preferably, those wherein R 1 is ethyl.
Other preferred compounds of formula I include those wherein R 2 is a group of formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond.
Other preferred compounds of formula I include those wherein R 2 is a group of formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond and R 3 is cyano.
Other preferred compounds of formula I include those wherein R 2 is a group of formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond, m is 0 and R 5 is hydrogen.
Other preferred compounds of formula I include those wherein R 2 is a group of formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond, m is 0, R 5 is hydrogen and R 4 is —OH, —CH 2 OH, —C(CH 3 ) 2 OH, —CO 2 H, —CO 2 CH 3 , —CO 2 CH 2 CH 3 , or —CH 2 C(O)NH 2 .
Other more preferred compounds of formula I include those wherein R is cyclobutyl, cyclopentyl, cyclohexyl, or 4-fluoro-phenyl; R 1 is ethyl; R 2 is a group of formula (Ia) wherein the dashed line attached to the ring carbon atom to which R 3 is attached represents a single bond, R 3 is cyano, m is 0, R 5 is hydrogen, and R 4 is —CO 2 H.
Preferred compounds of formulas X, XVI, and XIX include those wherein R 1 is ethyl.
Other preferred compounds of formulas X and XIX include those wherein R is cyclohexyl, cyclopentyl, methylenecyclopropyl, isopropyl, phenyl or 4-fluoro-phenyl.
Specific preferred compounds include:
1-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-oxocyclohexanecarbonitrile;
Trans-4-cyano-4-(1 -cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester;
Cis-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester;
Trans-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
Cis-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
1-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-oxocyclohexanecarbonitrile;
Cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester;
Trans-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester;
Cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
Trans-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazole-6-yl)-4-hydroxymethylcyclohexanecarbonitrile;
Cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid amide;
Trans-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid amide;
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-(1-hydroxy-1-methylethyl)cyclohexanecarbonitrile;
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile;
Cis-1-[3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]-4-hydroxycyclohexanecarbonitrile;
Cis-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile;
Cis-1-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile;
Cis-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-4-methylcyclohexanecarbonitrile;
Trans-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-4-methylcyclohexanecarbonitrile;
Cis-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
Trans-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid;
6-Bromo-3-ethyl-1-(4-fluorophenyl)-1H-indazole;
4-[3-Ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]-4-hydroxycyclohexanecarboxylic acid ethyl ester;
4-Cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]cyclohexanecarboxylic acid ethyl ester;
4-[3-Ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]cyclohex-3-enecarboxylic acid ethyl ester;
4-Cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid ethyl ester;
Cis-4-Cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]cyclohexanecarboxylic acid;
4-[3-Ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]cyclohex-3-enecarboxylic acid; and
4-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarboxylic acid.
The phrase “pharmaceutically acceptable salt(s)”, as used herein, unless otherwise indicated, includes salts of acidic or basic groups which may be present in the compounds of formula I. For example, pharmaceutically acceptable salts include sodium, calcium and potassium salts of carboxylic acid groups and hydrochloride salts of amino groups. Other pharmaceutically acceptable salts of amino groups are hydrobromide, sulfate, hydrogen sulfate, phosphate, hydrogen phosphate, dihydrogen phosphate, acetate, succinate, citrate, tartrate, lactate, mandelate, methanesulfonate (mesylate) and p-toluenesulfonate (tosylate) salts.
Certain compounds of formula I may have asymmetric centers and therefore exist in different enantiomeric forms. All optical isomers and stereoisomers of the compounds of formula I, and mixtures thereof, are considered to be within the scope of the invention. With respect to the compounds of formula I, the invention includes the use of a racemate, a single enantiomeric form, a single diastereomeric form, or mixtures thereof. The compounds of formula I may also exist as tautomers. This invention relates to the use of all such tautomers and mixtures thereof.
The present invention further relates to a pharmaceutical composition for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) in a mammal comprising a pharmaceutically effective amount of a compound according to formula I, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
The present invention further relates to a method for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) by administering to a patient an effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
The present invention further relates to a pharmaceutical composition for the prevention or treatment of asthma, joint inflammation, rheumatoid arthritis, gouty arthritis, rheumatoid spondylitis, osteoarthritis, and other arthritic conditions; sepsis, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, acute respiratory distress syndrome, cerebal malaria, chronic pulmonary inflammatory disease, silicosis, pulmonary sarcoidosis, bone resorption diseases, reperfusion injury, graft vs. host reaction, allograft rejections, fever and myalgias due to infection (e.g. bacterial, viral or fungal infection) such as influenza, cachexia secondary to infection or malignancy, cachexia secondary to human acquired immune deficiency syndrome (AIDS), AIDS, HIV, ARC (AIDS related complex), keloid formation, scar tissue formation, Crohn's disease, ulcerative colitis, pyresis, multiple sclerosis, type 1 diabetes mellitus, autoimmune diabetes, systemic lupus erythematosis, bronchitis, chronic obstructive airway disease, psoriasis, Bechet's disease, anaphylactoid purpura nephritis, chronic glomerulonephritis, inflammatory bowel disease, leukemia, allergic rhinitis, or dermatitis, in a mammal, comprising a pharmaceutically effective amount of a compound according to formula I, or a pharmaceutically acceptable salt thereof, together with a pharmaceutically acceptable carrier.
This invention further relates to a method of treating or preventing the foregoing specific diseases and conditions by administering to a patient an effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
Certain “aminal” or “acetal”-like chemical structures within the scope of formula I may be unstable. Such structures may occur where two heteroatoms are attached to the same carbon atom. For example, where R is C 1 -C 6 alkyl substituted by hydroxy, it is possible that the hydroxy may be attached to the same carbon that is attached to the nitrogen atom from which R extends. It is to be understood that such unstable compounds are not within the scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following reaction schemes 1-4 illustrate the preparation of the compounds of the present invention. Unless otherwise indicated, R and R 1 in the reaction schemes are defined as above.
The preparation of compounds of formula I can be carried out by one skilled in the art according to one or more of the synthetic methods outlined in schemes 1-4 above and the examples referred to below. In step 1 of scheme 1, the carboxylic acid of formula II, which is available from known commercial sources or can be prepared according to methods known to those skilled in the art, is nitrated under standard conditions of nitration (HNO 3 /H 2 SO 4 , 0° C.) and the resulting nitro derivative of formula III is hydrogenated in step 2 of scheme 1 using standard hydrogenation methods (H 2 -Pd/C under pressure) at ambient temperature (20-25° C.) for several hours (2-10 hours) to provide the compound of formula IV. In step 3 of scheme 1, the amino benzoic acid of formula IV is reacted with a base such as sodium carbonate under aqueous conditions and gently heated until mostly dissolved. The reaction mixture is chilled to a lower temperature (about 0° C.) and treated with sodium nitrate in water. After about 15 minutes, the reaction mixture is slowly transferred to an appropriate container holding crushed ice and a strong acid such as hydrochloric acid. The reaction mixture is stirred for 10-20 minutes and then added, at ambient temperature, to a solution of excess t-butyl thiol in an aprotic solvent such as ethanol. The reaction mixture is acidified to a pH of 4-5 through addition of an inorganic base, preferably saturated aqueous Na 2 CO 3 , and the reaction mixture is allowed to stir at ambient temperature for 1-3 hours. Addition of brine to the reaction mixture, followed by filtration, provides the sulfide of formula V.
In step 4 of scheme 1, the sulfide of formula V is converted to the corresponding indazole carboxylic acid of formula VI by reacting the sulfide of formula V with a strong base, preferably potassium t-butoxide, in dimethyl sulfoxide (DMSO) at ambient temperature. After stirring for several hours (1-4 hours), the reaction mixture is acidified with a strong acid, such as hydrochloric or sulfuric acid, and then extracted using conventional methods. In step 5 of scheme 1, the indazole carboxylic acid of formula VI is converted to the corresponding ester of formula VII by conventional methods known to those skilled in the art. In step 6 of scheme 1, the compound of formula VIII is provided through alkylation of the ester of formula VII by subjecting the ester to conventional alkylation conditions (strong baselvarious alkylating agents and, optionally, a copper catalyst such as CuBr 2 ) in a polar aprotic solvent, such as tetrahydrofuran (THF), N-methylpyrrolidinone or dimethylformamide (DMF), at ambient or higher temperature (25-200° C.) for about 6-24 hrs, preferably about 12 hours. In step 7 of scheme 1, the compound of formula VIII is converted to the corresponding alcohol of formula IX by following conventional methods known to those skilled in the art for reducing esters to alcohols. Preferably, the reduction is effected through use of a metal hydride reducing agent, such as lithium aluminum hydride, in a polar aproptic solvent at a low temperature (about 0° C.). In step 8 of scheme 1, the alcohol of formula IX is oxidized to the corresponding aldehyde of formula X according to conventional methods known to those skilled in the art. For example, the oxidation can be effected through use of a catalytic amount of tetrapropylammonium perrutenate and excess N-methylmorpholine-N-oxide, as described in J. Chem. Soc., Chem. Commun., 1625 (1987), in an anhydrous solvent, preferably methylene chloride.
Scheme 2 provides an alternative method of preparing the aldehyde of formula X. In step 1 of scheme 2, the compound of formula XI is nitrated using conventional nitration conditions (nitric and sulfuric acid) to provide the compound of formula XII. In step 2 of scheme 2, the nitro derivative of formula XII is reduced to the corresponding amine of formula XIII according to conventional methods known to those skilled in the art. Preferably, the compound of formula XII is reduced to the amine of formula XIII using anhydrous stannous chloride in an anhydrous aprotic solvent such as ethanol. In step 3 of scheme 2, the amine of formula XII is converted to the corresponding indazole of formula XIV by preparing the corresponding diazonium fluoroforates as described in A. Roe, Organic Reactions, Vol. 5, Wiley, New York, 1949, pp. 198-206, followed by phase transfer catalyzed cyclization as described in R. A. Bartsch and I. W. Yang, J. Het. Chem. 21, 1063 (1984). In step 4 of scheme 2, alkylation of the compound of formula XIV is performed using standard methods known to those skilled in the art (i.e. strong base, polar aprotic solvent and an alkyl halide) to provide the N-alkylated compound of formula XV. In step 5 of scheme 2, the compound of formula XV is subjected to metal halogen exchange employing an alkyl lithium, such as n-butyl lithium, in a polar aprotic solvent, such as THF, at low temperature (−50° C. to 100° C. (−78° C. preferred)) followed by quenching with DMF at low temperature and warming to ambient temperature to provide the aldehyde compound of formula X.
Scheme 3 illustrates the preparation of a compound of formula XXII which is a compound of formula I wherein R 2 is a ring moiety of formula (Ia). In step 1 of scheme 3, the aldehyde moiety of the compound of formula X is converted to an appropriate leaving group, such as a halogen, mesylate or another leaving group familiar to those skilled in the art, followed by reacting the resulting compound with sodium cyanate in a polar solvent such as DMF to provide the compound of formula XVI. In step 2 of scheme 3, the compound of formula XVI is reacted under basic conditions with methyl acrylate (or related derivatives depending on the R 2 group to be added) in an aprotic solvent such as ethylene glycol dimethyl ether (DME) at high temperature, preferably at reflux, to provide the compound of formula XVII. In step 3 of scheme 3, the compound of formula XVII is converted to the compound of formula XVIII using a strong base, such as sodium hydride, and a polar aprotic solvent, such as DMF or THF, at elevated temperature, preferably at reflux.
In step 4 of scheme 3, the compound of formula XVIII is decarboxylated using conventional methods, such as using sodium chloride in DMSO at a temperature of about 140° C., to provide the compound of formula XIX. In step 5 of scheme 3, derivatization of the compound of formula XIX to the corresponding dithian-2-ylidine cyclohexane carbonitrile of formula XX is done by reaction with 2-lithio-1,3-dithiane. In step 5-a of scheme 3, further derivatization of the compound of formula XIX to the corresponding cyclohexane carbonitrile of formula XXV which is para-substituted on the cyclohexane group with an hydroxyl moiety and an R 4 substituent, e.g., methyl, is carried out by reacting the ketone with a nucleophilic reagent, e.g., an alkyl lithium compound or a Grignard reagent in accordance with procedures well known in the art. In step 5-b of scheme 3, further derivatization of the compound of formula XIX to the corresponding cyclohexane carbonitrile of formula XXVI which is para-substituted on the cyclohexane group with an hydroxyl moiety, is carried out by reducing the ketone with, e.g., lithium aluminum hydride or sodium borohydride in accordance with procedures well known in the art. In step 6 of scheme 3, the compound of formula XX is converted to the corresponding ester of formula XXI using mercury (II) chloride and perchloric acid in a polar aprotic solvent such as methanol. In step 7 of scheme 3, the compound of formula XXI is converted through hydrolysis to the corresponding carboxylic acid of formula XXII using a standard method of hydrolysis, such as using aqueous sodium hydroxide in a polar solvent, or any of numerous existing hydrolysis methods known to those skilled in art as described in T. Green and P. G. M. Wets, Protecting Groups in Organic Synthesis, 2nd Edition (John Wiley and Sons, New York (1991)). The synthetic steps described for scheme 3 are analogous to the synthetic methods provided for the preparation of corresponding catechol-containing compounds in PCT published applications WO 93/19751 and WO 93/17949.
Other compounds of formula I wherein R 2 is selected from moieties (Ia), (Ib), (Ic) and (Id), can be prepared from one or more of the intermediate compounds described in schemes I-III. In particular, the aldehyde of formula X or the keto compound of formula XIX can be used to prepare various compounds of formula I. Any of the various R 2 moieties of formulas (Ia), (Ib), (Ic) or (Id) can be introduced into one or more of the intermediate compounds referred to above using synthetic methods provided for corresponding non-indazole analogs in PCT published applications WO 93/19748, WO 93/19749, WO 93/09751, WO 93/19720, WO 93/19750, WO 95/03794, WO 95/09623, WO 95/09624, WO 95/09627, WO 95/09836, and WO 95/09837. For example, with reference to step 1 of scheme 4, the carboxylic acid of formula XXII can be converted to the alcohol of formula XXIII by reduction with various metal hydrides in a polar solvent as described in Example 9, referred to below, and in accordance with synthetic methods provided for corresponding non-indazole analogs in PCT published applications publication numbers WO 93/19747, WO 93/19749 and WO 95109836. Further, with reference to step 2 of scheme 4, the carboxylic acid of formula XXII can be converted to the corresponding carboxamide of formula XXIV through conversion to an intermediate acid chloride using conventional synthetic methods, and then reacting the acid chloride with ammonia in an aprotic solvent. Other carboxamide analogs of formula XXIV can be prepared through reaction of the acid chloride intermediate with various primary or secondary amines according to conventional methods known to those skilled in the art and as described in the PCT published applications referred to above.
Other compounds of formula I can be prepared from the intermediate compound of formula XIX in accord with synthetic methods provided for corresponding non-indazole analogs in the PCT published applications referred to above. Compounds of formula I wherein R 2 is a moiety of formula (Ia), and either R 4 or R 5 is H, can be prepared from the keto intermediate of formula XIX by reaction with a base such as lithium diisopropylamine in a polar aprotic solvent, such as THF, and excess N-phenyltrifluoromethylsulfonamide as described in POT published application WO 93/19749 for corresponding non-indazole analogs. Compounds of formula I wherein R 2 is a moiety of formula Ia, R 4 is hydrogen, and R 5 is —CO 2 CH 3 or —CO 2 H, can be prepared from the keto intermediate of formula XIX through reaction with triflic anhydride in the presence of a tertiary amine base followed by reaction of the resulting triflate with (triphenylphosphine)palladium and carbon monoxide in the presence of an alcohol or amine to provide the methyl ester compounds of formula I wherein R 5 is —CO 2 CH 3 . The methyl ester compound can be hydrolyzed to obtain the corresponding carboxylic acid compound by employing standard methods for hydrolysis such as sodium or potassium hydroxide in aqueous methanol/tetrahydrofuran. Such synthetic methods are further described in PCT published application WO 93/19749 for corresponding non-indazole analogs.
Other compounds of formula I can be prepared from the intermediate compound of formula XIX in accord with synthetic methods described for corresponding non-indazole analogs in the published PCT applications referred to above. Compounds of formula I wherein R 2 is a moiety of formula (Ia), R 5 is hydrogen, and R 4 is hydroxy, can be prepared through reaction of the intermediate of formula XIX with an appropriate reducing agent such as lithium borohydride, diamyl borane, lithium aluminum tris(t-butoxide), or sodium borohydride in a suitable non-reacting solvent such as 1,2-dimethoxy ethane, THF or alcohol. Compounds of formula I wherein R 2 is a moiety of formula (Ia), R 5 is hydrogen and R 4 is —NH 2 , —NHCH 3 , or —N(CH 3 ) 2 , can be prepared by reacting the intermediate of formula XIX with an ammonium salt, such as ammonium formate, methylamine hydrochloride or dimethylamine hydrochloride, in the presence of sodium cyanoborohydride in an appropriate solvent such as alcohol.
Alternatively, compounds of formula I wherein R 2 is a moiety of formula Ia, R 4 amino, and R 5 is hydrogen, can be prepared by reacting the corresponding alcohol of formula I (R 4 =OH, R 5 =H) with a complex of an azadicarboxylate ester in the presence of an imide or phthalimide followed by reaction in an alcoholic solvent such as ethanol. Compounds of formula I wherein R 2 is a moiety of formula (Ia), R 5 is H, and R 4 is —SR 14 can be prepared by reacting the corresponding compound wherein R 4 is a leaving group such as mesylate, tosylate, bromine or chlorine, with a metal salt of mercaptan such as NaSR 14 in an appropriate aprotic solvent. Corresponding compounds of formula I wherein R 4 is —SH can be prepared by reacting the corresponding alcohol (R 4 =OH) with a complex of a phosphine, such as triphenyl phosphine, and an azidocarboxylate ester in the presence of thiolacetic acid followed by hydrolysis of the resulting thiolacetate. Furthermore compounds of this structure wherein R 4 is hydroxy can be interconverted using a standard alcohol inversion procedure known to those skilled in the art. The foregoing compounds of formula I wherein R 2 is a moiety of formula (Ia), R 5 is hydrogen, and R 4 is hydroxy, —SH or —NH 2 , can be converted to various other compounds of formula I through one or more synthetic methods described in PCT published applications WO 93/19751 and WO 93/19749 for corresponding non-indazole analogs.
Compounds of formula I wherein R 2 is a moiety of formula (Ia) and the dashed line represents a double bond attached to the ring carbon atom to which substituent R 3 is attached, can be prepared from the intermediate of formula XIX by following one or more synthetic methods provided for the preparation of corresponding non-indazole analogs in PCT published application WO 93/19720. Compounds of formula I wherein R 2 is a moiety of formula (Ia), and R 4 and R 5 are taken together to form =O or =R 8 , wherein R 8 is as defined above, can be prepared from the corresponding ketone intermediate of formula XIX following one or more synthetic methods provided for corresponding non-indazole analogs in PCT published application WO 93/19750. Other compounds of formula I wherein R 2 is a moiety of formula (Ia) and R 4 and R 5 are taken together as =R 8 can be prepared from the intermediate of formula XIX following one or more synthetic methods provided for the preparation of corresponding non-indazole analogs in PCT published application WO 93/19748.
Compounds of formula I wherein R 2 is a moiety of formula (Ib) can be prepared from one or more of the intermediates referred to above, such as the bromoindazole intermediate of formula XV, following one or more synthetic methods provided for the preparation of corresponding non-indazole analogs in PCT published applications WO 95/09627, WO 95/09624, WO 95/09623, WO 95/09836 and WO 95/03794. Compounds of formula I wherein R 2 is a moiety of formula (Ic) can be prepared from the intermediate of formula XV following one or more of synthetic methods provided for the preparation of corresponding non-indazole analogs in PCT published applications WO 95/09624 and WO 95/09837. Compounds of formula I wherein R 2 is a moiety of formula (Id) can be prepared from the bromoindazole intermediate of formula XV employing one or more synthetic methods provided for the preparation of the corresponding catechol-containing analogs in PCT published applications WO 95109627, WO 95/09623 and WO 95/09624.
Particularly preferred compounds of the present invention are those represented by the following formulas:
A method for the preparation of the second of the above-depicted compounds is described in further below-recited Example 23. It is also possible to prepare said compound in accordance with the synthesis method described in above-depicted Scheme 2 and Scheme 3, using as the starting material for said method the compound prepared as described in below-recited Example 20, and represented by the formula:
The preferred compound depicted in the first formula above may be prepared in accordance with the synthesis methods described in above-depicted Scheme 1, Scheme 2, and Scheme 3, and as further detailed in the below-recited Examples. Another, preferred, method of preparing said compound may also be employed, and is represented in the following synthesis scheme:
SCHEME 5
Scheme 5, illustrated below, is a more generalized representation of the above-mentioned preferred method of preparing said above-described preferred compound of the present invention.
As illustrated, the starting material XXVIII is reacted with a hydrazine XXIX and the in situ product XXX is heated without separation to yield an indazole XXXI, which is in turn reacted with dicyanocyclohexane XXXII to yield the cyano- analog of said above-described preferred compound, XXXIII.
In step 1 of Scheme 5, the compound of formula XXVIII is treated with a hydrazine derivative of formula XXIX and an acid, preferably ammonium acetate, in a solvent such as heptane, tetrahydrofuran, xylenes, toluene, or mesitylene, or a mixture of two or more of the foregoing solvents, preferably toluene, to provide the compound of formula XXX. In general, the compound of formula XXX need not be separated or isolated from the reaction mixture.
In step 2 of Scheme 5, the reaction mixture containing the compound of formula XXX is heated at a temperature between about 75° C. and about 200° C., preferably between about 90° and 120° C., for a period of about 2 hours to 48 hours, preferably 12 hours, to provide the compound of formula XXXI.
Alternatively, the process of step 1 of Scheme 5 may be accomplished using a salt of the hydrazine derivative, such as the hydrochloride, hydrobromide, mesylate, tosylate, or oxalate salt of said compound, preferably the mesylate salt, which is reacted with a base, such as sodium or potassium acetate, in a solvent such as heptane, tetrahydrofuran, xylenes, toluene, or mesitylene, or a mixture of two or more of the foregoing solvents, preferably toluene.
In step 3 of Scheme 5, the compound of formula XXXI is treated with the compound of formula XXXII in the presence of a base such as lithium bis(trimethylsilyl)amide, sodium bis(trimethylsilyl)amide, potassium bis(trimethylsilyl)amide, lithium diisopropylamide, or lithium 2,2,6,6-tetramethylpiperidine, preferably potassium bis(trimethylsilyl)amide, in a solvent such as tetrahydrofuran, toluene, or xylenes, preferably toluene, at a temperature between about 25° C. and about 125° C., preferably about 100° C., for a period 1 hour to 15 hours, preferably 5 hours, to provide compound of formula XXXIII.
In step 4 of Scheme 5, the compound of formula XXXIII is treated with an acid such as hydrochloric acid, hydrobromic acid, sulfuric acid, p-toluenesulfonic acid, methanesulfonic acid, or trifluoromthanesulfonic acid, preferably hydrochloric acid, in a solvent of the formula XXXIV, i.e., R 14 —OH wherein R 14 is as defined herein, e.g., C 1 -C 6 alkyl, such as methanol, ethanol, propanol, isopropanol, preferably ethanol, at a temperature between 0° C. and 50° C., preferably ambient temperature (20-25° C.) for a period of 1 hour to 48 hours, preferably 14 hours, to provide a compound of formula XXXV. In general, the compound of formula XXXV need not to be separated or isolated from the reaction mixture.
In step 5 of Scheme 5, the compound of formula XXXV is treated with water in a solvent such as toluene, ethyl acetate, diisopropyl ether, methyl tert-butyl ether, or dichloromethane, preferably toluene, at a temperature between about 0° C. and 50° C., preferably ambient temperature (20-25° C.) for a period of 1 hour to 24 hours, preferably 8 hours, to provide a compound of formula XXXVI.
A particular version of the synthesis of Scheme 5 above carried out with reactants suitable for obtaining the preferred cyclohexanecarboxylic acid compound of the present invention, is illustrated below in Scheme 6:
Scheme 7 set out below illustrates a procedure to facilitate the handling and purification of the indazole intermediate of formula XXXI which is described above in reference to Scheme 5. In step 1 of Scheme 7, the indazole of formula XXXI is treated with an acid, such as hydrobromic, hydrochloric, or sulfuric acid, preferably hydrobromic acid, in a solvent such as toluene, xylenes, acetic acid, or ethyl acetate, preferably toluene, at a temperature ranging from 0° C. to ambient temperature (20-25° C.), preferably ambient temperature, to form a salt of the compound of formula XXXVIII, wherein HX indicates the acid used to prepare the salt and X is the anion of said acid. The salt may be separated and purified according to methods familiar to those skilled in the art. In step 2 of Scheme 7, the salt is converted back to the free base. In this step, the salt of the compound of formula XXXVIII is treated with an aqueous base, such as sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, potassium carbonate, or potassium bicarbonate, preferably sodium hydroxide, in a solvent such as hexane, toluene, dichloromethane, diisopropyl ether, methyl tert-butyl ether, or ethyl acetate, preferably toluene, at a temperature ranging from 0° C. to ambient temperature (20-25° C.), preferably ambient temperature, for a period of 5 minutes to 1 hour, preferably 20 minutes, to provide the compound of formula XXXI.
The compounds of the formulas XXVIII-XXXVIII may have asymmetric carbon atoms and therefore exist in different enantiomeric forms. Diastereomeric mixtures can be separated into their individual diastereomers on the basis of their physical chemical differences by methods known to those skilled in the art, for example, by chromatography or fractional crystallization. Enantiomers may be separated by converting the enantiomeric mixtures into a diastereomeric mixture by reaction with an appropriate optically active compound, e.g., alcohol, separating the diastereomers and converting, e.g., hydrolyzing, the individual diastereomers to the corresponding pure enantiomers. The use of all such isomers, including diastereomer mixtures and pure enantiomers, are considered to be part of the present invention.
Further details concerning the above-identified synthesis methods which are preferred for preparing the above-recited preferred compound of the present invention may be found in copending U.S. Ser. No. (Attorney Docket No. PC10004), filed Nov. 3, 1997, which is incorporated herein by reference in its entirely.
Pharmaceutically acceptable acid addition salts of the compounds of this invention include, but are not limited to, those formed with HCl, HBr, HNO 3 , H 2 SO 4 , H 3 PO 4 , CH 3 SO 3 H, p-CH 3 C 6 H 4 SO 3 H, CH 3 CO 2 H, gluconic acid, tartaric acid, maleic acid and succinic acid. Pharmaceutically acceptable cationic salts of the compounds of this invention of formula I wherein, for example, R 3 is CO 2 R 9 , and R 9 is hydrogen, include, but are not limited to, those of sodium, potassium, calcium, magnesium, ammonium, N,N′-dibenzylethylenediamine, N-methylglucamine (meglumine), ethanolamine, tromethamine, and diethanolamine.
For administration to humans in the curative or prophylactic treatment of inflammatory diseases, oral dosages of a compound of formula I or a pharmaceutically acceptable salt thereof (the active compounds) are generally in the range of 0.1-1000 mg daily for an average adult patient (70 kg). Individual tablets or capsules should generally contain from 0.1 to 100 mg of active compound, in a suitable pharmaceutically acceptable vehicle or carrier. Dosages for intravenous administration are typically within the range of 0.1 to 10 mg per single dose as required. For intranasal or inhaler administration, the dosage is generally formulated as a 0.1 to 1% (w/v) solution. In practice the physician will determine the actual dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient. The above dosages are exemplary of the average case but there can, of course, be individual instances where higher or lower dosage ranges are merited, and all such dosages are within the scope of this invention.
For administration to humans for the inhibition of TNF, a variety of conventional routes may be used including orally, parenterally, topically, and rectally (suppositories). In general, the active compound will be administered orally or parenterally at dosages between about 0.1 and 25 mg/kg body weight of the subject to be treated per day, preferably from about 0.3 to 5 mg/kg. However, some variation in dosage will necessarily occur depending on the condition of the subject being treated. The person responsible for administration will, in any event, determine the appropriate dose for the individual subject.
For human use, the active compounds of the present invention can be administered alone, but will generally be administered in an admixture with a pharmaceutical diluent or carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they may be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They may be injected parenterally; for example, intravenously, intramuscularly or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which may contain other substance; for example, enough salts or glucose to make the solution isotonic.
Additionally, the active compounds may be administered topically when treating inflammatory conditions of the skin and this may be done by way of creams, jellies, gels, pastes, and ointments, in accordance with standard pharmaceutical practice.
The active compounds may also be administered to a mammal other than a human. The dosage to be administered to a mammal will depend on the animal species and the disease or disorder being treated. The active compounds may be administered to animals in the form of a capsule, bolus, tablet or liquid drench. The active compounds may also be administered to animals by injection or as an implant. Such formulations are prepared in a conventional manner in accordance with standard veterinary practice. As an alternative the compounds may be administered with the animal feedstuff and for this purpose a concentrated feed additive or premix may be prepared for mixing with the normal animal feed.
The ability of the compounds of formula I or the pharmaceutically acceptable salts thereof to inhibit PDE IV may be determined by the following assay.
Thirty to forty grams of human lung tissue is placed in 50 ml of pH 7.4 Tris/phenylmethylsulfonyl fluoride (PMSF)/sucrose buffer and homogenized using a Tekmar Tissumizer® (Tekmar Co., 7143 Kemper Road, Cincinnati, Ohio 45249) at full speed for 30 seconds. The homogenate is centrifuged at 48,000×g for 70 minutes at 4° C. The supernatant is filtered twice through a 0.22 mm filter and applied to a Mono-Q FPLC column (Pharmacia LKB Biotechnology, 800 Centennial Avenue, Piscataway, N.J. 08854) pre-equilibrated with pH 7.4 Tris/PMSF Buffer. A flow rate of 1 ml/minute is used to apply the sample to the column, followed by a 2 ml/minute flow rate for subsequent washing and elution. Sample is eluted using an increasing, step-wise NaCl gradient in the pH 7.4 Tris/PMSF buffer. Eight ml fractions are collected. Fractions are assayed for specific PDE IV activity determined by [ 3 H]cAMP hydrolysis and the ability of a known PDE IV inhibitor (e.g. rolipram) to inhibit that hydrolysis. Appropriate fractions are pooled, diluted with ethylene glycol (2 ml ethylene glycol/5 ml of enzyme prep) and stored at −20° C. until use.
Compounds are dissolved in dimethylsulfoxide (DMSO) at a concentration of 10 mM and diluted 1:25 in water (400 mM compound, 4% DMSO). Further serial dilutions are made in 4% DMSO to achieve desired concentrations. The final DMSO concentration in the assay tube is 1%. In duplicate the following are added, in order, to a 12×75 mm glass tube (all concentrations are given as the final concentrations in the assay tube).
i) 25 ml compound or DMSO (1%, for control and blank)
ii) 25 ml pH 7.5 Tris buffer
iii) [ 3 H]cAMP (1 mM)
iv) 25 ml PDE IV enzyme (for blank, enzyme is preincubated in boiling water for 5 minutes)
The reaction tubes are shaken and placed in a water bath (37° C.) for 20 minutes, at which time the reaction is stopped by placing the tubes in a boiling water bath for 4 minutes. Washing buffer (0.5 ml, 0.1 M 4-(2-hydroxyethyl)-1-piperazine-ethanesulfonic acid (HEPES)/0.1M naci, pH 8.5) is added to each tube on an ice bath. The contents of each tube are applied to an AFF-Gel 601 column (Biorad Laboratories, P.O. Box 1229, 85A Marcus Drive, Melvile, N.Y. 11747) (boronate affinity gel, 1 ml bed volume) previously equilibrated with washing buffer. [ 3 H]CAMP is washed with 2×6 ml washing buffer, and [ 3 H]5′AMP is then eluted with 4 ml of 0.25M acetic acid. After vortexing, 1 ml of the elution is added to 3 ml scintillation fluid in a suitable vial, vortexed and counted for [ 3 H].
% inhibition=1−average cpm (test compound−average cmp (blank)
average cpm (control)−average cpm (blank)
IC 50 is defined as that concentration of compound which inhibits 50% of specific hydrolysis of [ 3 H]cAMP to [ 3 H]5′AMP.
The ability of the compounds I or the pharmaceutically acceptable salts thereof to inhibit the production TNF and, consequently, demonstrate their effectiveness for treating disease involving the production of TNF is shown by the following in vitro assay:
Peripheral blood (100 mls) from human volunteers is collected in ethylenediaminetetraacetic acid (EDTA). Mononuclear cells are isolated by FICOLL/Hypaque and washed three times in incomplete HBSS. Cells are resuspended in a final concentration of 1×10 6 cells per ml in pre-warmed RPMI (containing 5% FCS, glutamine, pen/step and nystatin). Monocytes are plated as 1×10 6 cells in 1.0 ml in 24-well plates. The cells are incubated at 37° C. (5% carbon dioxide) and allowed to adhere to the plates for 2 hours, after which time non-adherent cells are removed by gentle washing. Test compounds (10 ml) are then added to the cells at 3-4 concentrations each and incubated for 1 hour. LPS (10 ml) is added to appropriate wells. Plates are incubated overnight (18 hrs) at 37° C. At the end of the incubation period TNF was analyzed by a sandwich ELISA (R&D Quantikine Kit). IC 50 determinations are made for each compound based on linear regression analysis.
The following Examples further illustrate the invention. In the following examples, “DMF” means dimethylformamide, “THF” means tetrahydrofuran, “DMSO” means dimethyl sulfoxide, and “DMAP” means 4-dimethylaminopyridine.
EXAMPLE 1
A. 3-Nitro-4-propyl-benzoic acid
9.44 g (57.5 mmol, 1.0 equiv.) of 4-propylbenzoic acid were partially dissolved in 50 mL conc. H 2 SO 4 and chilled in an ice bath. A solution of 4.7 mL (74.7 mmol, 1.3 equiv) conc. HNO 3 in 10 mL conc. H 2 SO 4 was added dropwise over 1-2 min. After stirring 1 hour at 0° C., the reaction mixture was poured into a 1 L beaker half full with ice. After stirring 10 minutes, the white solid which formed was filtered, washed 1×H 2 O, and dried to give 12.01 g (100%) of the title compound: mp 106-109° C.; IR (KBr) 3200-3400, 2966, 2875, 2667, 2554, 1706, 1618, 1537, 1299, 921 cm −1 ; 1 H NMR (300 MHz, DMSO-d 6 ) d 0.90 (t, 3H, J=7.4 Hz), 1.59 (m, 2H), 2.82 (m, 2H), 7.63 (d, 1H, J=8.0 Hz), 8.12 (dd, 1H, J=1.7, 8.0 Hz), 8.33 (d, 1H, J=1.7 Hz); 13 C NMR (75.5 MHz, DMSO-d 6 ) d 14.2, 23.7, 34.2, 125.4, 130.5, 132.9, 133.6, 141.4, 149.5, 165.9; Anal. calcd for C 10 H 11 NO 4 .¼H 2 O: C, 56.20; H, 5.42; N, 6.55. Found: C, 56.12; H, 5.31; N, 6.81.
B. 3-Amino-4-propyl-benzoic acid
A mixture of 11.96 g (57.2 mmol) 3-nitro-4-propyl-benzoic acid and 1.5 g 10% Pd/C, 50% water wet, in 250 mL CH 3 OH was placed on a Parr hydrogenation apparatus and shaken under 25 psi H 2 at ambient temperature. After 1 hour, the reaction mixture was filtered through celite, and the filtrate concentrated and dried to give 9.80 g (96%) of a pale yellow crystalline solid: mp 139.5-142.5° C.; IR (Kbr) 3200-2400, 3369, 3298, 2969, 2874, 2588, 1690, 1426, 916, 864 cm −1 ; 1 H NMR (300 Mhz, DMSO-d 6 ) d 0.90 (t, 3H, J=7.2 Hz), 1.52 (m, 2H), 2.42 (m, 2H), 5.08 (brs, 2H), 6.96 (d, 1H, J=7.8 Hz), 7.05 (dd, 1H, J=1.7, 7.8 Hz), 7.20 (d, 1H, J=1.7 Hz); MS (Cl, NH 3 ) m/z 180 (M+H + , base); Anal. calcd for C 10 H 13 NO 2 .⅓H 2 O: C, 64:85; N, 7.89; N, 7.56. Found: C, 64.69; H, 7.49; N, 7.86.
C. 3-Carboxy-6-propyl-benzenediazo t-butyl sulfide
A mixture of 8.80 g (49.1 mmol, 1.0 equiv) 3-amino-4-propyl-benzoic acid and 2.34 g (22.1 mmol, 0.45 equiv) sodium carbonate in 55 mL H 2 O was heated gently with a heat gun until mostly dissolved. The reaction mixture was chilled in an ice bath, and a solution of 3.73 g (54.0 mmol, 1.0 equiv.) sodium nitrite in 27 mL H 2 O was added dropwise. After 15 min., the reaction mixture was transferred to a dropping funnel and added over 10 minutes to a beaker containing 55 g of crushed ice and 10.6 mL concentrated HCl. After stirring 10 min., the contents of the beaker were transferred to a dropping funnel and added over 5 minutes to a room temperature solution of 5.31 mL (47.1 mmol, 0.96 equiv) t-butyl thiol in 130 mL ethanol. The pH was adjusted to 4-5 by addition of saturated aqueous Na 2 CO 3 solution, and the reaction mixture was allowed to stir 1 hour at ambient temperature. 200 mL brine were added, and the mixture was filtered. The solid was washed 1×H 2 O and dried overnight to give 12.25 g (89%) of a brown/rust colored powder (caution−stench): mp 102° C. (dec); IR (KBr) 3200-2400, 2962, 2872, 2550, 1678, 1484, 1428, 1298, 1171 cm −1 ; 1 H NMR (300 MHz, DMSO-d 6 ) d 0.84 (t, 3H, J=7.3 Hz), 1.48 (m, 2H), 1.55 (s, 9H), 2.42 (m, 2H), 7.29 (d, 1H, J=1.6 Hz), 7.50 (d, 1H, J=8.0 Hz), 7.86 (dd, 1H, J=1.7, 7.9 Hz), 13.18 (br s, 1H); MS (thermospray, NH 4 OAc) m/z 281 (M+H+, base); Anal. calcd for C 14 H 20 N 2 O 2 S: C, 59.96; H, 7.19; N, 9.99. Found: C, 59.71; H, 7.32; N, 10.02.
D. 3-Ethyl-1H-indazole-6-carboxylic acid
A solution of 12.0 g (42.8 mmol, 1.0 equiv) 3-carboxy-6-propyl-benzenediazo t-butyl sulfide in 150 mL DMSO was added dropwise over 15 min. to a room temperature solution of 44.6 g (398 mmol, 9.3 equiv) potassium t-butoxide in 200 mL DMSO. After stirring 2 hours at ambient temperature, the reaction mixture was poured into 1.5 L of 0° C. 1N HCl, stirred 5 min., then extracted 2×350 mL ethyl acetate. The ethyl acetate extracts (caution—stench) were combined, washed 2×250 mL H 2 O, and dried over MgSO 4 . Filtration, concentration of filtrate and drying gave a tan solid, which was triturated with 1 L of 1:3 Et 2 O/Hexanes and dried to give 7.08 g (87%) of a tan crystalline powder: mp 248-251° C.; IR (KBr) 3301, 3300-2400, 2973, 2504, 1702, 1455, 1401, 1219 cm −1 ; 1 H NMR (300 MHz, DMSO-d 6 ) d 1.31 (t, 3H, J=7.6 Hz), 2.94 (q, 2H, J=7.6 Hz), 7.63 (dd, 1H, J=1.1, 8.4 Hz), 7.81 (d, 1H, J=8.4 Hz), 8.06 (d, 1H, J=1.1 Hz) 12.95 (br s, 1H); MS (Cl, NH 3 ) m/z 191 (M+H+, base); Anal. calcd for C 10 H 10 N 2 O 2 : C, 63.14; H, 5.30; N, 14.73. Found: C, 62.66; H, 5.42; N. 14.80.
E. 3-Ethyl-1H-indazole-6-carboxylic acid methyl ester
8.78 g (45.8 mmol, 1.1 equiv) 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added in one portion to a room temperature solution of 7.92 g (41.6 mmol, 1.0 equiv) 3-ethyl-1H-indazole-6-carboxylic acid, 16.9 mL (416 mmol, 10 equiv) methanol and 5.59 g (45.8 mmol, 1.1 equiv) DMAP in 250 mL CH 2 Cl 2 . After 18 hours at room temperature, the reaction mixture was concentrated to 150 mL, diluted with 500 mL ethyl acetate, washed 2×100 mL 1N HCl, 1×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 7.8 g of a brown solid, which was purified on a silica gel column (30% to 50% ethyl acetate/hexanes gradient) to give 6.41 g (75%) of a tan solid: mp 107-108° C.; IR (KBr) 3100-2950, 1723, 1222 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 8.19 (m, 1H), 7.7-7.8 (m, 2H), 3.96 (s, 3H), 3.05 (q, 2H, J=7.7 Hz), 1.43 (t, 3H, 7.7 Hz); MS (Cl, NH 3 ) m/z 205 (M+H + , base); Anal. calcd for C 11 H 12 N 2 O 2 : C, 64.70; H, 5.92; N, 13.72. Found: C, 64.88; H, 6.01; N, 13.96.
F. 1-Cyclopentyl-3-ethyl-1H-indazole-6-carboxylic acid methyl ester
1.17 g (29.4 mmol, 1.05 equiv) sodium hydride, 60% oil dispersion, was added in one portion to a room temperature solution of 5.7 g (27.9 mmol, 1.0 equiv) 3-ethyl-1H-indazole-6-carboxylic acid methyl ester in 125 mL anhydrous DMF. After 20 minutes, 3.89 mL (36.6 mmol, 1.3 equiv) cyclopentyl bromide were added dropwise, and the reaction was mixture allowed to stir overnight at room temperature. The mixture was then poured into 1 L H 2 O and extracted 3×450 mL ethyl acetate. The organic extracts were combined, washed 3×400 mL H 2 O, 1×200 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave an amber oil, which was purified on a silica gel column (10% ethyl acetate/hexanes, gravity) to give 5.48 g (72%) of a clear oil: 1 H NMR (300 MHz, CDCl 3 ) d 8.16 (d, 1H, J=1.0 Hz), 7.7 (m, 2H), 5.00 (quintet, 1H, J=7.5 Hz), 3.97 (s, 3H), 3.01 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.8 (m, 2H), 1.39 (t, 3H, J=7.6 Hz); HRMS calcd for C 16 H 20 N 2 O 2 ; 272.1526. Found: 272.15078.
G. (1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-methanol
7 mL (7.0 mmol, 1.0 equiv) lithium aluminum hydride, 1.0 M solution in THF, were added to a 0° C. solution of 1.02 g (7.05 mmol, 1.0 equiv) 1-cyclopentyl-3-ethyl-1H-indazole-6-carboxylic acid methyl ester in 50 mL anhydrous THF. After 20 minutes, 1 mL methanol was added cautiously, then the reaction mixture was poured into 500 mL of 5% H 2 SO 4 and extracted 3×50 mL ethyl acetate. The organic extracts were combined, washed 2×40 mL H 2 O, 1×40 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate, and drying gave 1.58 g of a clear oil, which was purified on a silica gel column to give 1.53 g (89%) clear oil: IR (CHCl 3 ) 3606, 3411, 3009, 2972, 2875, 1621, 1490 cm −1 ; 1 H NMR (300 Mhz, CDCl 3 ) d 7.65 (d, 1H, J=8.0 Hz), 7.42 (s, 1H), 7.06 (dd, 1H, J=1.0, 8.2 Hz), 4.92 (quintet, 1H, J=7.7 Hz), 4.84 (s, 2H), 2.98 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 3H), 1.38 (t, 3H, J=7.6 Hz); MS (thermospray, NH 4 OAc) m/z 245 (M+H + , base); HRMS calcd for C 15 H 20 N 2 O+H: 245.1654. Found: 245.1675.
H. 1-Cyclopentyl-3-ethyl-1H-indazole-6-carbaldehyde
0.06 mg (0.301 mmol, 0.05 equiv) tetrapropylammonium perruthenate (VII) were added to a room temperature suspension of 1.47 g (6.02 mmol, 1.0 equiv) (1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-methanol, 1.06 g (9.03 mmol, 1.5 equiv) N-methylmorpholine N-oxide and 3.01 g 4A molecular sieves in 12 mL anhydrous CH 2 Cl 2 . After 30 minutes, the reaction mixture was filtered through a short column of silica gel (eluted with CH 2 Cl 2 ). Fractions containing product were concentrated, and the residue chromatographed on a silica gel column (15% ethyl acetate/hexanes, flash) to give 924 mg (63%) of a pale yellow solid: mp 41° C.; IR (KBr) 3053, 2966, 2872, 2819, 1695 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 10.13 (s, 1H), 7.93 (d, 1H, J=0.9 Hz), 7.77 (d, 1H, J=8.4 Hz), 7.60 (dd, 1H, J=1.2, 8.4 Hz), 5.00 (quintet, 1H, J=7.5 Hz), 3.01 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.39 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 243 (M+H + , base); Anal. calcd for C 15 H 18 N 2 O: C, 74.35; H, 7.49; N, 11.56. Found: C, 74.17; H, 7.58; N, 11.79.
EXAMPLE 2
A. 4-Bromo-2-nitro-1-propyl-benzene
125 g (628 mmol, 1.0 equiv) 1-bromo-4-propyl-benzene were added in one portion to a 10° C. solution of 600 mL concentrated H 2 SO 4 and 200 mL H 2 O. With vigorous mechanical stirring, a room temperature mixture of 43.2 mL (691 mmol, 1.1 equiv) conc. HNO 3 (69-71%, 16M) in 150 mL conc. H 2 SO 4 and 50 mL H 2 O was added dropwise over 30 minutes. The ice bath was allowed to warm to room temperature, and the reaction stirred at room temperature for 68 hours. The reaction mixture was poured into a 4 L beaker, loosely packed full with crushed ice. After stirring 1 hour, the mixture was transferred to a 4 L separatory funnel and extracted 4×800 mL isopropyl ether. The organic extracts were combined, washed 3×800 mL H 2 O, 1×500 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 150 mL of a yellow liquid, which was purified by silica gel chromatography (2 columns, 3 kg silica gel each, 2% ethyl acetate/hexanes) to afford 63.9 g (42%) of a yellow liquid. The desired regioisomer is the less polar of the two, which are formed in a 1:1 ratio. bp 108° C., 2.0 mm; IR (CHCl 3 ) 3031, 2966, 2935, 2875, 1531, 1352 cm −1 ; 1 H NMR (300 MHZ, CDCl 3 ) d 8.01 (d, 1H, J=2.1 Hz), 7.62 (dd, 1H, J=2.1, 8.3 Hz), 7.23 (d, 1H, J=8.3 Hz), 2.81 (m, 2H), 1.67 (m, 2H), 0.98 (t, 3H, J=7.4 Hz); 13 C NMR (75.5 MHz, CDCl 3 ) d 13.94, 23.74, 34.43, 119.6, 127.4, 133.3, 135.7, 136.4, 149.8; GCMS (El) m/z 2451243 (M + .), 147 (base); HRMS calcd for C 9 H 10 NO 2 BR+H: 243.9973. Found: 243.9954.
B. 5-Bromo-2-propyl-phenylamine
121 g (639 mmol, 3.0 equiv) of stannous chloride (anhydrous) were added in one portion to a room temperature solution of 51.9 g (213 mmol, 1.0 equiv) 4-bromo-2-nitro-1-propyl-benzene in 1200 mL absolute ethanol and 12 mL (6 equiv) H 2 O. After 24 hours at room temperature, most of the ethanol was removed on a rotary evaporator. The residue was poured into a 4 L beaker, three-quarters full with crushed ice and H 2 O. 150 g of NaOH pellets were added portionwise, with stirring, until the pH=10 and most of the tin hydroxide has dissolved. The mixture was divided in half, and each half extracted 2×750 mL ethyl acetate. All four ethyl acetate extracts were combined, washed 1×500 mL each 1N NaOH, H 2 O, and brine, then dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow liquid, which was purified on a 1.2 kg silica gel column (1:12 ethyl acetate/hexanes) to give 41.83 g (92%) of a pale yellow liquid: IR (CHCl 3 ) 3490, 3404, 3008, 2962, 2933, 2873, 1620, 1491 cm 1 ; 1 H NMR (300 MHz, CDCl 3 ) d 6.8-6.9 (m, 3H), 3.90 br s, 2H), 2.42 (m, 2H0, 1.62 (m, 2H), 0.99 (t, 3H, J=7.3 Hz); GCMS (EI) m/z 215/213 (M+.), 186/184 (base); Anal. calcd for C 9 H 12 NBr: C, 50.49; H, 5.65; N, 6.54. Found: C, 50.77; H, 5.70; N, 6.50.
C. 6-Bromo-3-ethyl-1H-indazole
49.22 g (230 mmol, 1.0 equiv) 5-bromo-2-propyl-phenylamine were placed in a 3 L flask and chilled in an ice bath. A 0° C. solution of 57.5 mL (690 mmol, 3.0 equiv) conc. HCl in 165 mL H 2 O was added, and the resulting solid mass which formed was ground up until a fine white suspension resulted. 100 mL more H 2 O were added, then a solution of 15.9 g (230 mmol, 1.0 equiv) sodium nitrite in 75 mL H 2 O was added dropwise over 10 min. The ice bath was removed, and the reaction allowed to stir at room temperature for 30 minutes. The reaction mixture was then filtered through a sintered glass funnel, precooled to 0° C. The filtrate was chilled in an ice bath, and with mechanical stirring, a 0° C. solution/suspension of 32.8 g (313 mmol, 1.36 equiv) ammonium tetrafluoroborate in 110 mL H 2 O was added dropwise over 10 min. The thick white suspension which formed (aryl diazonium tetrafluoroborate salt) was allowed to stir 1.5 hours at 0° C. The mixture was then filtered, and the solid washed 1×200 mL 5% aq. NH 4 BF 4 (cooled to 0° C.), 1×150 mL CH 3 OH (cooled to 0° C.), then 1×200 mL Et 2 O. Drying at high vacuum, room temperature for 1 hour gave 54.47 g (76%) of the diazonium salt, an off-white solid.
1500 mL of ethanol free chloroform was placed in a 3 L flask, then 34.16 g (348 mmol, 2.0 equiv) potassium acetate (powdered and dried) and 2.3 g (8.7 mmol, 0.05 equiv) 18-crown-6 were added. After 10 minutes the diazonium salt was added in one portion, and the reaction mixture allowed to stir at room temperature under nitrogen atmosphere for 18 hours. The mixture was then filtered, the solid washed 2× with CHCl 3 , and the filtrate concentrated to give 47 g of crude product (brown crystals). Silica gel chromatography (1.23 kg silica gel, ethyl acetate/hexanes gradient 15%, 20%, 40%) gave 21.6 g (55% for second step, 42% overall) of tan crystals: mp 112-114° C.; IR (KBr) 3205, 3008, 2969, 2925, 1616, 1340, 1037 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 9.86 (br s, 1H), 7.61 (d, 1H, J=1.3 Hz), 7.57 (d, 1H, J=8.4 Hz), 7.24 (dd, 1H, J=1.5, 8.6 Hz), 2.99 (q, 2H, J=7.6 Hz), 1.41 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 227/225 (M+H + , base); Anal. calcd for C 9 H 9 N 2 Br: C, 48.02; H, 4.03; N, 12.45. Found: C, 48.08; H, 3.87; N, 12.45.
D. 6-Bromo-1-cyclopentyl-3-ethyl-1H-indazole
2.46 g (61.4 mmol, 1.05 equiv) sodium hydride, 60% oil dispersion, was added in 0.5 g portions to a 10° C. solution of 13.17 g (58.5 mmol, 1.0 equiv) 6-bromo-3-ethyl-1H-indazole in 500 mL anhydrous DMF. The mixture was stirred at room temperature for 20 minutes, then a solution of 8.8 mL (81.9 mmol, 1.4 equiv) cyclopentyl bromide in 10 mL anhydrous DMF was added dropwise. After 18 hours, the reaction mixture was poured into 2 L H 2 O and extracted 2×1 L ethyl acetate. The organic extracts were combined, washed 2×750 mL H 2 O, 1×500 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 20.7 g of crude product, which was purified on a silica gel column (1.1 kg silica gel, 3% ethyl acetate/hexanes) to give 10.6 g (62%) of an amber liquid: IR (CHCl 3 )2972, 2875, 1606, 1501, 1048 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.56 (d, 1H, J=1.3 Hz), 7.52 (d, 1H, J=8.7 Hz), 7.17 (dd, 1H, J=1.5, 8.5 Hz), 4.83 (quintet, 1H, J=7.6 Hz), 2.96 (q, 2H, J=7.6 Hz), 2.15 (m, 4H), 2.0 (m, 2H), 1.65 (m, 2H), 1.36 (t, 3H, J=7.7 Hz); MS (thermospray, NH 4 OAc) m/z 295/293 (M+H + , base); Anal. calcd for C 14 H 17 N 2 Br: C, 57:35; H, 5.84; N, 9.55. Found: C, 57.48; H, 5.83; N, 9.90.
E. (1-Cyclopentyl-3-ethyl-1H-indazole)-6-carbaldehyde
11.6 mL (28.4 mmol, 1.0 equiv) n-BuLi, 2.45 M in hexanes, were added to a −78° C. solution of 8.32 g (28.4 mmol, 1.0 equiv) 6-bromo-1-cyclopentyl-3-ethyl-1H-indazole in 200 mL anhydrous THF. After 30 min. at −78° C., 8.8 mL (114 mmol, 4.0 equiv) anhydrous DMF was added dropwise, and the reaction mixture was allowed to stir an additional 30 min. at −78° C. The mixture was warmed to room temperature over 1 hour, then 125 mL 1N HCl was added. After stirring for 10 minutes, most of the THF was removed on a rotary evaporator. The residue was diluted with 500 mL H 2 O, and extracted 2×250 mL ethyl acetate. The organic extracts were combined, washed 1×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow oil, which was purified on a silica gel column (15% ethyl acetate/hexanes, gravity) to give 4.70 g (68%) of a yellow crystalline solid: 1 H NMR (300 MHz, CDCl 3 ) identical to the spectrum of the compound from example 8.
F. (1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-acetonitrile
4.44 mL (35.0 mmol, 1.5 equiv) trimethylsilyl chloride were added dropwise to a room temperature suspension of 5.65 g (23.3 mmol, 1.0 equiv) 1-cyclopentyl-3-ethyl-1H-indazole-6-carbaldehyde and 3.84 g (44.3 mmol, 1.9 equiv) lithium bromide in 115 mL anhydrous acetonitrile. After 15 minutes, the reaction mixture was cooled in an ice bath, and 6.84 mL (38.7 mmol, 1.66 equiv) 1,1,3,3-tetramethyldisiloxane were added dropwise, and the reaction was allowed to warm to room temperature over 2 hours. The reaction mixture was heated to reflux for 6 hours, then cooled to room temperature, diluted with 300 mL CH 2 Cl 2 , and filtered through Celite®. The filtrate was concentrated and dried at high vacuum, room temperature to give 13.08 g of a tan oily solid.
This solid was dissolved in 200 mL anhydrous DMF, 259 g (52.9 mmol, 2.27 equiv) sodium cyanide were added, and the mixture stirred at room temperature for 2 hours. The reaction mixture was then poured into 500 mL H 2 O and extracted 3×200 mL ethyl acetate. The organic extracts were combined, washed 3×200 mL H 2 O, 1×200 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a brown oil, which was purified on a silica gel column (10%-20% ethyl acetate/hexanes gradient) to give 2.98 g of impure product and 2.05 g of recovered (impure) starting material.
The recovered starting material was resubjected to the reaction conditions described above, using 50 mL 1,1,3,3-tetramethyldisiloxane, followed by 50 mL DMF and 940 mg sodium cyanide. Silica gel chromatography gave 0.62 g of impure product, which was then combined with the 2.98 g lot of impure product and rechromatographed (10% ethyl acetate/hexanes) to give 3.27 g (55%) of a yellow oil: IR (CHCl 3 ) 3062, 2972, 2874, 2255, 1623 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.66 (d, 1H, J=8.3 Hz), 7.39 (s, 1H), 6.97 (dd, 1H, J=1.1, 8.4 Hz), 4.90 (quintet, 1H, J=7.6 Hz), 3.89 (s, 2H), 2.98 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.37 9t, 3H, J=7.4 Hz); MS (Cl, NH 3 ) m/z 254 (M+H + , base); Anal. calcd for C 16 H 19 N 3 : C, 75.86, H, 7.56; N, 16.59. Found: C, 75.84; H, 7.94; N, 16.60.
G. 4-Cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-heptanediol acid dimethyl ester
530 mL (1.26 mmol, 0.1 equiv) triton B, 40% in methanol, was added to a room temperature solution of 3.19 g (12.6 mmol, 1.0 equiv) (1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-acetonitrile in 100 mL anhydrous acetonitrile. The reaction mixture was heated to reflux, and 11.3 mL (126 mmol, 10.0 equiv) methyl acrylate was added dropwise. After 15 minutes, the reaction mixture was cooled to room temperature, and concentrated on a rotary evaporator. The residue was diluted with 300 mL ether, washed 1×50 mL 1N HCl, 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a brown oil, which was purified on a silica gel column (20% ethyl acetate/hexanes, flash) to give 4.00 g (75%) of a yellow oil: IR (CHCl 3 ) 3031, 2972, 2955, 2874, 2250, 1735 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.68 (d, 1H, J=8.5 Hz), 7.49 (s, 1H), 6.97 (d, 1H, J=8.5 Hz); 4.93 (quintet, 1H, J=7.6 Hz), 3.58 (s, 6H), 2.97 (q, 2H), J=7.7 Hz), 2.45 (m, 6H), 2.2 (m, 6H), 2.0 (m, 2H), 1.8 m, 2H), 1.37 (t, 3H, J=7.7 Hz); MS (Cl, NH 3 ) m/z 426 (M+H + , base); Anal. calcd for C 24 H 31 N 3 O 4 : C, 67.74; H, 7.34; N, 9.88. Found: C, 67.76; H, 7.40; N, 10.08.
H. (±)-5-Cyano-5-(1-cyclonentyl-3-ethyl-1H-indazol-6-yl)-2-oxo-cyclohexane-carboxylic acid methyl ester
924 mg (23.1 mmol, 2.5 equiv) sodium hydride, 60% oil dispersion, was added in one portion to a room temperature solution of 3.93 g (9.24 mmol, 1.0 equiv) 4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-heptanedioic acid dimethyl ester in 100 mL anhydrous 1,2-dimethoxyethane. The reaction mixture was heated to reflux under nitrogen atmosphere for 1.5 hours, then cooled to room temperature. After 18 hours, the reaction mixture was quenched with 50 mL H 2 O, poured into 200 mL ethyl acetate, and washed 1×100 mL 1N HCl. The aqueous layer was extracted 1×50 mL ethyl acetate. The organic extracts were combined, washed 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow oil, which was purified on a silica gel column (10% ethyl acetate/hexanes) to give 2.78 g (76%) of a white amorphous solid: IR (KRr) 2954, 2871, 2240, 1663, 1619 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 12.27 (s, 1H), 7.70 (d, 1H, J=8.5 Hz), 7.57 (s, 1H), 7.15 (dd, 1H, J=1.6, 8.5 Hz), 4.93 (quintet, 1H, J=7.6 Hz), 3.78 (s, 3H), 3.05 (m, 1H), 2.98 (q, 2H, J=7.6 Hz), 2.9 (m, 1H), 2.75 (m, 1H), 2.6 (m, 1H), 2.35 (m, 2H), 2.2 (m, 4H), 2.0 (m, 2H), 1.75 (m, 2H), 1.38 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 394 (M+H + , base); Anal. calcd for C 23 H 27 N 3 O 3 : C, 70.22; H, 6.92; N, 10.68. Found: C, 70.07; H, 7.01; N, 10.70.
I. 1-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile
A mixture of 2.72 g (6.91 mmol, 1.0 equiv) (±)-5-cyano-5-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-2-oxo-cyclohexanecarboxylic acid methyl ester and 2.58 g (44.2 mmol, 6.4 eqiv) sodium chloride in 50 mL dimethyl sulfoxide and 4 mL H 2 O was heated in 140° C. oil bath under nitrogen atmosphere. After 3 hours, the reaction mixture was cooled to room temperature and allowed to stir for 72 hours. The reaction mixture was poured into 250 mL H 2 O and extracted 2×150 mL ethyl acetate. The organic extracts were combined, washed 2×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . The crude product was purified on a silica gel column (20% ethyl acetate/hexanes) to give 1.82 g (78%) of a white crystalline solid: mp 81-89° C.; IR (KBr) 2969, 2951, 2872, 2236, 1716 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.71 (d, 1H, J=8.5 Hz), 7.58 (s, 1H), 7.16 (dd, 1H, J=1.5, 8.5 Hz), 4.93 (quintet, 1H, J=7.6 Hz), 3.0 (m, 4H), 2.7 (m, 4H), 2.45 (m, 2H), NH 4 OAc) m/z 336 (M+H + , base); Anal. calcd for C 21 H 25 N 3 O: C, 75.20; H, 7.51; N, 12.53. Found: C, 74.06; H, 7.59; N, 12.41; HRMS calcd for C 21 H 25 N 3 O+H: 336.20778. Found 336.2088.
EXAMPLE 3
A. 1-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-[1,3]dithian-2-ylidene-cyclohexane-carbonitrile
3.94 mL (9.84 mmol, 2.09 equiv) n-BuLi, 2.5 M in hexanes, was added dropwise to a 0° C. solution of 1.88 mL (9.89 mmol, 2.1 equiv) 2-trimethylsilyl-1,3-dithiane in 80 mL anhydrous THF. After 25 minutes at 0° C., the reaction mixture was cooled to −78° C. and a solution of 1.58 g (4.71 mmol, 1.0 equiv) 1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile in 40 mL anhydrous THF was added. After 1 hours at −78° C., the reaction mixture was quenched by addition of 50 mL brine, then warmed to room temperature, diluted with 100 mL H 2 O, and extracted 1×100 mL CH 2 Cl 2 and 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a clear oil, which was purified on a silica gel column (10% ethyl acetate/hexanes) to give 1.51 g (73%) of a white amorphous solid: IR (KBr) 2962, 2870, 2232, 1620, 1569, 1508, 1434, 1217 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.67 (d, 1H, J=8.5 Hz), 7.53 (s, 1H), 7.15 (dd, 1H, J=1.5, 8.6 Hz), 4.92 (quintet, 1H, J=7.6 Hz), 3.36 (m, 2H), 3.0 (m, 6H), 2.42 (m, 2H), 2.34 (m, 2H), 2.2 (m, 6H), 2.0 (m, 4H), 1.8 (m, 2H), 1.37 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 438 (M+H + , base); Anal. calcd for C 25 H 31 N 3 S 2 : C, 68.60; H, 7.14; N, 9.60. Found: C, 68.26; H, 7.29; N, 9.58.
B. Trans-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester and cis-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid methyl ester
A mixture of 1.45 g (3.31 mmol, 1.0 equiv) 1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-[1,3]dithian-2-ylidene-cyclohexane-carbonitrile, 3.59 g (13.2 mmol, 4.0 equiv) mercury (II) chloride and 1.48 mL (16.9 mmol, 5.1 equiv) 70% perchloric acid in 60 mL methanol was heated to reflux under nitrogen atmosphere. After 2 hours, the reaction mixture was cooled to room temperature, diluted with 250 mL CH 2 Cl 2 and filtered through Celite®. The filtrate was washed 1×100 mL saturated aqueous NaHCO 3 , 1×75 mL 10% aqueous sodium sulfite, 1×100 mL H 2 O, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a clear oil, which was purified on a silica gel column (15% ethyl acetate/hexanes) to give 340 mg (27%) of trans isomer (less polar) as a white solid, and 794 mg (63%) of cis isomer (more polar) as a white solid:
data for trans isomer: mp 79-82° C.; IR (KBr) 2973, 2949, 2890, 2871, 2235, 1721, 1618, 1484, 1453, 1217, 1170 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.67 (d, 1H, J=8.4 Hz), 7.52 (s, 1Y), 7.14 (dd, 1H, J=1.4, 8.5 Hz), 4.93 (quintet, 1H, J=7.6 Hz), 3.74 (s, 3H), 2.97 (q, 2H, J=7.6 Hz), 2.85 (m 1H0, 2.3 (m, 2H), 2.2 (m, 10H), 2.0 (m, 2H), 1.75 (m, 2H), 1.37 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 380 (M+H + , base); Anal. calcd for C 23 H 29 N 3 O 2 : C, 72.79; H, 7.70; N, 11.07. Found: C, 73.05; H, 7.80; N, 11.03.
data for cis isomer: mp 112-114° C.; IR (KBr) 3065, 2952, 2868, 2234, 1731, 1622, 1487, 1445, 1220, 1204 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) d 7.68 (d, 1H, J=8.5 Hz), 7.55 (s, 1H), 7.14 (dd, 1H, J=1.3, 8.4 Hz), 4.93 (quintet, 1H, J=7.6 Hz), 3.73 (s, 3H), 2.98 (q, 2H, J=7.6 Hz), 2.42 (m, 1H), 2.36 (m, 1H), 1.9-2.3 (m, 13H), 1.8 (m, 2H), 1.37 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 380 (M+H + , base); Anal. calcd for C 23 H 29 N 3 O 2 : C, 72.79; H, 7.70; N, 11.07. Found: C, 72.93; H, 7.56; N, 10.92.
EXAMPLE 4
Trans-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid
A mixture of 337 mg (0.888 mmol, 1.0 equiv) trans-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester in 10 mL methanol, 2 mL THF and 2.7 mL (2.66 mmol, 3.0 equiv) 1N NaOH was allowed to stir at room temperature. After 3 hours, the reaction mixture was concentrated on a rotary evaporator, diluted with 100 mL H 2 O, acidified to pH 1, and extracted 2×70 mL ethyl acetate. The organic extracts were combined, washed 1×50 mL H 2 O, 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration and drying gave a white solid, which was purified on a silica gel column (5% CH 3 OH/CH 2 Cl 2 ) to give 197 mg (61%) of a white amorphous solid: IR (KBr) 3200-2500, 3060, 2963, 2871, 2245, 1729, 1702, 1621, 1453, 1219 cm −1 ; 1 H NMR (300 MHz, DMSO-d 6 ) d 12.4 (br s, 1H), 7.77 (d, 1H, J=8.5 Hz), 7.69 (s, 1H), 7.20 (dd, 1H, J=1.3, 8.5 Hz); 5.17 (quintet, 1H, J=7.6 Hz), 2.90 (q, 2H, J=7.6 Hz), 2.75 (m, 1H), 1.9-2.3 (m, 16H), 1.7 (m, 2H), 1.28 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 366 (M+H + , base); Anal. calcd for C 22 H 27 N 3 O 2 : C, 72.29; H, 7.45; N, 11.50. Found: C, 71.98; H, 7.75; N, 11.21.
EXAMPLE 5
Cis-4-cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid
A mixture of 831 mg (2.19 mmol, 1.0 equiv) cis-4cyano-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester in 20 mL methanol, 4 mL THF and 6.6 mL (6.57 mmol, 3.0 equiv) 1N NaOH was allowed to stir at room temperature. After 1.5 hours, the reaction mixture was concentrated on a rotary evaporator, diluted with 100 mL H 2 O, acidified to pH 1, and extracted 2×70 mL ethyl acetate. The organic extracts were combined, washed 1×50 mL H 2 O, 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration and drying gave 0.80 g of a white solid, which was purified on a silica gel column (5% CH 3 OH/CH 2 Cl 2 ) to give 730 mg (91%) of a white crystalline solid. Recrystallization from ethyl acetate/hexanes gave 538 mg of white crystals: mp 197-199° C.; IR (KBr) 3200-2600, 3061, 2961, 2948, 2939, 2871, 2245, 1732, 1625, 1451, 1255, 1185, 1169 cm −1 ; 1 H NMR (300 MHz, DMSO-d 6 ) d 12.35 (br s, 1H), 7.77 (d, 1H, J=8.6 Hz), 7.73 (s, 1H0, 7.27 (dd, 1H, J=1.5, 8.5 Hz), 5.13 (quintet, 1H, J=7.5 Hz), 2.90 (q, 2H, J=7.6 Hz), 2.42 (m, 1H), 2.30 (m, 2H), 1.7-2.1 (m, 14H), 1.29 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 366 (M+H + , base); Anal. calcd for C 22 H 27 N 3 O 2 : C, 72.29; H, 7.45; N, 11.50. Found: C, 72.01; H, 7.60; N, 11.29.
EXAMPLE 6
A. 6-Bromo-1-cyclohex-2-enyl-3-ethyl-1H-indazole
2.12 g (52.9 mmol, 1.05 equiv) sodium hydride, 60% oil dispersion, was added in four portions over 10 min. to a room temperature solution of 11.35 g (50.4 mmol, 1.0 equiv) 6-bromo-ethyl-1H-indazole in 300 mL anhydrous DMF. After stirring 20 min., 9.0 mL (70.6 mmol, 1.4 equiv) 3-bromo-cyclohexene were added dropwise, and the reaction concentrated and dried at high vacuum, room temperature to give 7.52 g of an orange/yellow solid.
This solid was dissolved in anhydrous DMF, 1.56 g (31.8 mmol, 2.27 equiv) sodium cyanide were added, and the mixture stirred at room temperature for 2.5 h. The reaction mixture was then poured into 400 mL H 2 O and extracted 3×200 mL ethyl acetate. The organic extracts were combined, washed 3×150 mL H 2 O, 1×150 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow oil, which was purified on a silica gel column (5%-10% ethyl acetate/hexanes gradient) to give 1.40 g (38%) of a yellow/green oil; MS (Cl, NH 3 ) 268 (M+H + , base); Anal. calcd for C 17 H 21 N 3 : C, 76.38; H, 7.92; N, 15.72. Found C, 76.43; H, 7.53; N, 15.39.
B. 6-Bromo-1-cyclohexyl-3-ethyl-1H-indazole
A mixture of 10.22 g (33.5 mmol, 1.0 equiv) 6-bromo-1-cyclohex-2-enyl-3-ethyl-1H-indazole and 1.5 g 10% Pt/C in 1 L cyclohexane was placed on a Par® hydrogenation apparatus and shaken under 2-5 psi H 2 at room temperature. After 1 h, the reaction mixture was filtered through celite®, and the filtrate concentrated on a rotary evaporator and chromatographed (5% ethyl acetate/hexanes, flash) to give 9.70 g (94%) of a pale yellow oil: MS (Cl, NH 3 ) m/z 309/307 (M+H + , base); Anal. calcd for C 15 H 19 N 2 Br: C, 58.64; H, 6.23; N, 9.12. Found: C, 58.56; H, 6.29; N, 8.77.
C. 1-Cyclohexyl-3-ethyl-1H-indazole-6-carbaldehyde
This compound was prepared according to the method of example 2.E., using 5.02 g (16.3 mmol, 1.0 equiv) 6-bromo-1-cyclohexyl-3-ethyl-1H-indazole as starting material to give 3.65 g (87%) of a pale yellow oil: MS (Cl, NH 3 ) m/z 257 (M+H + , base); Anal. calcd for C 16 H 20 N 2 O: C, 74.97; H, 7.87; N, 10.93. Found: C, 75.00; H, 7.70; N, 10.74.
D. (1-(Cyclohexyl-3-ethyl-1H-indazol-6-yl)-acetonitrile
2.7 mL (21.0 mmol, 1.5 equiv) trimethylsilyl chloride were added dropwise to a room temperature suspension of 3.58 g (14.0 mmol, 1.0 equiv) 1-cyclohexyl-3-ethyl-1H-indazole-6-carbaldehyde and 2.31 g (26.6 mmol, 1.9 equiv) lithium bromide in 100 mL anhydrous acetonitrile. After 15 min., the reaction mixture was cooled in an ice bath, and 4.1 mL (23.2 mmol, 1.66 equiv) 1,1,3,3-tetramethyldisiloxane were added dropwise, and the reaction was allowed to warm to room temperature over 30 min. The reaction mixture was heated to reflux for 3 h, then cooled to room temperature, diluted with 300 mL CH 2 Cl 2 , and filtered through Celite®. The filtrate was concentrated and dried at high vacuum, room temperature to give 7.52 g of an orange/yellow solid.
This solid was dissolved in 100 mL anhydrous DMF, 1.56 g (31.8 mmol, 2.27 equiv) sodium cyanide were added, and the mixture stirred at room temperature for 2.5 h. The reaction mixture was then poured into 400 mL H 2 O and extracted 3×200 mL ethyl acetate. The organic extracts were combined, washed 3×150 mL H 2 O, 1×150 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow oil, which was purified on a silica gel column (5%-10% ethyl acetate/hexanes gradient) to give 1.40 g (38%) of a yellow/green oil: MS (Cl, NH 3 ) 268 (M+H + , base); Anal. calcd for C 17 H 21 N 3 : C, 76.38; H, 7.92; N, 15.72. Found: C, 76.43; H, 7.53; N, 15.39.
E. 4-Cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-heptanedioic acid dimethyl ester
This compound was prepared according to the method of example 2.G., using 1.33 g (4.98 mmol, 1.0 equiv) of (1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-acetonitrile as starting material, to give 1.38 g (63%) of a yellow oil; MS (Cl, NH 3 ) m/z 440 (M+H + , base); Anal. calcd for C 25 H 33 N 3 O 4 : C, 68.32; H, 7.57; N, 9.56. Found: C, 68.18; H, 7.52; N, 9.28.
F. 5-Cyano-5-(1-cyclohexyl-3-ethyl-1H-indazol-t-yl)-2-oxo-cyclohexanecarboxylic acid methyl ester
This compound was prepared according to the method of example 2.H., using 1.33 g (3.03 mmol, 1.0 equiv) 4-cyano-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-heptanedioic acid dimethyl ester as starting material, to give 983 mg (80%) of a white amorphous solid: MS (Cl, NH 3 ) m/z 408 (M+H + , base); Anal. calcd for C 24 H 29 N 3 O 3 : C, 70.75; H, 7.18; N, 10.31. Found: C, 70.75; H, 7.33; N, 10.19.
G. 1-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile
This compound was prepared according to the method of example 2.I., using 933 mg (2.29 mmol, 1.0 equiv) 5-cyano-5-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-2-oxocyclohexanecarboxylic acid methyl ester as starting material, to give 588 mg (74%) of a white amorphous solid: MS (Cl, NH 3 ) m/z 350 (M+H + , base); Anal. calcd for C 22 H 27 N 3 O: C, 75.62; H, 7.79; N, 12.03. Found: C, 75.57; H, 7.90; N, 12.15.
EXAMPLE 7
Cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester and trans-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester
These compounds were prepared according to the method of example 3.B., using 540 mg (1.20 mmol, 1.0 equiv) 1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-[1,3]dithian-2-ylidene-cyclohexane-carbonitrile as starting material, to give 117 mg (25%) of trans isomer as a white oily solid, and 233 mg (50%) of cis isomer as a white crystalline solid:
Data for trans isomer: 1 H NMR (300 MHz, CDCl 3 ) d 7.68 (d, 1H, J=8.4 Hz), 7.50 (d, 1H, J=0.8 Hz), 7.13 (dd, 1H, J=1.6, 8.5 Hz), 4.34 (m, 1H), 3.74 (s, 3H), 2.98 (q, 2H, J+7.6 Hz), 2.85 (m, 1H), 2.35 (m, 2H), 1.9-2.2 (m, 12H), 1.8 (m, 2H), 1.55 (m, 2H), 1.37 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 394 (M+H + , base); Anal. calcd for C 24 H 31 N 3 O 2 : C, 73.25; H, 7.95; N, 10.68. Fund: C, 73.07; H, 8.12; N, 10.89.
Data for cis isomer 1H NMR (300 MHz, CDCl 3 ) d 7.68 (d, 1H, J=8.4 Hz), 7.53 (d, 1H, J=0.9 Hz), 7.14 (dd, 1H, J=1.6, 8.5 Hz), 4.34 (m, 1H), 3.74 (s, 3H), 2.98 (, 2H, J-7.6 Hz), 2.43 (m, 1H), 1.9-2.3 (m, 15H), 1.8 (m, 1H), 1.5 (m, 2H), 1.37 (t, 3H, J=7.6 Hz); MX (Cl, NH 3 ) m/z 394 (M+ + , base); Ana. calcd for C 24 H 31 N 3 O 2 : C, 73.25; H, 7.95; N, 10.68. Found: C, 73.17; H, 7.89; N, 10.43.
EXAMPLE 8
Cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid
This compound was prepared according to the method of example 5, using 201 mg (0.511 mmol, 1.0 equiv) cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester as starting material, to give 178 mg (92%) of a white crystalline solid, which was recrystallized from ethyl acetate hexanes to give 153 mg of a white crystalline powder; mp 192-194° C.; Anal. calculated for C 23 H 29 N 3 O 2 : C, 72.79; H, 7.70; N, 11.07. Found: C, 72.25; H, 7.99; N, 10.97.
EXAMPLE 9
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazole-6-yl)-4-hydroxylmethylcyclohexane carbonitrile
To a stirred solution of the product from Example 8 (220 mg, 0.58 mmol.) in dry tetrahydrofuran (5 mL) at 0° C. was added dropwise a solution of borane in tetrahydrofuran (1M, 1.3 mL, 1.3 mmol). The mixture was stirred at 0° C. for one hour then quenched by the slow addition of methanol (1 mL). The mixture was poured into water (100 mL) and extracted with ethyl acetate (2×100 mL). The organic extracts were combined, washed with water (1×20 mL), brine (1×20 mL) dried over magnesium sulfate and concentrated to give an oil. A separate identical experiment was carried out using the product from Example 8 (100 mg, 0.26 mmol.) and borane in tetrahydrofuran (1M, 0.6 mL, 0.58 mmol.). The crude product from both experiments were combined and chromatographed on Silica Gel eluting with 2.5% methanol in methylene chloride (v/v) to give an oil. Recrystallization from ethyl acetate/hexanes yielded 214 mg white solid (67%) mp 117-9° C. mass spectrum (m/e) 367 (M+1, 20), 366 (M+, 100).
EXAMPLE 10
Cis-4-Cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid amide
A mixture of the product from Example 8 (150 mg, 0.4 mmol.) thionyl chloride (36 uL, 0.49 mmol) and dimethylformamide (5 mL) in dry methylene chloride (3 mL) was refluxed for four hours. The mixture was cooled to 0° C. and dry ammonia gas was bubbled with chloroform (200 mL), washed with water (1×40 mL) dried over magnesium sulfate and concentrated to give a solid. Recrystallization from ethyl acetate/hexane yielded 125 mg white solid (83%) mp 180-2° C. mass spectrum (m/e) (M+1, 20), 379 (M+, 100).
EXAMPLE 11
Trans-4-Cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid amide
The title compound was prepared in a manner analogous to the synthesis provided in Example 4. The melting point of the isolated product was 140-143° C.
EXAMPLE 12
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-(1-hydroxy-1-methyl-ethyl)cyclohexanecarbonitrile
To a stirred solution of cis cyano-4-(1-cyclohexyl-3-ethyl-1H-indazolol-6-yl)-cyclohexanecarboxylic acid methyl ester (360 mg, 0.90 mmol) in 10 mL of dry tetrahydrofuran at −40° C. under nitrogen atmosphere was added 0.7 mL (2.1 mmol) of 3.0 M methyl magnesium bromide. Reaction mixture was allowed to warm up to room temperature over a period of one hour and stirred at room temperature for 3 hours. After this time, reaction mixture was quenched with excess of methanol (5.0 mL) and worked up by pouring into 100 mL of water and acidification with oxalic acid. Extraction with ethyl acetate followed by washing of ethyl acetate extract with water, brine and drying over magnesium sulfate (MgSO 4 ). Removal of ethyl acetate in vacuo gave crude final product which was homogenous by TLC analysis. Recrystallization from ethyl acetate/hexane gave 180 mg of pure final product or a white solid, mp=58-60° C. MS m/z 394 (M+H + , base).
EXAMPLE 13
Cis-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile
To a stirred solution of 2.9 g (8.6 mmol) 1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile (compound 2G page 35 of PC) in 100 mL absolute methanol at 0° C. was added sodium borohydride 382 mg (10.8 mmol) portionwise. The mixture was stirred at 0° C. for 30 min, then quenched with 2 mL saturated ammonium chloride solution. The mixture was concentrated to a volume of 20 mL, poured into a mixture of 100 mL water and 100 mL saturated ammonium chloride solution and extracted with ethyl acetate (2×200 mL). The organic extract was combined, washed with water (1×100 mL), brine (1×100 mL), dried (MgSO 4 ) and concentrated to give an oil. Chromatography on silica gel eluting with ethyl acetate/hexanes (1:1) afforded an oil. Recrystallization from ethyl acetate/hexanes yielded 1.9 g (66%) cis-1-(1-cyclopentyl-3-ethyl-1H-indazole-6-yl)-4-hydroxycyclohexanecarbonitrile as a white solid. mp 107-109° C.
Anal. Calc'd. for C 21 H 27 N 3 O: C, 74.74; H, 8.06; N, 12.45. Found: C, 74.81; H, 8.04; N, 12.43.
EXAMPLE 14
Cis-1-[3-ethyl-1(4-fluorophenyl)-1H-indazol-6-yl]-4-hydroxycyclohexanecarbonitrile
The title compound was prepared in an analogous manner to that described in the immediately preceding example for preparation of cis-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-cyclohexanecarbonitrile, starting with 0.415 g (1.148 mmol) of 1-(4-fluorophenyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile to give 0.28 g (76%) of white crystalline solid. mp=132-134° C.
Anal. Calc'd. for C 22 H 22 N 3 OF: C, 72.71; H, 6.10; N, 11.56. Found: C, 72.55; H, 6.22; N, 11.40.
The 1-(4-fluorophenyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile starting material was prepared from 6-bromo-3-ethyl-1-(4-fluorophenyl)-1H-indazole following the chemical synthesis sequence outlined in Scheme 3 (intermediate X→XIX) and described above in more detail.
EXAMPLE 15
Cis-1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-cyclohexanecarbonitrile
The title compound was prepared in an analogous manner to that described in a preceding example for preparation of cis-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-cyclohexanecarbonitrile, starting with 1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-4-oxo-cyclohexanecarbonitrile. mp=124-126° C.; MS m/z 352 (M+H + , base).
EXAMPLE 16
Trans-1-(1-Cyclobutyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile
The title compound was prepared in an analogous manner to that described in a preceding example for preparation of cis-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxycyclohexanecarbonitrile, starting from 1-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)-4-oxocyclohexanecarbonitrile. mp=60-65° C.; MS m/z 324 (M+H + , base).
EXAMPLE 17
Cis-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl-)-4-hydroxy-4-methyl-cyclohexanecarbonitrile and trans-1-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-4-hydroxy-4-methyl-cyclohexanecarbonitrile
To a stirred suspension of 0.275 grams (1.115 mmol) of anhydrous CeCl 3 in 10 mL of dry tetra-hydrofuran under N2 atmosphere at 0° C. was added dropwise 0.4 mL (1.115 mmol) of 3.0 N CH 3 MgCl. The reaction mixture was stirred at 0° C. for one hour. After this time, 0.3 g (0.891 mmol) of 1-(1-cyclopentyl-3-ethyl-1H-indazole-6-yl)-4-oxo-cyclohexanecarbonitrile dissolved in 10 mL of anhydrous tetrahydrofuran was added dropwise and the reaction mixture stirred at 0° C. for 1 hour. The mixture was quenched with 5 mL of 2N HOAc. The mixture was poured onto 100 mL of H 2 O and extracted with ethyl acetate (2×100 mL). The organic extracts were combined, washed with H 2 O (1×100 mL), brine (1×200 mL) and dried over MgSO 4 . Filtration, concentration and purification on a silica gel column (2% EtOAc/hexane) gave 0.15 grams of less polar product (trans isomer) as amorphous solid. MS (Cl, NH 3 ) m/z 353 (M+H + , base) and 0.045 grams of more polar product (cis isomer) as a white crystalline product. mp=156-158° C. MS (Cl, NH 2 ) m/z 352 (M+H + , base).
EXAMPLE 18
Cis-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl-)-cyclohexanecarboxylic acid
This compound was prepared according to the method of Example 5 using 0.28 g (0.767 mmol) of cis-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester as a starting material to give 0.24 grams (89%) of white solid, which was recrystallized from ethyl acetate/hexane to give 0.15 grams of white crystalline product.mp=201-203° C.; MS (m/z) 352 (M+H + , base).
EXAMPLE 19
Trans-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl-)-cyclohexanecarboxylic acid
This compound was prepared according to the method of Example 4 using 0.13 g (0.356 mmol) of trans-4-cyano-4-(1-cyclobutyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid methyl ester as a starting material to give white solid. Purification on silica gel column using 5% methanol/95% methylene chloride gave pure product (80 mg) which was recrystallized from ethyl acetate/hexane to give 43 mg of white crystalline solid; mp=157-159° C., MS (m/z) 312, (M+H + , base).
EXAMPLE 20
6-Bromo-3-ethyl-1-(4-fluorophenyl)-1H-indazole
Methanesulfonic acid 5-bromo-2-propionyl-phenyl ester, prepared as described in U.S. Ser. No. 09/308,954, now U.S. Pat. No. 6,011,159, filed May 8, 1997 as Attorney Docket No. PC9798, 30 grams (97.66 mmol) was combined with 4-fluorophenyl hydrazine hydrochloride (31.76 g, 175.33 mmol) and sodium acetate (30 g, 364 mmol) in mesitylene (400 mL). The reaction mixture was heated to reflux in a Dean-Stark apparatus for 96 hours. The reaction mixture was cooled to room temperature and concentrated under reduced pressure. The crude product was diluted with 500 mL of diethyl ether and 600 mL of water. Organic layer was separated and aqueous layer extracted with 500 mL of ethyl acetate. Combined organic extracts were washed with water (2×600 mL), brine (1×200 mL), dried over MgSO 4 and concentrated which gave a brown-red oil. Hexane (600 mL) was added to crude reaction product and the mixture boiled in a steam bath for a few minutes. This was followed by cooling still the heterogeneous mixture to room temperature and allowing to stand at room temperature for 12-14 hours. The reaction mixture was filtered, undissolved solid washed with additional hexane and filtrate which contained approximately 80% pure desired product concentrated in vacuo to give brown-yellow solid. Purification of this product on silica gel column and eluting with 15% ethyl acetate/85% hexane gave 14.1 grams of light brown-tan solid. Recrystallization from hexane gave light tan needles. mp=72-73° C.; MS (APCI) m/z 319 (base).
EXAMPLE 21
4-[3-Ethyl-1-(4-fluorophenyl)-1H-indazole-6-yl]-4-hydroxy-cyclohexanecarboxylic acid ethyl ester
This compound was prepared according to the method described in Example 6 of U.S. Ser. No. 09/308,954, filed May 8, 1997 as Attorney Docket No. PC9798, starting with 3.0 grams (9.4 mmol) of 6-bromo-3-ethyl-1-(4-fluoro-phenyl)-1H-indazole and 2.0 grams (11.7 mmol) of 4-oxo-cyclohexanecarboxylic acid ethyl ester to give after silica gel flash column chromatography (using 20% ethyl acetate 80% hexane as elutant) 2.17 grams of light yellow semi-solid which was a mixture of diastereoisomers. 1 H NMR (400 MHz, CDCl 3 ) δ 1.25-1.3 (t, 3H); 1.4-1.5 (t, 3H); 1.6-1.78 (m, 2H); 1.8-2.5 (m, 7H); 2.70 (m, 1H); 3.04 (m, 2H); 4.16 (m, 2H); 7.17-7.28 (m, 3H); 7.61-7.79 (m, 4H); MS, m/z 324.4 (M+H + , base).
EXAMPLE 22
4-Cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazole-6-yl]cyclohexanecarboxylic acid ethyl ester and 4-[3-ethyl-1-(4-fluoro-phenyl)-1H-indazol-6-yl]cyclohex-3-enecarboxylic acid ethyl ester
This compound was prepared according to the method described in Example 7 of U.S. Ser. No. 09/308,954, filed May 8, 1997 as Attorney Docket No. PC9798, starting with 2.1 grams (5.12 mmol) of 4-[3-ethyl-1-(4-fluorophenyl)-1H-indazole-6-yl]-4-hydroxy-cyclohexanecarboxylic acid ethyl ester to give after silica gel Flash 40 Biotage column chromatography (10% EtOAc/90% hexane) 0.714 grams of product which existed as a mixture of diastereoisomers. MS, m/z 420 (M+H + , base); 1 H NMR (400 MHz, CDCl 3 ) δ 1.27 (t, J=7.26, 3H), 1.43 (t, J=7.68, 3H), 1.57 (S, 2H), 1.85-1.98 (m, 2H); 2.02-2.19 (m, 2H); 2.18-2.40 (m, 3H); 3.04 (q, J=7.67, 2H); 4.15 (q, J=7.26, 2H); 7.2-7.3 (m, 3H); 7.61 (m, 2H); 7.71 (s, 1H); 7.71 (d, J=8.5, 1H). In addition to the desired product 4-cyano-4-[3-ethyl-1-(4fluorophenyl)-1H-indazol-6-yl]cyclohexanecarboxylic acid ethyl ester, a major byproduct, namely 4-[3-ethyl-1-(4-fluoro-phenyl)-1H-indazol-6-yl]cyclohex-3-enecarboxylic acid ethyl ester (1.16 grams) was obtained. MS m/z 393 (M+H + , base). 1 H NMR (400 MHz, CDCl 3 ) δ 1.24 (m, 3H); 1.43 (m, 3H); 1.6-2.7 (m, 7H); 3.02 (m, 2H); 4.13 (m, 2H); 6.17 (br, s 1H); 7.15-7.25 (m, 4H); 7.50 (s, 1H); 7.61-7.67 (m, 2H).
EXAMPLE 23
Cis-4-cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]-cyclohexanecarboxylic acid
This compound was prepared in analogous manner as cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexanecarboxylic acid, synthesis of which is described in detail in Schemes I and II of U.S. Ser. No. 09/308,954, filed May 8, 1997 as Attorney Docket No. PC9798, starting with 0.71 grams (1.694 mmol) of 4-cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl]-cyclohexanecarboxylic acid ethyl ester.
mp=173-175° C.; MS m/z 392 (M+H + , base). Anal. Calc'd for C 23 H 23 O 2 N 2 F: C, 70.57; H, 5.66; N, 10.73. Found: C, 70.39; H, 5.61; N 10.82. 1 H NMR (400 MHz, CDCl 3 ) δ 1.42-1.45 (t, J=7.57, 3H); 1.91 (t, J=13.28, 2H); 2.09 (m, 2H); 2.23-2.35 (m, 4H); 2.40-2.48 (m, 1H); 3.06 (q, J=7.67, 2H); 7.2-7.26 (m, 2H); 7.29 (d, J=7.47, 1H); 7.60 (m, 2H); 7.71 (s, 1H); 7.78 (d, J=8.5, 7H).
Alternatively, cis-4-cyano-4-[3-ethyl-1-(4-fluorophenyl)-1H-indazole-6-yl]cyclohexane-carboxylic acid can be prepared in analogous manner as cis-4-cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid starting with 6-bromo-3-ethyl-1-(4-fluorophenyl)-1H-indazole following the synthetic steps outlined in Scheme 2, step 5, and Scheme 3, steps 1-7 described further above in more detail.
EXAMPLE 24
4-(3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl)-cyclohex-3-ene-carboxylic acid
To a stirred solution of 1.13 g (2.87 mmol) of 4-(3-ethyl-1-(4-fluorophenyl)-1H-indazol-6-yl)-cyclohex-3-ene-carboxylic acid ethyl ester dissolved in 50 mL of methanol and 15 mL of tetrahydrofuran was added 8.62 mL (8.61 mmol) of 1N sodium hydroxide and reaction mixture heated to reflux for 3 hr. After 3 hr, the reaction mixture was concentrated on a rotary evaporator, diluted with 200 mL of H 2 O, acidified to pH 1 with 1N HCl and extracted 2×200 mL ethyl acetate. The organic extracts were combined, washed with water, brine and dried over Na 2 SO 4 . Filtration, concentration and drying gave crude product. Recrystallization from ethyl acetate/hexane gave 0.31 grams of white crystalline product. mp=214-216° C.; MS, m/z 365 (M+H + , base).
EXAMPLE 25
1-Cyclohexyl-3-ethyl-6-fluoro-1H-indazole
To a solution of 1-(2,4-difluoro-phenyl)-propan-1-one (21.29 g, 125.1 mmol) in toluene (120 mL) was added sodium acetate (26.75 g, 326.1 mmol) and cyclohexyl/hydrazine mesylate (34.0 g, 163 mmol). The reaction mixture was heated to reflux in a Dean-Stark apparatus for 12 hours. The reaction was cooled to room temperature and poured into 1 N hydrochloric acid (100 mL). The toluene layer was separated and washed with water (75 mL) and brine (75 mL). The organic layer was dried over magnesium sulfate, filtered, and concentrated to yield 30.07 g of 1-cyclohexyl-3-ethyl-6-fluoro-1H-indazole (98% yield). 1 H NMR (400 MHz, CDCl 3 ) d 1.33 (t, 3, J=7.7), 1.35-1.44 (m, 2), 1.47-1.96 (m, 8), 2.93 (q, 2, J=7.7), 4.14-4.22 (m, 1), 6.81 (dt, 1, J=8.9, 2.1), 6.99 (dd, 1, J=9.8, 2.1), 7.40 (ddd, 1, J=8.7, 5.2, 0.4). 13 C NMR (100 MHz, CDCl 3 ) d 13.97, 20.53, 25.37, 25.84, 32.32, 58.18, 94.77 (d, J=27.4), 109.11 (d, J=26.0), 119.38, 121.75 (d, J=11.5), 139.89 (d, J=13.0), 146.61, 161.95 (d, J=242). IR 2968, 2934, 2856, 1624, 1507, 1174, 1125, 825 cm −1 . Analysis calculated for C 15 H 19 FN 2 : C, 73.14; H, 7.77; N, 11.37. Found: C, 73.33; H, 7.90; N, 11.46.
EXAMPLE 26
1-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexane-1,4-dicarbonitrile
To a solution of 1-cyclohexyl-3-ethyl-6-fluoro-1H-indazole (1.50 g, 6.09 mmol) and cylohexane-1,4-dicarbonitrile (3.27 g, 24.4 mmol) in toluene (15 mL) was added potassium bis(trimethylsilyl) amide (1.82 g, 9.12 mmol). The reaction mixture was heated to 100° C. and stirred for 5 hours. The reaction mixture was cooled to room temperature and poured into 1N HCl (15 mL). The layers were separated and the organic extracts were concentrated. The crude product was stirred in 20% EtOAc/Hexanes (15 mL) for 20 minutes and the solids were filtered (1.1 g of cyclohexane-1,4-dicarbonitrile recovered). The filtrate was concentrated to a crude oil. For characterization purposes, the diastereoisomers were obtained by purification by chromatography on silica gel (125 g) eluting with 2:1 hexanes/ethylacetate (1.69 g product isolated, 77% yield). Higher Rf diastereoisomer: 1 H NMR (400 MHz, CDCl 3 ) d 1.37 (t, 3, J=7.7), 1.24-1.78 (m, 4), 1.92-2.10 (m, 6), 2.19-2.35 (m, 8), 2.98 (q, 2, J=7.7), 3.15-3.17 (m, 1), 4.30-4.39 (m, 1), 7.19 (dd, 1, J=8.5, 1.7), 7.51 (d, 1, J=0.8), 7.71 (d, 1, J=8.5). 13 C NMR (100 MHz, CDCl 3 ) d 14.07, 20.60, 25.34, 25.79, 25.92, 32.61, 33.36, 44.30, 57.66, 105.92, 117.04, 121.00, 121.52, 121.79, 122.09, 137.33, 139.54, 146.41. IR 2934, 2239, 1620, 1448, 1435, 1238, 1049, 803 cm −1 . Analysis calculated for C 25 H 28 N 4 : C, 76.63; H, 7.83; N, 15.54. Found: C, 76.69; H, 7.87; N, 15.65. Lower Rf diastereoisomer: 1 H NMR (400 MHz, CDCl 3 ) d 1.36 (t, 3, J=7.7), 1.42-1.53 (m, 2), 1.74-1.82 (m, 2), 1.89-2.08 (m, 8), 2.17-2.34 (m, 6), 2.58 (tt, 1, J=12.2, 3.5), 2.97 (q, 2, J=7.7), 4.28-4.36 (m, 1), 7.09 (dd, 1, J=8.5, 1.7), 7.49 (d, 1, J=1.0), 7.69 (d, 1, J=8.5). 13 C NMR (100 MHz, CDCl 3 ) d 14.02, 20.57, 25.32, 25.81, 27.07, 27.27, 32.57, 36.04, 43.63, 57.75, 106.05, 116.65, 121.17, 121.50, 122.13, 137.17, 139.54, 146.38. IR 2935, 2231, 1620, 1447, 1211, 1061, 807 cm −1 . Analysis calculated for C 25 H 28 N 4 : C, 76.63; H, 7.83; N, 15.54. Found: C, 76.52; H, 7.95; N, 15.37.
EXAMPLE 27
4-Cyano-4-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)cyclohexanecarboxylic acid ethyl ester
To a solution of 1-(1-cyclohexyl-3-ethyl-1H-indazol-6-yl)-cyclohexane-1,4-dicarbonitrile (2.589, 7.16 mmol) in ethanol (35 mL) was bubbled hydrochloric acid gas for 20 minutes. The reaction mixture was stirred 20 minutes after which the solvent was concentrated. To the crude product was added toluene (20 mL) and water (20 mL) and the mixture was stirred for 8 hours. The layers were separated and the toluene layer was concentrated to a crude foam. For characterization purposes, the diastereoisomers were obtained by purification by chromatography on silica gel eluting with 4:1 hexanes/ethylacetate (2.37 g product isolated, 81% yield).
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The invention relates to compounds of the formula I
and pharmaceutically acceptable salts thereof, wherein
R 2 a and R 2 b are independently selected from the group consisting essentially of hydrogen and hereinafter recited substituents, provided that one, but not both of R 2 a and R 2 b must be independently selected as hydrogen, wherein said substituents comprise:
wherein the dashed lines in formulas (Ia) and (Ib) independently and optionally represent a single or double bond, provided that in formula (Ia) both dashed lines cannot both represent double bonds at the same time; and
R, R 1 , R 3 , R 4 , R 5 , R 6 , R 7 , R 18 and m are as defined. The invention further relates to intermediates for the preparation of the compounds of formula I, and to pharmaceutical compositions containing, and methods of using, the compounds of formula I, or acceptable salts thereof, for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) in a mammal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to methods for cultivating infectious laryngotracheitis virus and egg drop syndrome virus in a continuous cell line.
BACKGROUND OF THE INVENTION
Infectious laryngotracheitis virus (ILTV), the causative agent of a highly infectious upper respiratory tract disease in chickens, is a member of the family Herpesviridae, subfamily Alphaherpesviridae and was first identified in 1930. ILTV is highly contagious with mortality rates as high as 70% and is therefore of considerable economic importance. Immunization is the only efficient way to prevent this disease. Available vaccines against ILTV have relied on the cultivation of live artificially attenuated ILTV, naturally occurring non-pathogenic forms of the virus, or subunits of the virus. See for example, U.S. Pat. Nos. 3,444,293; 3,331,736; and 4,980,162 as well as patent applications WO 91 02053 and WO 92 03554 which all describe various ILTV vaccines.
Egg Drop Syndrome virus (EDS), the causative agent in a disease which is characterized mainly by a serious decrease in the egg production in laying hen flocks, is an adenovirus. During the past few years, this disease has become economically important in Western Europe where the virus was first isolated (Van Eck et al. (1976) Avian Pathology 5:261-272). Inactivated vaccines, which may impart immunity to the virus, have been produced in primary cells of duck embryo fibroblast (for example, U.S. Pat. No. 4,302,444).
ILTV has traditionally been cultivated in embryonic eggs and primary chicken cell cultures (Guo, P. (1982) Chinese J. Vet. Med. 8(7):18-20; Guo, P. (1982) J. South China Agri. Univ. 3(4):13-20), such as embryonic kidney (Chang et al. (1960) Avian Dis. 4:484-490), kidney (Mayer et al. (1967) Am. J. Vet. Res. 28(124):825-832) and embryonic liver (Hughes et al. (1988) Avian Pathol. 17:295-303) cells. Recent publications on ILTV show that it is still cultured in primary chicken cells (Griffin, A. (1991) J. Gen. Virol. 72:393-398; Kongsuwan et al. (1991) Virology 184:404-410; Keeler et al. (1991) Avian Dis. 35:920-929; Sheppard and York, (1991) Acta Virol. 34:443-448).
Likewise, recent publications on EDS show that it also is cultured in primary chicken cells (Zsak et al. (1981) J. Gen. Virol. 56:87-95; Todd et al. (1978) J. Gen. Virol. 40:63-75; Todd et al. (1988) Avian Pathology 17:909-919).
Preparation and maintenance of primary cell cultures are laborious and, therefore, time consuming enterprises requiring the sacrifice of many animals. Until now no continuous cell line has been identified which is capable of supporting either ILTV or EDS replication.
The advantages of a continuous cell line for the cultivation of ILTV and EDS in comparison to primary cells are many. Due to high multiplication rates, large numbers of cells are available within a short period of time. Demands on the complexity of culture medium are low. Continuous cell lines are easily maintained and passaged, and can be frozen for storage. Continuous cell line cultivation allows constant and more stringent parameter controls in experiments, while each preparation of primary cells imposes new parameters.
Continuous cell lines from different species have been established. However, considerable difficulty has been encountered when trying to obtain continuous culture cell lines from chicken tissues (Schneider et al. (1965) Exp. Cell Res. 39:631-636; Ponten, J. (1970) Int. J. Cancer 6:323-332; Gey et al. (1974) Exp. Cell Res. 84:63-71; Beug et al. (1977) Exp. Cell Res. 107:417-428; Kaji et al. (1979) Exp. Cell res. 119:231-236). More recently a number of continuous cell lines from chicken tissues have been described. These include lymphoblastoid cell lines from avian virus induced lymphomas (Akiyama and Kato, (1974) Biken J. 17:105-116; Hihara et al. (1974) Natl. Inst. Anim. Health Q. 14:163-173), or leukemias (Langlors et al. (1976) Cancer Res. 36:3894-3904; Pfeifer et al. (1980) Int. J. Cancer 25:235-242), fibroblastic cells from normal, Rous Sarcoma virus-treated or carcinogen-treated chicken embryo cells (Kaaden et al. (1982) In Vitro 18:827-834; Ogura et al. (1984) Gann. 75:410-414; Dinowitz, M. (1977) J. Natl. Cancer Inst. 58:307-312; Lerman et al. (1976) J. Natl. Cancer Inst. 57:295-301), and hepatocellular cells from carcinoma treated chickens (Kawaguchi et al. (1987) Cancer Res. 47:4460-4464). None of these cells have been suggested to be capable of supporting replication of either ILTV or EDS.
SUMMARY OF THE INVENTION
Accordingly, objects of the present invention include providing: methods for cultivating ILTV in a continuous cell line, a continuous cell line infected with ILTV, a vaccine for providing immunity against ILTV, methods for cultivating EDS in a continuous cell line infected with EDS, a continuous cell line, and a vaccine for providing immunity against EDS.
The present invention provides a method for obtaining infectious laryngotracheitis virus comprising (i) infecting a continuous avian hepatocellular cell line, wherein said cell line is CH-SAH, with infectious laryngotracheitis virus, (ii) culturing said virus, and (iii) recovering virus produced thereby.
The present invention also provides a method for obtaining egg drop syndrome virus comprising (i) infecting a continuous avian hepatocellular cell line, wherein said cell line is CH-SAH, with egg drop syndrome virus, (ii) culturing said virus, and (iii) recovering virus produced thereby.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 Uninfected confluent monolayer of CH-SAH cells.
FIG. 2 Formation of multi-nucleated areas or syncytia following infection with ILTV.
FIG. 3 Progression of ILTV induced syncytia to stage of rounding up and detachment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Accordingly, the present invention provides a method for cultivating either ILTV or EDS in a hepatocellular carcinoma cell line (CH-SAH, which is alternatively called the LMH cell line). The CH-SAH cell line has been deposited with the American Type Culture Collection (ATCC), 12301 Parklawn Drive, Rockville, Md. 29852 under the provisions of the Budapest Treaty as accession number ATCC CRL 11354 on May 26, 1993. Growth of CH-SAH cells after passaging can be done in Waymouth, DMEM with glucose or fructose, DMEM/F-12 medium supplemented with L-glutamine, sodium bicarbonate, appropriate antibiotics (preferably gentamicin), calf serum and fetal calf serum. Suitable serum concentrations are 0%-20%. Cells can suitably be grown at a temperature range of from 35° to 40° C. (preferably 37°-38° C.) in a CO 2 incubator (preferably in an atmosphere containing 2%-5% CO 2 ). Alternatively, these cells can be grown in roller bottles, which provide a closed system without CO 2 exchange. CH-SAH cells flourish well at somewhat high density (see FIG. 1). CH-SAH cells can suitably be seeded at densities ranging from 5×10 4 to 5×10 5 cells/cm 2 , preferably at 1×10 5 cells/cm 2 to 4×10 5 cm, and then split on day 3-7 with media. The media is preferably changed every 3-4 days. A suitable pH range is from 6 to 8 (preferably, 7.0 to 7.2). If the cells are grown in roller bottles, the seeding density is as described above and the cells are split on day 3-7 with 0-2 media changes during that period.
CH-SAH cells can suitably be infected with ILTV by known methods 3 to 24 hours after seeding. The same media and growth conditions as mentioned above for the propagation of these cells can be used to cultivate the infected cells. Suitable ILTV inoculum can be material grown in embryonated eggs, preferably chicken embryonated eggs, such as chorioallantoic membranes or allantoic fluid. Inoculum can alternatively be virus grown on CH-SAH cells. Preferably, inoculum is prepared by one or two cycles freezing at -70° C. followed by quick thawing to release viruses from infected cells. Inoculum can additionally be briefly sonicated. Absorption of the inoculum material onto the CH-SAH cells can be as brief as 1 hour. Alternatively, the inoculum can be left on the CH-SAH cells.
Following infection with ILTV, viral growth typically occurs after 24 to 48 hours. Morphological changes (cytopathic effect) in cell monolayers can be observed as a result of viral growth resulting in multi-nucleated areas, best described as syncytia (see FIG. 2). As these areas enlarge, the syncytia round up and detach from the vessel surface and begin to float in the supernatant (see FIG. 3).
Virus can suitably be harvested when the maximal cytopathic effect is observed. Suitable harvest methods include: agitation, aspiration, scraping, or freeze thawing accompanied by aspiration. Preferably, harvested viruses are stored at -70° C.
Harvested ILTV can suitably be titered either on CH-SAH cells, in embryonated eggs, or in primary cell cultures of embryonic kidney, kidney, or embryonic liver cells. 9-12 day old embryonated eggs are preferably used for virus titration. The inoculum is placed on the dropped chorioallantoic membrane (CAM). The inoculum is preferably made cell free and diluted in cell culture media or Tryptose phosphate broth.
Observation of ILTV cytopathic effect in cell cultures can be endpoint determined up to 7 days; this can suitably be done by visual evaluation of morphological changes on the monolayer or by fluorescent antibody staining techniques. Alternatively, observation of cytopathic effect in embryonated eggs can be visually evaluated by the detection of plaques on the CAM that have opaque edges and depressed central areas of necrosis. The plaques result from proliferation and necrosis of the affected cells in the CAM.
The activity of ILTV is suitably measured quantitatively by preparing dilutions of the sample and determining the highest dilution (endpoint) at which activity is still detectable. The preferred method is the Reed Muench method which permits interpretation of the 50% endpoint from data derived from a quantal response. The formula can be applied similarly to rates of infection in any host system. The unit of infectivity used to express the results are mean embryo infective dose, EID 50 , and mean tissue culture infective dosed TCID 50 .
CH-SAH cells can suitably be infected with EDS by known methods 24-72 hours, preferably 48 hours, after seeding. Growth of infected CH-SAH cells can be done in Waymouth, DMEM with glucose or fructose, DMEM/F-12 medium supplemented with L-glutamine, sodium bicarbonate, appropriate antibiotics (preferably gentamicin), calf serum and fetal calf serum. Suitable serum concentrations are 0%-20%. Cells can suitably be grown at a temperature range of from 35° to 40° C. (preferably 37°-38° C.) in a CO 2 incubator (preferably in an atmosphere containing 2%-5% CO 2 ). EDS infected CH-SAH cells can suitably be seeded at densities ranging from 5×10 4 to 5×10 5 cells/cm 2 , preferably at 1×10 5 cells/cm 2 to 4×10 5 cm, and then split on day 3-7 with media. The media is preferably changed every 3-4 days. A suitable pH range is from 6 to 8 (preferably, 7.0 to 7.2).
Suitable EDS inoculum can be material grown in embryonic eggs, preferably duck embryonated eggs in the allantoic sac. Embryonic eggs are suitably inoculated by placing the inoculum on the allantoic sac. Alternatively, EDS inoculum can be virus grown in chicken embryo liver cells. Inoculum can alternatively be virus grown on CH-SAH cells. The inoculum is diluted, preferably in tissue culture medium, and brought in contact with the CH-SAH cells for 1 or more hours. Alternatively the inoculum can be left on the cells.
After infection of CH-SAH cells with EDS virus morphological changes in the cell culture occur. A cytopathological effect can be observed. Cells degenerate, become rounded and detach from the surface.
Virus can be harvested when the cytopathic effect is 50%. Methods include scraping, agitation or freeze thawing. Harvested virus fluids are preferably stored below -50° C.
Harvested EDS virus fluids can suitably be titrated in embryonated duck eggs, cell cultures of embryonic liver or kidney cells. Embryonated duck eggs, princubated 9-12 days, are preferably used for EDS virus titrations. The virus fluid is inoculated into the allantoic sac. Growth of EDS virus is monitored using the haemagglutination reaction. Titers are calculated using the Reed Muench method or the Spearmann-Karber method.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
The purpose of this experiment was to determine optimal parameters for propagation of CH-SAH cells in roller bottles. Parameters evaluated were roller bottle types, media volume and seeding densities.
CH-SAH cells were grown in DMEM/F-12 media supplemented with L-glutamine 0.2 mM, gentamicin 50 mg/ml and 10% non-heat inactivated, sterile filtered, fetal calf serum. A pool of cells were made from stock roller bottles that had been disassociated with 10% trypsin-EDTA and 90% saline A (saline with 10 gm/L glucose and 0.5% Phenol red). The cells were seeded on day 0 into roller bottles at a target density of 3×10 5 cells/cm 2 . The manufacturers of the roller bottles were Corning (850 and 1700 cm 2 ), Falcon (850 and 1500 cm 2 ) and InVitro (1020 and 1700 cm 2 ). Media volumes per roller bottle were 350 ml/850 cm 2 , 400 ml/1020 cm 2 , 450 ml/1500 cm 2 and 450 ml/1700 cm 2 . The roller bottles were incubated for 4 days at 37° C. with daily observation.
At the end of this time period, cells were harvested by trypsinization from each roller bottle. The individual roller bottle cell pool was then counted by tryphan blue staining.
______________________________________ Cell Yield/cm.sup.2 Yield______________________________________Corning 850 cm.sup.2 1.383 × 10.sup.6 4.6 XCorning 1700 cm.sup.2 7.964 × 10.sup.5 2.7 XFalcon 850 cm.sup.2 1.265 × 10.sup.6 4.0 XFalcon 1500 cm.sup.2 6.411 × 10.sup.5 2.1 XInVitro 1020 cm.sup.2 7.182 × 10.sup.5 2.4 XInVitro 1700 cm.sup.2 6.441 × 10.sup.5 2.2 X______________________________________
The optimal parameters arrived at for growth of CH-SAH cells were to use Corning 850 cm 2 or Falcon 850 cm 2 roller with 350 ml media. Cells seeded at 3×10 5 per cm 2 would increase 4.6 and 4.0 times original density after 4 days propagation.
Example 2
The purpose of this experiment was to determine optimal parameters for infection of ILTV in CH-SAH cells. Parameters evaluated were multiplicity of infection (m.o.i.) and harvest time period.
ILT Challenge Virus as supplied by the USDA National Veterinary Services Laboratory and passaged 3 times in embryonated eggs has a titer of 1×10 6 .5 TCID 50 /ml. This material was composed of homogenized chorioallantoic membranes. It was frozen (-70° C.) and thawed (room temperature) twice. The inoculum was added at the same time as cells to 20 ml of media per flask. CH-SAH cells were seeded at 1×10 5 cells/cm 2 in 75 cm 2 Falcon filter vented flasks. The media used was described in Example 1 at 37° C., 2% CO 2 for the infection period. Harvest times used were 24, 48 and 72 hours. At the end of these time periods the flasks were placed at -30° C. until frozen. The flasks were then placed at room temperature until thawed. The virus homogenate was then titrated for activity at TCID 50 /ml. M.O.I.'s used were 0.03, 0.006 and 0.0006.
______________________________________HarTime MOI Amt Inoc Amt Har Yield______________________________________48 0.03 1 × 10.sup.5.4 TCID.sub.50 1 × 10.sup.5.7 TCID.sub.50 2.1 X72 0.03 1 × 10.sup.5.4 TCID.sub.50 1 × 10.sup.6.1 TCID.sub.50 5.3 X72 0.006 1 × 10.sup.4.7 TCID.sub.50 1 × 10.sup.6.5 TCID.sub.50 67.0 X72 0.0006 1 × 10.sup.3.7 TCID.sub.50 ** NA______________________________________ ** = Virus level was below lower limit in titration assay NA = Not Applicable
All the other harvest samples from time point 24 hours (all MOI's), and 48 hours (MOI 0.006 and 0.0006) were below the lower limit of the titration assay.
The optimal harvest parameters of infecting CAM ILTV unto CH-SAH cells were: seed cells at 1×10 5 /cm 2 , MOI of 0.006 and incubate for 72 hours before harvest.
Example 3
The purpose of this experiment was to determine the titer (TCID 50 ) of the virus harvested in Example 2.
Media used was previously described in Example 1. Plates used were Falcon Primeria 96-well MICROTEST III™ (flat-bottom) plates, catalog #3872. CH-SAH cells were split within a 24 hour period before the titration was performed (cells were still in lag phase, this was p.m. of Day -1). Seeding density was 1×10 5 cells/cm 2 . Volume per well was 200 μl. Maintained at 37° C. and 5% CO 2 .
Titration was started (Day 0) in the a.m. Virus samples were thawed and kept on ice until diluted. They were diluted in CH-SAH complete media. As each sample was diluted, 1×10 -1 to 1×10 -8 , it was placed at 4° C. until used After dilution of samples, 90 μl/well of media (10 μl remaining) was removed by use of a Costar multipipettor, same set of tips. This was done one sample at a time. 100 μl/well of virus dilution (4 replicates per dilution) was then added one sample at a time. Adsorption time of 1 hour (from last addition) was done at 37° C. and 2% CO 2 . After the adsorption time, complete CH-SAH media was added, 100 μl/well, one sample at a time.
Plates and cells were observed for a 7-day period as follows:
Day 0: Pre-inoculation for % confluency (50%-70%).
Day 0: Post-inoculation for disturbance of monolayer (none).
Day 1: For pH and confluency (pH good, 80% confluency).
Day 3: As for Day 1.
Day 7: Briefly observed for % confluency (100%) and estimation of endpoint CPE (marked plate). Plate contents were then dumped and monolayer was fixed with 60% acetone/40% absolute ethanol.
Fluorescent antibody staining was done on these plates after washing with PBS. The chicken antisera was diluted 1:100 in PBS and incubated for 1 hour at 37° C. (SPAFAS antisera to ILTV). The plates were washed again with PBS and the conjugate was added for 1 hour at 37° C. (KPL FITC labeled affinity purified antibody to chicken IgG [H+L] produced in goats). The plates were washed again with PBS and then either read or stored at 4° C.
Any fluorescence was considered positive. Calculation of virus activity was done by the Reed Muench method (Reed, L. J., and H. Muench. "A simple method for estimating fifty percent endpoints" Am. J. Hyg. (1938) 27:493-497). The titer of this material in TCID 50 /ml was listed in the table in Example 2.
Example 4
The purpose of the following experiments was to increase the titer (TCID 50 /ml) of the virus harvested in Example 2. The method was to continually pass the virus in CH-SAH cells over a period of time (actual 32 passes).
CH-SAH cells were seeded in 75 cm 2 Corning flasks and were incubated at 37° C. with 5% CO 2 (pre infection). The media was the same as mentioned in Example 1. Seeding density varied from 30%-90% confluency of the monolayer at time of infection.
The inoculum was passed both cell-associated and cell-free. Cell-associated meaning that the cell monolayer was scraped in the presence of media and then a portion was inoculated directly into the next flask's media. Cell-free meaning that the cell monolayer was scraped in the presence of media and then freeze-thawed (-70° C./RT) twice before inoculating into the next flask's media. The inoculum volume varied from entire contents (20 ml) to 1/30th of the harvest volume. Due to the frequent passing of virus and the fact that a titration takes 7 days, m.o.i. was not determined.
After inoculation the flasks were incubated at 37° C., 2% CO 2 until harvest. The incubation time varied from 1 day to 7 days, with daily observation. Harvest times were determined when maximal CPE was exhibited.
At the end of passaging this CH-SAH adapted virus material was titrated according to example 3. The titer of this material was 1×10 6 .6 TCID 50 /ml (geometric mean [GMT] of 8 samples).
Example 5
ILT Challenge Virus adapted to growth on CH-SAH as described in Example 4, was administered to a group of 7 week old specific pathogen free Leghorn chickens. A second group was given the parent (non-adapted) virus. Groups of 13 birds each were used. The parent virus and the CH-SAH adapted virus were given intratracheally at the same dose level each (target =1×10 4 .3 EID 50 ). At the end of a 14 day observation period, the challenge virus group exhibited 100% morbidity (nasal discharge, moist rales, coughing, gasping, violent coughing and convulsive respiration including expulsion of blood clots) and 38% mortality. The CH-SAH adapted virus group exhibited 0% morbidity and 0% mortality. These results indicated that propagation in the CH-SAH cells attenuated the virus.
The attenuated virus was administered intraocularly (1×10 3 .9 TCID 50 ) to 4 week old specific pathogen free Leghorn chickens. On day 14 after vaccination the vaccinated group, along with an unvaccinated control group, was given ILT Challenge Virus intratracheally (1×10 4 .2 TCID 50 ). For 10 days after administration of the challenge virus the birds were observed. The control group exhibited 100% morbidity and 73% mortality while the attenuated virus group exhibited 0% morbidity and 0% mortality.
Comparative Example 1
Since both primary hepatocytes and macrophages have been shown to be infected by ILTV in vitro (Hughes and Jones (1988), Avian Pathology 17:295-303; Calnek et al. (1986), Avian Diseases 27:261-270), the retrovirus transformed cell lines of these cells were tested by Dr. Guo at Purdue University for propagation of ILTV.
Chicken cell line 249TK - was derived from an MC29 induced hepatoma and was obtained from Dr. R. F. Silva, Avian Diseases and Oncology Laboratory, United States Department of Agriculture, East Lansing, Mich. The 249TK - cells were grown in M199 medium (Gibco) supplemented with 10% FCS plus 2% chicken serum.
The macrophage cell line HD11 is a cell line transformed by the replication defective avian retrovirus reticuloendotheliosis virus (REV-T) and was obtained from Dr. V. Hinshaw, University of Wisconsin. HD11 cells were grown in RPMI 1640 (Gibco) supplemented with 5% FCS.
HD11, and 249TK - cells were infected with ILTV at an m.o.i. of 0.1. Primary embryonic liver cells served as control cells. Neither HD11 nor 249TK - cells showed any sign of infection within a week of incubation at 37° C. while the control cells showed complete CPE after only 2 days.
The lack of CPE or plaque formation does not exclude the possibility that ILTV DNA replicated in the cell but the viral assembly or egress step were blocked. To answer the question of whether ILTV DNA can replicate in the cell, ILTV-infected HD11 cells were tested for the presence of ILTV DNA. An ILTV DNA extraction from the cytoplasm of HD11 cells was performed 2 days post inoculation.
Extracted DNA was run on an agarose gel and blotted onto a nylon membrane. ILTV DNA derived from growth on primary embryonic hepatocytes served as a positive control. The DNAs were hybridized with a 32 P-labeled ILTV EcoRI DNA fragment and exposed to a Kodak X-ray film. The positive control DNA gave a signal, but no positive hybridization signal could be found for DNA derived from either the cytoplasmic or the nuclear fraction of the infected macrophage cell line, though DNA has been present in all preparations as could be seen in the agarose gel prior to blotting. No ILTV DNA was synthesized in the macrophage cell line HD11. These findings lead to the conclusion that cells permissive for infection with ILTV, such as hepatocytes and macrophages, were rendered non-permissive for infection after transformation with avian retroviruses.
Comparative Example 2
QT35 is a chemically induced quail fibroblast cell line. The QT35 cells were obtained from Dr. R. Nodgreen, Solvay Animal Health, Inc., Mendota Heights, Minn.
QT35 was tested by Dr. Guo at Purdue University for its potential to propagate ILTV. QT35 cells were infected at an m.o.i, of 0.1 and incubated at 37° C. for 4 days. No signs of infection such as formation of syncytial cells or plaques were observed.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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This invention involves a chemically transformed chicken hepatocyte derived cell line which is capable of efficiently supporting replication of infectious laryngotracheitis virus (ILTV) and methods for cultivating ILTV using this hepatocellular carcinoma cell line. The virus harvested from these continuous cell culture methods can be used as a vaccine against ILTV infection.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is cross-referenced to and claims priority from U.S. Provisional Application 60/792,761 filed Apr. 17, 2006, which is hereby incorporated by reference.
FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with Government support under contract N66001-03-C-8045 awarded by the Space and Naval Warfare Systems Center. The Government has certain rights in this invention.
FIELD OF THE INVENTION
The invention generally relates to climbing robots. In particular, the invention relates to directional and distributed control of adhesive forces for a climbing robot.
BACKGROUND OF THE INVENTION
Robots capable of climbing vertical surfaces would be useful for disaster relief, surveillance, and maintenance applications. Various robots have used suction and magnets for climbing smooth surfaces. A controlled vortex that creates negative aerodynamic lift has also been demonstrated. However, these solutions require substantial power and generate noise even when stationary. Microspines, drawing inspiration from insects and spiders, have been used to climb rough surfaces such as brick and concrete.
For climbing on a range of vertical surfaces from smooth glass to rough stucco, various animals including insects, spiders, tree frogs and geckos employ wet or dry adhesion. The impressive climbing performance of these creatures has lead to a number of robots that employ adhesives for climbing. Sticky adhesives have the disadvantage that they quickly become dirty and lose adhesion. Another disadvantage is that the adhesive requires relatively high forces for attachment and detachment. Some researchers have circumvented this problem by using spoke-wheel designs that allow the detachment forces at a receding point of contact to provide the necessary attachment force at the next.
To overcome the problems with sticky adhesives, there has been a trend toward developing dry adhesives, which generally have a higher elastic modulus than pressure sensitive adhesives (PSAs) and rely on van der Waals forces between arrays of microscopic features and the substrate for adhesion. These have been modeled on the adhesive properties of geckos. In other work, climbing robots have used elastomeric microstructured tape or elastomeric pads that attract dirt after repeated use but, in contrast to PSAs, can be cleaned with water and reused. As feature sizes grow smaller, increasingly stiff and hydrophobic materials can be used while still obtaining sufficient real areas of contact for van der Waals forces to provide useful levels of adhesion. The result is an adhesive that resists dirt accumulation.
Currently, no single solution generates high adhesion, attaches with low preload, is rugged, self-cleaning, and can be scaled to climbing robot applications. The present invention addresses these shortcomings and advances the art of climbing robots and its applications thereof. In particular, the present invention provides new design mechanisms that are essential for a legged robot to climb and maneuver on vertical surfaces using dry adhesion. These design mechanisms enable: (i) hierarchical compliance for conforming at centimeter, millimeter, and micrometer scales; (ii) 2) directional adhesives so that the robot can control adhesion by controlling shear; and (iii) distributed force control that works with compliance and anisotropy to achieve stability.
SUMMARY OF THE INVENTION
The present invention entails a climbing robot using directional and distributed control of adhesive forces. The climbing robot has multiple limbs each with a plurality of toes. Each toe contains a plurality of parallel anisotropic hair features. These hair features make an acute angle with respect to a reference plane to define a hair direction. In one example the acute angle, φ 1 , ranges from 45<φ 1 <90 degrees. In another example the acute angle is about 70 degrees. Each of the anisotropic hair features have a tip angle with respect to the reference plane and with the hair tip in the direction of the hair direction. In one example the tip angle, φ 2 , ranges from 0<φ 2 <φ 1 degrees. In another example the tip angle is about 45 degrees.
A backing layer with embedded therein a flexible and inextensible fiber is affixed to the plurality of parallel anisotropic hair features. In one example, the backing layer varies in height. In another example the backing layer increases height in a direction opposite to the hair direction. The flexible and inextensible fiber is for example a fiber mesh, a fabric, a synthetic fiber or a synthetic cloth fiber.
A plurality of segments is affixed to the backing layer on the side of the backing layer opposite to the hair features. In one example, the segment thickness varies in height. In another example the segment thickness increases height in a direction opposite to the hair direction. The material of the backing layer is softer than the material of segments.
A cable goes through and near the surface of the plurality of segments. This cable controls the toes through an actuator. In one example the actuator is a push-pull actuator and push-pulls the cable. When the actuator controls the cable and herewith the toes, the backing layer hinges at gaps between the segments.
The design and control mechanisms of this invention provide several advantages over prior solutions. For example, the design features embodied in the climbing robot are multiple levels of compliance, at length scales ranging from centimeters to micrometers, to allow the robot to conform to surfaces and maintain large real areas of contact so that adhesive forces can support it. Structures within the feet ensure even stress distributions over each toe and facilitate engagement and disengagement of the adhesive materials. A force control strategy works in conjunction with the anisotropic adhesive materials to obtain sufficient levels of friction and adhesion for climbing with low attachment and detachment forces.
The invention could be a device or a system useful in non-robotic applications such as hanging or suspending objects on inclined, vertical or non-horizontal surfaces. For example, the features of the present invention could be combined as a device or system to create a hanging device, a picture hanger, a suspension mechanism, a finger, a robot finger, a toe or a robot toe.
BRIEF DESCRIPTION OF THE FIGURES
The present invention together with its objectives and advantages will be understood by reading the following description in conjunction with the drawings, in which:
FIGS. 1A-B shows according to the present invention a three-dimensional schematic of the toes ( FIG. 1A ) and a schematic cross section view of a toe of Stickybot ( FIG. 1B ).
FIGS. 2A-B shows according to the present invention a two-stage differential system actuated by a single push-pull actuator ( FIG. 2A ), which facilitates conformation on uneven surfaces and distributes the contact forces among the four toes. FIG. 2B shows an example of how the single servomotor actuates the toes using a double-rocker linkage “bogie”.
FIGS. 3A-B shows according to the present invention details of the nomenclature used to calculate the cable profile of the toes ( FIG. 3B ). FIG. 3A shows a three-dimensional schematic of a toe and FIG. 3B s
FIG. 4 shows according to the present invention anisotropic hair features made of 20 Shore-A polyurethane. The hair features in this example measure 380 micrometers in diameter at the base. The base angle (acute angle) is about 70 degrees and the tip angle is about 45 degrees in this example. The length of the hair features is typically larger than 500 micrometers, and the hairs have a diameter/length ratio of between 1/3 and 1/4.
FIG. 5 shows according to the present invention a comparison of the frictional-adhesion model (See Autumn et al. (2006) in a paper entitled “Frictional adhesion: a new angle on gecko attachment” and published in J. Exp. Biol. 209(18): 3569-3579) and the Johnson-Kendall-Roberts (JKR) model (See Johnson et al. (1971) in a paper entitled “Surface energy and the contact of elastic solids” and published in the Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences, 324(1558): 301-313) with pull off force data from a single toe of Stickybot's anisotropic patches (513 stalks). (A) When dragged against the preferred direction, the anisotropic patch exhibits negligible adhesion, although it sustains greater tangential force than would be expected from Coulomb friction when the normal force is zero. (B) When dragged in the preferred direction, the anisotropic patch demonstrates adhesion proportional to the shear force, albeit with saturation at the highest levels (unlike gecko setae). (C) The frictional-adhesion model has an upper shear force limit. In comparison, the JKR model shows the typical behavior of an isotropic elastic material with adhesion.
FIG. 6 shows according to the present invention a schematic used to generate values for the grasp matrix.
FIG. 7 shows according to the present invention force plate data of rear left foot (left) and front right foot (right) of Stickybot climbing with a 6 second period at a speed of 1.5 cm/s (data were filtered at 10 Hz). Two successive runs (solid and dotted lines) are shown to illustrate repeatability.
DETAILED DESCRIPTION OF THE INVENTION
A. Hierarchical Compliance
Climbing with van der Waals forces requires intimate contact because the forces scale as A/d 3 where A is the Hammacher constant and d is the local separation between two surfaces. For particular material combinations the Hammacher constant can vary by as much as a factor of 4. However, reducing the separation distance has a much greater effect, making it essential to comply to surfaces at all length scales above tens of nanometers.
Natural materials, and many man-made materials such as concrete, have an approximately fractal surface topography. As a result, surface features such as protrusions or indentations can be found at many length scales, from centimeters to fractions of micrometers. Consequently, a general-purpose solution for dry adhesion must involve conformability over similar length scales.
In the gecko, the flex of the body and limbs allows for conformation at the centimeter scale. The feet are divided into several toes that can conform independently at a scale of several millimeters. The bottom surfaces of toes are covered with lamellae that conform at the millimeter scale. The lamellae are composed of many individual setae, each of which acts as a spring-loaded beam that provides conformability at the 1-50 micrometer scale. The tips of the setae are divided into hundreds of spatulae that provide conformability at the <500 nanometer scale. The consequence of the gecko's hierarchical system of compliances is that it can achieve levels of adhesion of over 500 KPa on a wide variety of surfaces from glass to rough rock and can support its entire weight from just one toe.
To enable a climbing robot to climb a variety of surfaces from glass to corrugated siding an analogous, albeit much less sophisticated, hierarchy of compliances has been employed and provided herein. In one example, the body of Stickybot is a highly compliant under-actuated system comprised of 12 servos and 38 degrees of freedom. The torso and limbs were created via Shape Deposition Manufacturing using two different grades of polyurethane (Innovative Polymers: 72 Shore-DC and 20 Shore-A hardness).
The stiffest and strongest components of Stickybot are the upper and lower torso and the forelimbs, which are reinforced with carbon fiber. The central part of the body represents a compromise between sufficient compliance to conform to gently curved surfaces and sufficient stiffness so that maximum normal forces of approximately +/−1N can be applied at the feet without producing excessive body torsion. Additionally, the spine structure at the center of body has the ability to provide body articulation for greater maneuverability.
In this example, each limb of Stickybot is equipped with four segmented toes. Each toe has two grades of polyurethane and reinforced with embedded synthetic cloth fiber or fiber mesh, which is flexible but inextensible ( FIGS. 1A-B ). A single servomotor actuates the toes using a double-rocker linkage and cables in (metal) sleeves ( FIGS. 2A-B ) that allow the toes to attach independently to objects with a minimum radius of curvature of 5 centimeters. The toes can also peel backward in a motion approximating the digital hyperextension that geckos use to detach their feet with very little force.
Assuming an approximately uniform toe width, the toe's cable profile is calculated to achieve a uniform stress distribution when the toes are deployed on flat surfaces ( FIGS. 3A-B ). The sum of the forces in the y direction is given as:
T sin θ− T sin(θ+δθ)+ F n =0 (1)
where T is the force acting along the cable, θ is the angle of the cable with respect to the horizontal, and F n is the normal force acting on the bottom of the toe. To ensure uniform attachment of the foot, a constant pressure on the bottom of the toe is desired:
T ( sin ( θ + ⅆ θ ) - sin θ ) ⅆ x = F n d x = σ ( 2 )
Expanding the term sin(θ+dθ) and assuming that dθ is small such that cos dθ=1 and sin dθ=dθ yields:
cos θ ⅆ θ = σ T ⅆ x ( 3 )
Integrating both sides and solving for θ gives:
θ = arcsin ( σ x T ) ( 4 )
The slope of the cable profile is thus:
ⅆ y ⅆ x = tan ( arcsin ( σ x T ) ) ( 5 )
Integrating with respect to x yields the profile of the cable:
y ( x ) = - T σ 1 - ( σ x T ) 2 ( 6 )
which is simply a circular arc with radius T/σ.
At the finest scale, the contact surfaces of the feet are equipped with synthetic adhesive materials ( FIGS. 1A-B ). To date, the best results have been obtained with arrays of small, asymmetric elastomeric features as shown in FIG. 4 . The arrays were made by micromolding with a soft (Shore 20-A) urethane polymer. This structure allows anisotropic compliance that is essential for the directional adhesive behavior addressed in following section.
Anisotropic Friction and Adhesion
As mentioned in the previous section, geckos can achieve levels of adhesion of over 500 KPa over areas of several square millimeters. However, adhesion only occurs if the lamellae and setae are loaded in the proper direction (inward from the distal toward the proximal region of the toes). As the setae first contact the surface there is a transient positive normal force due to their elasticity. Shortly thereafter, the tips of the setae grab the surface and the normal force becomes tensile. The maximum pull-off force is related directly to the amount of tangential force present. Conversely, if the toes are brought into contact while moving from the proximal toward the tip regions (i.e., pushing along the toes rather than pulling) no adhesion is observed and the tangential force is limited by a coefficient of friction. The tangential and normal forces contact limits can be modeled as:
F N ≥ - 1 μ F T F N ≥ - tan ( α *) F T { F T < 0 0 ≤ F T ≤ F max ( 7 )
where α* is the critical peel angle, μ is the coefficient of friction, F T is tangential (shear) load, taken positive when pulling inward, and F N is the normal force, taken positive when compressive. The limit, F max , is a function of the maximum shear load that the gecko or robot can apply, the material strength, and the shear strength of the contact interface. Thus, the adhesion increases proportionally with the applied tangential force. This feature, coupled with the gecko's hierarchical compliance, allows it to adhere to surfaces without applying a significant preload. This is beneficial since any preload can cause a gecko (or robot) to push itself away from the wall. Additionally, by decreasing the shear load, the gecko is able to release its foot from the wall gracefully, with zero normal force. FIG. 5 illustrates the directional adhesion model in comparison to the commonly used isotropic Johnson-Kendall-Roberts (JKR) model for elastomers. In contrast to the frictional adhesion model, the JKR model's limit surface does not intersect the origin. Instead, the maximum adhesion force is obtained when there is zero shear force, which is much less useful for climbing on vertical surfaces. Moreover, detachment requires a high normal force unless a high tangential force is also present.
Stickybot's anisotropic adhesive patches approximately follow the frictional-adhesion model as shown by data in FIG. 5 . Evidence of low preload and detachment forces is presented in the Results section. Early versions of Stickybot used isotropic adhesive patches comprised of polyurethane (Innovative Polymers Shore 20A) or Sorbothane. The large detachment forces caused undesirable force transients to propagate throughout the body and prematurely detach the other feet. Reliable climbing was not obtained until the anisotropic features were added. The anistropic patches also work in conjunction with Stickybot's underactuated limbs: because the patches essentially self-adhere when they are pulled in shear, the toes automatically align themselves to surfaces to maximize the contact area.
Distributed Force Control
Distributed force control ensures that stresses are uniformly distributed over the toes and that undesirable force transients and accompanying oscillations are avoided. At the toe level, embedded flexible but inextensible fabric ( FIG. 1B ) allows the feet to obtain a more uniform shear loading over the toes. Together, the fabric and the cable “tendons” provide a load path that routes tangential forces from the toes to the ankles without producing undesired bending moments or stretching that would cause crack propagation and premature peeling at one edge of a toe. At the foot level, ankle compliance and a two stage differential mechanism balance normal forces among toes. At the body level, Stickybot utilizes force control to manage the tangential forces at the feet. This allows Stickybot to maintain dynamic equilibrium as well as increase or decrease the allowable adhesion force.
Unlike a walking or running quadruped, a climbing quadruped must pay continuous attention to the control of internal forces whenever feet are in contact with the climbing surface. Also, it is important to unload feet in the tangential direction (to relax any built-up forces and accompanying elastic deflections) immediately before lift-off so as to prevent transient forces and associated oscillations that could cause other feet to lose their grip. In geckos, it has been observed that there are virtually no noticeable transient forces as feet make and break contact. Attachment and liftoff are smooth, low-force events. In Stickybot, as in geckos, the combination of toe peeling (digital hyperextension) and directional adhesion are used to minimize detachment forces.
To achieve smooth engagement and disengagement and control its internal forces, Stickybot uses force feedback coupled with a stiffness controller. Stickybot has force sensors located on its shoulder joints that measure the deflection of an elastomeric spring via a ratiometric Hall effect sensor (Honeywell: SS495A). In addition to providing an estimate of the force, the compliance helps to distribute forces among the limbs such that excessive internal forces do not occur and lead to contact failure.
Stickybot is controlled using a single master microcontroller (PIC18F4520) connected to four slave microcontrollers (PIC12F683) using an I2C bus. The master microcontroller produces twelve pulse-width-modulation signals to control each servo separately. Each slave microcontroller reads and digitizes data from the force sensors and transmits it to the master microcontroller.
Stickybot's controller must consider limb coordination, which presents two different and sometimes contradictory goals: force balancing and leg phasing. In addition, certain stable limb combinations must be in contact with the climbing surface at all times (i.e., Stickybot must use either a diagonal trot or tripedal crawl). To achieve this, three separate control laws for four different stages of leg motion (stance, detachment, flight, attachment) are implemented.
1) Stance Controller: During stance, the controller implements force balancing using a grasp-space stiffness controller. Since in this example of Stickybot servomotors are used that only accept position commands, the stiffness control law is given as:
x cmd ( s ) = x ff ( s ) + ( k P + k I s ) C ( f s ( s ) - f d ( s ) ) ( 8 )
where x cmd is a vector comprised of the stroke servo commanded positions, x ff is the feed forward position command, k P and k I are the proportional and integral gains respectively, C is the compliance matrix, f s is a vector comprised of sensed traction forces from each leg, and f d is a vector of desired traction forces. While a diagonal compliance matrix would result in independent leg control, during stance C is defined as:
C=G −1 C 0 G (9)
where C 0 is a diagonal gain matrix chosen such that C 0 ≠I and G is the grasp matrix given as:
G
=
1
2
[
1
1
1
1
1
-
1
1
-
1
1
1
-
1
-
1
1
-
1
-
1
1
]
(
10
)
The grasp matrix is comprised of four independent “grasp modes.” The first row in G is formed by summing the grasp forces in tangential direction (i.e. parallel to the toes) ( FIG. 6 ). The second row is produced by summing the moments about the center of mass. The third and fourth rows are chosen such that G is orthogonal. The chosen values correspond to a fore-aft coupling and a diagonal coupling of the legs respectively. The implementation of stiffness control in grasp space creates a framework for force distribution. By increasing the compliances of all but the total-traction mode, the robot will evenly distribute the forces between feet and achieve force balance while remaining stiff to other variations in loading.
2) Attachment and Detachment Controller: This controller is identical to the stance controller except that C=I, which allows each leg to act independently.
3) Flight Controller: During flight, the controller performs phase adjustments, which effectively keeps the legs close to a predefined gait. The flight controller is defined as:
x cmd_i ( s ) = v ff s + k ( ϕ i - ϕ i + 1 + ϕ i - 1 2 ) ( 11 )
where v ff is a feed forward velocity, k is a proportional gain, φ t is the phase angle along a nominal leg trajectory, φε[0,1], and i is the leg detachment order, i=1 . . . 4.
Results
Stickybot is capable of climbing a variety of surfaces at 90 degrees including glass, glossy ceramic tile, acrylic, and polished granite at speeds up to 4.0 cm/s (0.12 body-lengths/s, excluding the tail). The maximum speed of Stickybot on level ground is 24 cm/s and is limited by the speed of its actuators (Table I).
TABLE I
Physical parameters for Stickybot.
Body size
600 × 200 × 60 mm (excluding cables)
Body mass
370 g (including batteries and servo circuitry)
Maximum speed
4.0 cm/s (0.05 bodylength/s)
Servo motors
Hitec HB65 × 8 Hs81 × 4
Batteries
Lithium polymer × 2 (3.7 V, 480 mAh per pack)
FIG. 7 presents force plate data of Stickybot climbing vertical glass. The left side shows data from the rear left foot and the right side displays data from the front right foot. Forces are in N and time in seconds. Data from two successive runs are shown to give an indication of the typical repeatability.
Section A (0 to 1.5 seconds) represents the preloading and flexing of the foot. There is almost no force in the lateral (X) direction during preload. The traction force (−Y) is increasing.
Although each foot would ideally engage with negligible normal force, there is a small amount of positive normal force during engagement. Weight transfer between diagonal pairs also occurs during section A.
Section B represents the ground stroke phase. There are equal and opposite forces in the X direction for the front right and rear left feet, indicating that the legs are pulling in toward the body. This helps stabilize the body and is similar to the lateral forces exhibited in geckos (and in contrast to the outward lateral forces observed in small running animals such as lizards and insects). The Y direction shows relatively steady traction force, and the Z-direction indicates adhesion on both the front and rear feet. Note that this differs from gecko data, in which the rear feet exhibit positive normal force. This is due to the fact that Stickybot uses its tail to prevent the body from pitching back, and geckos use their rear feet.
In section C Stickybot releases the feet both by reducing the traction force (Y) and by peeling (utilizing digital hyperextension). Both the front and rear feet exhibit low detachment forces in the Z-direction, especially the rear foot. We note also that the transition between B and C is accompanied by a temporary increase in adhesion (−Z force) and subsequent decrease as the opposite diagonal feet come into engagement.
The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. For example:
The elastomer for the adhesive hairs could be a silicone rubber instead of polyurethane. The cable that actuates the toes could be a synthetic cable, carbon graphic cable or a single or multi-strand cable. The feature size of the hairs could be reduced from a diameter of 380 micrometers, while preserving the diameter/length ratio of between 1/3 and 1/4 and preserving the base angle (acute angle) and tip angle as described in FIG. 4 . The material for the backing layer and segments could be a polyurethane, whereby the backing layer material is softer compared to the material of the segments. Other materials that could be used are e.g. materials with a high strength castable resin. The invention could be a device or a system useful in non-robotic applications such as hanging or suspending objects on inclined, vertical or non-horizontal surfaces.
All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents.
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A bio-inspired device is provided designed to scale smooth vertical surfaces using anisotropic frictional materials. The device draws its inspiration from geckos and other climbing lizards and employs similar compliance and force control strategies to climb (or hang onto) smooth vertical surfaces including glass, tile and plastic panels. Foremost among the design features embodied in the device are multiple levels of compliance, at length scales ranging from centimeters to micrometers, to allow the device to conform to surfaces and maintain large real areas of contact so that adhesive forces can support it. Structures within the feet ensure even stress distributions over each toe and facilitate engagement and disengagement of the adhesive materials. A force control strategy works in conjunction with the anisotropic adhesive materials to obtain sufficient levels of friction and adhesion for climbing with low attachment and detachment forces.
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BOTANICAL/COMMERCIAL CLASSIFICATION
[0001] Rosa hybrida /Shrub Rose Plant
VARIETAL DENOMINATION
[0002] cv. Spromel
SUMMARY OF THE INVENTION
[0003] The new variety of landscape shrub rose plant of the present invention was created by artificial pollination carried out in April/May 2008 at Bakersfield, Calif., U.S.A., wherein two parents were crossed which previously had been studied in the hope that they would contribute the desired characteristics. Each parent possessed a complex parentage as indicated hereafter. More specifically, the parentage of the female parent (i.e., seed parent) can be summarized as follows: {‘MORtoday’×[‘Geisha’×(‘KINbo’בMacivy’)]}בSPRoimpress’. The parentage of the male parent (i.e., pollen parent) can be summarized as follows: <[(‘Orangeade’בAuscot’)בWEKfabpur’]×(‘Geisha’בSCRiluv’)×mixed pollen}×mixed Hulthemia pollen>×mixed Hulthemia pollen. The ‘SPRoimpress’ variety is the subject of U.S. Plant Pat. No. 21,708, and the ‘Auscot’ variety is the subject of U.S. Plant Pat. No. 7,215. The other ancestoral plants identified herein are non-patented in the United States.
[0004] The seeds resulting from the above pollination were sown and small plants were obtained which were physically and biologically different from each other. Selective study resulted in the identification of a single plant of the new variety.
[0005] It was found that the new variety of shrub rose plant of the present invention possesses the following combination of characteristics:
[0006] (a) abundantly and substantially continuously forms attractive large semi-double blossoms that are orange to apricot with red coloration toward the center of the blossoms,
[0007] (b) exhibits an upright and bushy growth habit,
[0008] (c) forms vigorous and strong vegetation,
[0009] (d) forms attractive ornamental dark green foliage with a glossy finish, and
[0010] (e) is well suited for providing distinctive ornamentation.
[0011] A new rose variety is provided having attractive multi-colored blossoms, combined with substantially continuous blooming. The plant reblooms well and displays an attractive bushy growth habit.
[0012] The new variety well meets the needs of the horticultural industry particularly when grown in the Western landscape. It can be grown to advantage as attractive ornamentation in parks, gardens, public areas, and residential landscapes. The lavender and red blossom coloration contrasts nicely with the medium green foliage.
[0013] The new variety can be readily distinguished from the ‘Sprolem’ variety (U.S. Plant patent application Ser. No. 13/067,814, filed Jun. 28, 2011), as well as other plants in its ancestry. More specifically, the ‘Sprolem’ variety forms bright yellow blossoms. The ‘MORtoday’ variety displays pink blossoms with lavender at the base. The ‘Geisha’ variety displays mauve blossoms. The ‘KINbo’ variety forms double deep yellow blossoms. The ‘Macivy’ variety displays very double apricot blossoms. The ‘SPRoimpress’ variety displays dark yellow blossoms. The ‘Orangeade’ variety displays orange to orange-red blossoms. The ‘Auscot’ variety forms very large very double yellow blossoms with dark pink at the base. The WEKfabpur variety forms purple blossoms with a lighter under surface. The ‘SCRivluv’ variety displays single deep yellow blossoms. It is recognized that Hulthemia roses generally bloom only once a year and generally display an unattractive growth habit.
[0014] The characteristics of the new variety have been found to be homogeneous and stable and are strictly transmissible by asexual propagation by the use of cuttings from one generation to another at Wasco, Calif., U.S.A. Accordingly, the new variety can be asexually reproduced in a true-to-type manner.
[0015] The new variety has been named ‘Spromel’, and will be marketed under the EYCONIC and MELON LOMONADE trademarks.
BRIEF DESCRIPTION OF THE PHOTOGRAPH
[0016] The accompanying photograph shows, as nearly true as it is reasonably possible to make the same in a color illustration of this character, typical blossoms, buds, and foliage of the new variety. The illustrated plant was approximately two years of age and was growing during September, 2011 outdoors on its own roots in the field at Wasco, Calif., U.S.A.
DETAILED DESCRIPTION
[0017] The chart used in the identification of colors is that of The Royal Horticultural Society (R.H.S. Colour Chart-1995 Edition or equivalent). The description is based on the observation of two-year-old specimens of the new variety during May while growing on their own roots in a greenhouse at West Grove, Pa., U.S.A.
Class: Shrub Rose. Plant:
Height .—approximately 4 feet when mature. Width .—approximately 3 feet when mature. Habit .—upright and bushy.
Branches:
Color .—young stems: near Yellow-Green Group 144B. adult wood: near Greyed-Orange Group 165A. Texture .—young stems: smooth. adult wood: somewhat rough. Thorns .—size: approximately 5 mm in length on average. quantity: numerous. color on young stems: Yellow-Green Group 145B and commonly glossy. color on mature wood: Greyed-Orange Group 177A, and blending to Greyed-Orange Group 165B on at least some tips.
Leaves:
Size .—a five-leaflet leaf commonly is approximately 7 cm in length on average, and approximately 5.5 cm in width on average. Leaflets .—number: 3, 5, and 7. shape: ovate with a serrate margin. texture (upper surface): smooth and glossy. texture (under surface): smooth. size: terminal leaflets commonly are approximately 4 cm in length on average and approximately 3 cm in width on average, and lower leaflets commonly are approximately 2 cm in length on average and approximately 1.5 cm in width on average. color (young foliage): Yellow-Green Group 145A on the upper surface, and Yellow-Green Group 145B on the under surface. color (fully mature foliage): commonly near Green Group 137A on the upper surface, and Green Group 137C on the under surface.
Inflorescence:
Number of flowers .—singly or in cluster of up to approximately eight blossoms per stem, and commonly approximately 20 flowers on plant at a given time. Peduncle .—smooth in texture and commonly covered with small flexible thorns that are under 1 mm in length, near Yellow-Green Group 144A in coloration, and approximately 2.5 cm in length on average. Sepals .—number: five. length: commonly approximately 1.8 cm on average. width: commonly approximately 7 mm on average. upper surface: near Yellow-Green Group 146D, and covered with short hairs. under surface: near Yellow-Green Group 146B, and covered with short hairs. Buds .—shape: ovoid. length: approximately 2 cm on average. diameter: commonly approximately 1.3 cm on average. color: Orange-Red Group 31 B, and blending to Yellow-Orange Group 21C at the base. Flower .—form: semi-double, cuplike. diameter: approximately 6.5 cm on average. color (when opening begins): upper surface: near Red Group 37A at the point of petal attachment, transitioning to Red-Purple Group 57A, and blending to Yellow-Orange Group 17C at the petal apex. under surface: near Red Group 37B at the point of petal attachment, and blending to near Yellow-Orange Group 19A at the petal apex. color (when fully open): upper surface: near Red-Purple Group 71 C at the point of attachment, transitioning to near Red-Purple Group 69C, and finally blending to near Red-Purple Group 69A at the petal apex. under surface: near Red-Purple Group 62D at the point of attachment, and blending to Yellow Group 8C at the petal apex. fragrance: none noticeable. petal shape: obcordate. petal length: commonly approximately 3.5 cm on average. petal width: commonly approximately 3.7 cm on average. petal margin: entire. petal apex: broadly obcordate. petal base: broadly cuneate. petal number 8 to 12, and commonly approximately 10 on average. petal drop: good, with the petals commonly dropping cleanly and freely. stamen number: approximately 57 on average. anthers: near Greyed-Orange Group 164C in coloration. filaments: approximately 8 mm in length on average, and near Orange-Red Group 16A at the top, and transitioning to near Yellow-Orange Group 34B at the base. pollen: near Yellow-Orange Group 22A in coloration. pistils: separate and free, and commonly approximately 21 in number on average. stigmas: near Yellow Group 11 C in coloration, and approximately 1 mm in size. styles: near Orange Group 26C in coloration and approximately 2 mm in size. receptacle: circular in shape, smooth, achenes stand on the bottom and wall, approximately 7 mm in diameter, and near Yellow-Green Group 144A in coloration.
Development:
Vegetation .—vigorous and strong. Blossoming .—abundant and substantially continuous. Resistance to diseases .—typical for the type with the plant being best suited for growing in the Western States. Propensity to form hips/seeds .—sparse. Hardiness .—U.S.D.A. Hardiness Zone Nos. 6 to 9.
[0042] Plants of the new ‘Spromel’ variety have not been observed under all possible environmental conditions to date. Accordingly, it is possible that the phenotypic expression may vary somewhat with changes in light intensity and duration, cultural practices, and other environmental conditions.
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A new and distinct variety of shrub rose plant is provided which forms in abundance on a substantially continuous basis attractive semi-double blossoms that are orange to apricot with red coloration toward the center of the blossoms. The vegetation is vigorous and strong and the growth habit is upright and bushy. Attractive ornamental glossy dark green foliage is formed. The plant is particularly well suited for growing in a Western landscape. Distinctive ornamentation is provided.
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FIELD OF INVENTION
[0001] The present invention relates to a gutter and cover system such as is used at the edge of a roof, and in particular to a gutter and cover system with a singly formed gutter and cover structure.
DESCRIPTION OF THE PRIOR ART
[0002] Gutters are used on a majority of dwelling houses and other buildings to redirect water to a down pipe, which then directs the run-off to a more convenient disposal location. This avoids splashing, “trenching”, flooding, and other such nuisances. However, a persistent problem with such gutters is that they collect leaves, sticks, pine needles and other debris, which causes the gutters and/or down pipes to become blocked. As a result, water can back up and flood over the gutter edge and sometimes down the side of a building. Gutters blocked by debris can also cause devastating consequences during the winter months by not allowing melting snow and ice to properly drain off the roofs of buildings. During melting and refreezing cycles, this blocked water can then refreeze and act as a dam to the snow, which can continue to melt and leak into the interior of the building.
[0003] To cure this deficiency and alleviate the necessity for manually cleaning out gutters and/or down pipes, various systems have been made. Such systems include screen devices that cover the gutter opening to deflect debris from going into the gutter. However, instead of deflecting the debris, such screen devices instead cause an accumulation of debris, which still must be manually removed over a period of time. Other proposals have been made to utilize surface tension to direct the water into the gutter, while the leaves and other debris carried by the water is jettisoned off to the ground. It has been found, however, that surface tension of the water is often not sufficient to contain the water flow against certain counter-forces, such as large volumes of water. To cure this deficiency, proposals have been made to add measures for interrupting the flow of water, such as ribs, to the covers of gutters to slow the water, allowing the surface tension to direct debris-free water into the gutter. Although such measures do increase the effectiveness of surface tension, they still fail to satisfactorily alleviate the above problem. Further, gutter devices utilizing the surface tension to direct water and debris consist of at least two separate parts, a gutter and a cover over the gutter.
[0004] Earlier gutter devices utilizing the surface tension of water to separate water from leaves and other debris fail at effectively directing the debris-free water into the gutter portion of the devices. A system is needed that deflects leaves and other debris while effectively capturing and retaining the debris-free water within the gutter portion of the system. Such a gutter and cover system should be structurally simpler and easier to install and manufacture than the prior gutter devices.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a gutter and cover system for an edge of a roof. The present invention combines the cover with the gutter in a single interlocked structure. The configuration of the gutter may take on several embodiments, but generally includes a front face that may have a lip at an upper end thereof extending down to a gutter bottom and rear. The rear of the gutter extends upward and forms a flange. The flange extends above the cover, which extends outward forward from the flange. The cover forms a pooling section and a front curving section that extends under the cover and rearward above the gutter.
[0006] The pooling section receives rain falling from the roof and slows the speed of the water, dispersing kinematic energy. As the water pools, it fills the pooling section and flows over the front edge of the cover. Surface tension causes the slowed water to cling to the curving section and flow downward and rearward to drop off into the gutter. Debris falls over the front edge of the cover and is separated from the water so that it does not enter the gutter. In this manner, the gutter receives the rain while debris falls outside of the gutter and lessens the need for cleaning the gutter. A flange provides a stop or backsplash and aids in alignment for mounting at an edge of the roof.
[0007] A support element inserts into the combination cover and gutter. The support element extends upward to the underside of the cover and forward to the curving section in a preferred embodiment. A second arm of the support element extends downward under the front lip of the front face of the gutter. This forward element extends rearward to engage the rear portion of the gutter. The support element includes an orifice extending there through receiving mounting hardware, such as screws, bolts or nails that extends through the rear portion of the gutter and into a fascia of the building or roof edge. A typical system includes multiple support elements spaced at intervals along the edge of the roof. A typical distance may be approximately two feet, the distance depending upon the climate, roof construction and other design needs.
[0008] In a first embodiment of the application, the gutter includes a K-style profile. In other embodiments, the gutter includes a more squared front face and may have a slight angle relative to the vertical and horizontal orientation relative to horizontal and vertical. In a further embodiment, the front face of the gutter includes a continuously arcing profile. Each of these configurations includes the gutter and cover made from a single element and is preferably monolithic. Typical materials include aluminum and steel and thickness may run in the neighborhood of {fraction (3/100)} of an inch.
[0009] The cover and gutter system is made with a machine that forms a unitary cover and gutter or interlocks the cover to the gutter and then cuts to length, achieving a seamless structure. This allows for forming gutters, covers, or gutter and cover systems.
[0010] These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and the objections obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in that there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is an end view of a first embodiment of a gutter and cover system according to the principles of the present invention mounted to the edge of the roof;
[0012] [0012]FIG. 2 is an end view of an integral gutter and cover for the system shown in FIG. 1;
[0013] [0013]FIG. 3 is a side elevational view of a support member for the system shown in FIG. 1;
[0014] [0014]FIG. 4 is a side elevational view of a second embodiment of an integral gutter and cover for the system shown in FIG. 1;
[0015] [0015]FIG. 5 is a side elevational view of a third embodiment of an integral gutter and cover for the system shown in FIG. 1;
[0016] [0016]FIG. 6 is a side elevational view of a fourth embodiment of an integral gutter and cover for the system shown in FIG. 1;
[0017] [0017]FIG. 7 is a side elevational view of a fifth embodiment of an integral gutter and cover for the system shown in FIG. 1;
[0018] [0018]FIG. 8 is a side elevational view of a gutter and interlocked cover system according to the principles of the present invention;
[0019] [0019]FIG. 9 is a side elevational view of a forming machine for making a gutter and cover system; and
[0020] [0020]FIG. 10 is a detail view of the forming machine shown in FIG. 9 showing the rollers for forming an interlocked gutter and cover system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Referring now to the Figures, FIG. 1 illustrates an end view of a gutter and cover system 10 for mounting under an edge 32 of a roof 30 of building or structure 33 . In accordance with the present invention, the gutter and cover system 10 is typically rolled from a monolithic sheet of blank material in a first embodiment, preferably a metal material such as aluminum having a uniform wall thickness, with a typical thickness being about 0.032 inches. It can also be appreciated by those skilled in the art that other suitable materials such as steel and alloys and having different material thicknesses may be used, depending on the particular application. FIGS. 1 and 2 show the gutter and cover system 10 including a cover portion 22 and a gutter portion 24 integrally connected by a rear wall 17 . In one embodiment, the rear wall 17 continues approximately 1 inch above the cover portion 22 , forming a flange or extension 14 positioned under a drip edge of the structure 33 to prevent water flowing off the roof from splashing back onto the roof or the structure 33 . The gutter portion 24 includes a gutter bottom 15 that integrally connects the rear wall 17 to a front wall 19 . The gutter bottom 15 is shown in the Figures with a flat surface. However, it is readily understood by those skilled in the art that it may be rounded to collect water at the center or shaped to collect water closer to the front or back area of the gutter portion 24 . The front wall 19 extends upward toward the cover portion 22 , preferably concludes by extending rearward and downward to form a lip portion 20 .
[0022] [0022]FIGS. 4-7 illustrate alternate embodiments of the gutter and cover system, and are generally designated 50 , 60 , 70 and 80 respectively. The front wall 19 may define a number of different profile embodiments including, but not limited to, an Ogee profile, illustrated in FIG. 1, a continuously curved profile, illustrated in FIG. 7, or various straight profiles, as illustrated in FIGS. 4-6.
[0023] The cover portion of the present invention extends from and is integrally connected with the rear wall 17 in one embodiment. Extending generally over the gutter portion 24 , the cover portion 22 concludes by curving downward and rearward to form a debris separation portion 12 . The debris separation portion 12 has at least a minimum radius to provide sufficient surface tension such that water clings to the debris separation portion 12 and flows behind the lip portion 20 , and drops into the gutter portion 24 , while debris is jettisoned off the system, thereby separating the water, which is directed into the gutter, and the debris. Intermediate the rear wall 17 and the debris separation portion 12 , the cover portion 22 includes a kinetic energy dispersion section 18 . As shown in FIG. 2, the kinetic energy dispersion section 18 functions as a pooling section and preferably begins at the intersection 26 of the rear wall 17 and the cover portion 22 and ends at the top 25 of the debris separation portion 12 . In a preferred embodiment, the low point 28 of the kinetic energy dispersion section 18 is equal distance from the intersection 26 of the rear wall 17 and the cover portion 22 , and the top 25 of the debris separation portion 12 . In alternate embodiments, the low point of the kinetic energy dispersion section may be positioned in a variety of locations along the kinetic energy dispersion section 18 . As shown in FIG. 2, the low point of the kinetic energy dispersion section 18 is located below both a horizontal axis, a 1 , tangent to intersection 26 and a horizontal axis, a 2 , tangent the top 25 of the debris separation portion 12 , causing the water flowing over the cover portion 22 to pool and lose kinetic energy before flowing over the debris separation portion 12 and into the gutter portion 24 . By dispersing the kinetic energy of the flowing water, the kinetic energy dispersion section allows the surface tension properties of the water to effectively direct the slowly flowing water over the debris separation portion 12 and into the gutter portion 24 .
[0024] The gutter and cover system 10 of the present invention may also include a support member 40 extending under the cover portion 22 and lip the portion 20 of the front wall 19 for strengthening the gutter and cover system 10 against heavy rainfall, snow, ice and other natural elements. Support member 40 may be formed from metal, plastic or other suitable rigid material. As shown in FIG. 3, the support member 40 includes a first portion 46 engaging the underside of the cover portion 22 , as shown in FIG. 1, a second portion 44 engaging the underside of the lip portion 20 of the front wall 19 , and a third portion 42 engaging the rear wall 17 of the gutter and cover system 10 . The support member may further include a plurality of bracing members, such as crossbeams 45 , formed from metal, plastic or other suitable rigid material, to further strengthen the gutter and cover system 10 . Preferably, the support member 40 also includes a mounting orifice 41 extending through the support member 40 , wherein mounting hardware, such as nails, screws or similar fasteners, may extend through the orifice 41 to an opening in the rear wall 17 of the gutter system 10 and into the front of the structure 33 . In this manner, the gutter system 10 is affixed with respect to the building structure 33 and the roof of the building structure. Support members 40 are positioned at spaced apart-predetermined distances along the gutter and cover system 10 , with a typical spacing being about 2 feet.
[0025] [0025]FIGS. 4-7 illustrate further embodiments 50 , 60 , 70 and 80 of gutter and cover systems according to the present invention. A cover portion 22 includes a kinetic energy dispersion section 18 intermediate the rear wall 17 and the debris separation portion 12 that causes the water to pool and lose kinetic energy before flowing over the debris separation portion 12 and into the gutter portion 24 . In addition, the alternative embodiments illustrated in FIGS. 4-7 may include a support member, similar to the support member 40 , which extends under the cover portion and lip portion of the front wall of each of the embodiments.
[0026] Referring now to FIG. 8, there is shown another embodiment of gutter and cover system, generally designated 110 . The gutter and cover system 110 is similar to the gutter and cover system 10 except that the gutter and cover are made of different elements that are interlocked as they are formed to achieve a unitary gutter and cover structure. The gutter and cover system 110 includes a rear wall 117 , a gutter bottom 115 connecting to a front wall 114 and a lip portion 120 , forming the gutter portion 124 . The cover portion 122 includes a debris separation portion 112 , an energy dispersion portion 118 and an extension 114 , extending over the top of the rear wall 117 . The extension 114 wraps around the upper end of the rear wall and is crimped together, as explained hereinafter, to form the interlocked gutter and cover structure 110 . It can be appreciated that other profiles may also be utilized having an interlocked gutter portion 124 and cover portion 122 such as those shown in FIGS. 4-7. Moreover, it can be appreciated that different materials may be used for forming the gutter portion 124 and the cover portion 122 . For example, the gutter 124 may be made of aluminum or steel while the cover 122 may be made of copper, for decorative purposes. The interlocked gutter and cover structure 110 may also include a brace 40 similar to that shown in FIG. 1.
[0027] Referring now to FIGS. 9 and 10, there is shown an apparatus 1000 for making the various gutter and cover systems shown in FIGS. 1-8. The gutter and cover forming apparatus 1000 includes a series of rollers for forming coils of blank material into a gutter and cover. Such roll forming devices are well known for making various gutters and cover systems from coils of material with a series of rollers successively forming the gutters. Examples of such roll forming devices are shown in U.S. Pat. No. 2,505,241 to Gray et al. and U.S. Pat. No. 4,889,566 to Knudson, which are incorporated herein by reference. The coils and material 1010 , 1012 , 1014 and 1016 may be fed to make the various types of gutters and cover structures shown in FIGS. 1-8. As shown, an end coil 1010 feeds material to the end of the gutter forming apparatus 1000 where the blank material is bent and shaped to form the gutter portion 124 . A second coil of blank material 1014 is fed through another series of rollers to form the cover portion 122 . These two elements are then joined, as shown in FIG. 10 to form a single seamless structure and as explained hereinafter. In addition, the forming apparatus 1000 may form the entire integral gutter and cover apparatus out of a coil of blank material such as 1012 , which is wider than the blank material used for forming only the gutter portion. Moreover, a further coil 1016 may be utilized for other configurations of gutters or for a cover that may need a thinner or wider coil material. It can also be appreciated that the coils may hold different types of material. For example, some coils may be aluminum, some may be steel and some may be copper. The forming apparatus 1000 begins with a blank coil of material or blank coils of material and produces a seamless, single gutter and cover system that can be cut to length at a cutting station 1020 on site.
[0028] Referring now to FIG. 10, the forming apparatus 1000 may be configured for joining a cover portion 112 to a separate gutter portion 110 , after they are formed with different series of forming rollers. The lip portion 114 is configured to slide over the upper end of the rear wall 117 . These are pressed together and aligned by a guide roller 1030 and a pair of opposed guide rolls 1032 . A press roll 1034 presses the lip portion 114 downward onto the upper end of the rear wall 117 . An opposed punch roll and die roll 1036 and 1038 crimp and interlock the cover portion to the gutter portion to create an interlocked gutter and cover system 110 . The structure is a single, seamless complete gutter and cover system that is then cut to length at the cutting station 1020 , shown in FIG. 9.
[0029] It can be appreciated that the forming apparatus provides various options. A unitary gutter and cover system 10 may be formed or an interlocked gutter and cover system 110 may be formed on site. A gutter without a cover may also be formed and a cover without a gutter may be formed, depending upon the needs at the site. The apparatus 1020 is readily transported on a trailer so that on-site cutting to length may be possible, thereby avoiding seams and improving quality while saving labor and material.
[0030] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A gutter and cover system mounts at an edge of a roof to collect water into the gutter without other debris. The system includes a combination gutter and cover made from a monolithic element or interlocked to form a single structure. The gutter includes a front, bottom and rear extending up to the cover, which extends over the gutter. The cover has a pooling section and a front, curving edge. The pooling section slows down the flow of water and allows it to flow over the curving edge and adhere to the cover due to surface tension while debris falls outside of the gutter. A support element slides inward to provide support for the cover and a front face of the gutter. The support element includes structure for receiving mounting hardware.
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TECHNICAL FIELD
The present invention relates to an elevator renovation method for renovating a hydraulic elevator to a non-hydraulic elevator.
BACKGROUND ART
An elevator includes a hoistway which extends vertically and a car which is provided so as to be movable in the hoistway. Conventionally, the renovation of a hydraulic elevator to a machine room-less rope elevator or a pressure-driven elevator has been carried out. An example of the renovation is now described. According to a method described in Patent Literature 1, when an old existing hydraulic elevator is to be renovated to a rope elevator, devices relating to the driving of the hydraulic elevator are first removed. Thereafter, devices of the rope elevator are installed in the hoistway.
According to the above-mentioned elevator renovation method, however, the removal of devices for the hydraulic elevator, which are provided in the hoistway, such as a jack and a plunger, takes time and efforts. Therefore, there is a problem in that a period of renovation work becomes disadvantageously long. Moreover, when a top part of the hoistway has no room for a space for providing a new hoisting machine and deflector sheave, and further a space for providing beams for supporting the hoisting machine and the deflector sheave, there is another problem in that the renovation is difficult.
CITATION LIST
Patent Literature
[PTL 1] 2010-105805 A
SUMMARY OF INVENTION
Technical Problems
The present invention has been made to solve the problems described above, and therefore has an object to provide an elevator renovation method, which is capable of reducing a renovation period and enabling effective use of a space when an existing hydraulic elevator is renovated to a non-hydraulic elevator.
Solution to Problems
In order to attain the object described above, according to the present invention, there is provided an elevator renovation method for renovating a hydraulic elevator in which a plunger provided integrally with a car is hydraulically driven to a non-hydraulic elevator, including; providing a driving device for generating a driving force for raising the car; leaving the plunger so that the plunger can be raised and lowered inside an existing jack; and obtaining the non-hydraulic elevator by exerting the driving force of the driving device in a direction in which the plunger is moved up to raise the car.
Advantageous Effects of Invention
According to the elevator renovation method of the present invention, it is possible to reduce the renovation period and enable the effective use of a space when the existing hydraulic elevator is renovated to the non-hydraulic elevator.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A longitudinal sectional view of a hoistway of a machine room-less rope elevator obtained by renovation according to a first embodiment of the present invention.
FIG. 2 A plane view of the hoistway illustrated in FIG. 1 .
FIG. 3 A perspective view of a pit portion in the hoistway illustrated in FIG. 1 .
FIG. 4 A perspective view illustrating a state in which a return pulley is mounted to a lower end of a plunger.
FIG. 5 A perspective view illustrating a state in which a counterweight is additionally mounted.
FIG. 6 A front view illustrating a configuration of an emergency stop, a governor, a tension sheave, and a governor rope.
FIG. 7 A detailed diagram illustrating the vicinity of a portion VII of FIG. 6 in an enlarged manner.
FIG. 8 A perspective view illustrating a portion between a crosshead and a plank illustrated in FIG. 6 .
FIG. 9 A sectional view taken along the line IX-IX in FIG. 8 .
FIG. 10 An exploded perspective view of the emergency stop illustrated in FIG. 8 .
FIG. 11 An exploded perspective view of the vicinity of an actuating lever of the emergency stop illustrated in FIG. 8 .
FIG. 12 A diagram equivalent to FIG. 1 , according to a second embodiment of the present invention.
FIG. 13 A diagram equivalent to FIG. 2 , according to the second embodiment.
FIG. 14 A diagram equivalent to FIG. 3 , according to the second embodiment.
FIG. 15 A diagram equivalent to FIG. 5 , according to the second embodiment.
FIG. 16 A diagram equivalent to FIG. 1 , according to a third embodiment of the present invention.
FIG. 17 A diagram equivalent to FIG. 2 , according to the third embodiment.
FIG. 18 A front view illustrating a state in which pressure-driving belt devices are mounted to a plunger provided in the pit portion of the hoistway.
FIG. 19 A perspective view of FIG. 18 .
FIG. 20 A diagram illustrating a first mode of a rough surface provided to the plunger.
FIG. 21 A diagram illustrating a second mode of the rough surface.
FIG. 22 A diagram illustrating a third mode of the rough surface.
FIG. 23 A diagram illustrating a fourth mode of the rough surface.
FIG. 24 A diagram equivalent to FIG. 16 , according to a fourth embodiment of the present invention.
FIG. 25 A diagram equivalent to FIG. 17 , according to the fourth embodiment.
DESCRIPTION OF EMBODIMENTS
Embodiments of an elevator renovation method according to the present invention are hereinafter described referring to the accompanying drawings. In the drawings, the same reference symbol denotes the same or a corresponding part.
First Embodiment
A first embodiment describes a mode in which a hydraulic elevator referred to as a so-called “hydraulic direct plunger type elevator” in the field of art is renovated to a machine room-less rope elevator which is one of non-hydraulic elevators (elevators including a plunger driven by a force other than a hydraulic pressure of a jack). FIG. 1 is a longitudinal sectional view of a hoistway of a machine room-less rope elevator obtained by renovation according to the first embodiment, FIG. 2 is a plan view of the hoistway illustrated in FIG. 1 , and FIG. 3 is a perspective view of a pit portion of the hoistway illustrated in FIG. 1 . FIG. 4 is a perspective view illustrating a state in which a return pulley is mounted to a lower end of a plunger, and FIG. 5 is a perspective view illustrating a state in which a counterweight is additionally mounted. FIG. 6 is a front view illustrating a configuration of an emergency stop, a governor, a deflector sheave, and a governor rope. FIG. 7 is a detailed diagram illustrating a portion VII of FIG. 6 in an enlarged manner. FIG. 8 is a perspective view illustrating a portion between a crosshead and a plank illustrated in FIG. 6 , FIG. 9 is a sectional view taken along the line IX-IX of FIG. 8 , FIG. 10 is an exploded perspective view of the emergency stop illustrated in FIG. 8 , and FIG. 11 is an exploded perspective view of the vicinity of an actuating lever of the emergency stop illustrated in FIG. 8 .
In the hydraulic elevator before the renovation, a plunger 3 is provided integrally with a car 1 including a car floor 1 a and car doors 1 b . The plunger 3 extends downward from a bottom portion of the car 1 . The plunger 3 is inserted into a jack 4 and is moved up by a hydraulic pressure of the jack 4 . By the upward movement of the plunger 3 , the car 1 is configured to be raised.
One of features of the elevator renovation method according to the present invention resides in that the plunger 3 and the jack 4 of the hydraulic elevator are not removed but are used as a part of devices included in the rope elevator. Specifically, the plunger 3 is left so as to be movable upward and downward inside the existing jack 4 . Therefore, an oil draw out, a pipe, and a hydraulic driving portion (including a hydraulic tank, a pump, a motor, a control board, and the like), which are elements other than the plunger 3 and the jack 4 , are removed.
On a buffer base 16 c (buffer is not shown) provided in a pit, return pulleys 11 , a rope stopper 13 b , and a drum-type hoisting machine 10 are mounted as illustrated in FIG. 3 . The drum-type hoisting machine 10 is one specific mode of a rope driving device prepared as an example of a driving device for generating a driving force for raising the car. The drum-type hoisting machine 10 pulls up the plunger by a hoisting rope described later.
Next, as illustrated in FIG. 4 , a lid (oil-seal retention ring) 4 a provided on an opening for the jack, which is provided in the center of the buffer base 16 c , is removed from the opening for the jack. By a known winch (not shown), the plunger 3 is moved up together with the car 1 above the jack 4 . Then, a return pulley 12 is mounted to a lower end of the plunger 3 . As illustrated in FIG. 4 , the return pulley 12 is supported on a lower surface of a mounting plate 12 b through a bearing frame 12 a , and is mounted to the lower end of the plunger 3 by a clip 12 c and a bolt 12 e through the mounting plate 12 b . When a clearance between the plunger 3 and the jack 4 , through which hoisting ropes 13 a to be described later pass, is small at this time, a flange-like end portion of a bottom plate 3 m of the plunger 3 may be scraped away by a sander or the like as partially shown in FIG. 4 as a reference. As described above, in a state in which the car 1 and the plunger 3 are lifted up above the jack 4 , the hoisting ropes 13 a are looped around the return pulley 12 mounted to the plunger 3 . Shackles 8 a provided to end portions of the hoisting ropes 13 a are connected to the rope stopper 13 b . In this manner, there is obtained a non-hydraulic elevator for exerting the driving force of the drum-type hoisting machine 10 which is the driving device in a direction of the upward movement of the plunger 3 to raise the car 1 . Moreover, the car 1 can be lifted up together with the plunger 3 by the drum-type hoisting machine 10 . In practice, however, a driving load is large. Therefore, counterweights 6 are mounted on both side surfaces of the car 1 . The counterweights 6 are connected to the car 1 through compensating ropes. The counterweights and the car are raised and lowered in the directions opposite to each other.
The counterweights 6 provided on both sides of the car 1 are guided by a pair of counterweight guide rails 5 , each made of a steel plate having an approximately C-like transverse cross section. Each of the counterweight guide rails 5 is fixed by brackets 5 a mounted to hoistway walls by anchor bolts 5 b , as illustrated in FIG. 5 . When the hoistway walls do not have a concrete structure, the brackets can be welded and fixed to a structural iron frame of the hoistway. A weight buffer 9 is provided between lower ends of the pair of counterweight guide rails 5 . The counterweight 6 is provided between the corresponding pair of the counterweight guide rails 5 . A return pulley 7 is mounted to an upper end of the pair of counterweight guide rails 5 through an intermediation of a fitting 7 a . Then, as illustrated in FIGS. 1 and 5 , compensating ropes 8 are looped around the return pulley 7 . The shackles 8 a connected to one end of each of the compensating ropes 8 are connected to a rope stopper 2 c provided to the car 1 , whereas the shackles 8 a connected to another end thereof are connected to the counterweight 6 .
Next, as illustrated in FIGS. 6 to 10 , the emergency stop device is mounted in the vicinity of one of guide shoes 2 d provided to a lower part of a car frame 2 . After a mount bolt for a guide-shoe mounting plate 2 e provided to the lower part of the car frame 2 is removed, an emergency-stop main body 14 is inserted from a lower end of a column of the car frame. When an L-shaped emergency-stop back plate 15 c of the emergency-stop main body 14 is interposed between the guide-shoe mounting plate 2 e and a plank 2 a , a spacer 2 f is provided to a bolt hole portion. The degree of fastening of bolts 14 b provided on both sides of the emergency-stop main body 14 is adjusted on the inner side of the column to perform positional adjustment of the emergency-stop main body 14 in a horizontal direction. By fastening bolts 2 g through the guide-shoe mounting plate 2 e , the emergency-stop main body 14 is supported.
As illustrated in FIGS. 6 and 11 , a bearing fitting 14 a and a screw seat 14 k are provided so as to sandwich a flange portion of the plank 2 a of the car frame 2 therebetween. By connecting the bearing fitting 14 a and the screw seat 14 k to each other by bolts, the bearing fitting 14 a is fixed to the plank 2 a of the car frame 2 . An actuating lever 14 h for an emergency-stop operation and a connecting shaft 14 m are respectively connected to surfaces of the bearing fitting 14 a on the sides opposite to each other.
A governor rope guide device (mounting plate) 14 j is mounted to a lower part of a crosshead 2 b of the car frame 2 . The governor rope guide device 14 j is connected to a clip 14 e through a bolt in a mode in which the governor rope guide device 14 j and the clip 14 e sandwich the crosshead 2 b therebetween.
In a top part of the hoistway 15 , a governor device 16 is provided. On the other hand, a tension sheave 17 is provided in a lower part of the hoistway 15 . The governor device 16 is supported through an intermediation of a governor mount base 16 b , whereas the tension shave 17 is supported through an intermediation of a fitting 17 a and an arm 17 b . The governor mount base 16 b and the fitting 17 a are mounted to a car guide rail 16 a by using clips and bolts.
A governor rope 18 passes from a governor rope gripper 14 d provided to the car frame 2 through the tension sheave 17 and the governor 16 to return to the governor rope gripper 14 d provided to the car frame 2 again. As an exploded state illustrated in FIG. 8 , the governor rope gripper 14 d is connected to the governor rope guide device 14 j through an intermediation of a link 14 g . Springs 14 f are provided above and below the governor rope gripper 14 d , respectively, whereas a rope fixing rod 18 a is provided to extend above and below the governor rope gripper 14 d . The governor rope gripper 14 d and the lifting lever 14 h of the emergency stop device are connected to each other by a connecting bar 14 c.
After a new control board 25 is carried into the hoistway 15 and is mounted to the car guide rail 16 a through fittings, various types of wirings are provided. Then, after adjustment of mounting of various types of hoistway switches and various types of adjustment for operating the elevator are performed, the renovation to the rope-type elevator is completed.
As described above, according to the elevator renovation method according to this embodiment, the jack and the plunger of the hydraulic elevator are not removed but are used as a part of the car devices. Thus, the jack and the plunger are not required to be disassembled and carried out. Therefore, a work period can be significantly reduced, while renovation cost for renovation to the machine room-less elevator can also be reduced. The above-mentioned advantage also brings about an advantage in that waste is reduced to reduce an environmental load. Moreover, it is sufficient that the hoisting machine for raising and lowering the car be provided in the vicinity of the jack and the plunger, that is, in the lower part of the hoistway (bottom portion). Therefore, even in the case where the top portion of the hoistway has no room for a space for providing a new hoisting machine and deflector sheave and further a space for providing the beams for supporting the hoisting machine and the deflector sheave, the hydraulic elevator can be renovated to the rope type elevator.
Second Embodiment
Next, a second embodiment of the present invention is described referring to FIGS. 12 to 15 . FIGS. 12 to 15 are diagrams equivalent to FIGS. 1, 2, 3, and 5 , respectively. The second embodiment is the same as the first embodiment described above except for a part to be described below.
As illustrated in FIG. 14 , the pair of first return pulleys 11 , a second return pulley 13 , and a hoisting machine 19 are provided on the buffer base 16 c (buffer is not shown) provided in the pit of the hoistway 15 . The pair of first return pulleys 11 are respectively provided on both sides of the plunger 3 . The second return pulley 13 is provided on the side of the plunger 3 opposite to the side where one of the first return pulleys 11 is provided. The hoisting machine 19 is provided on the side of the plunger 3 opposite to the side where another of the first return pulleys 11 is provided.
Next, the lid of the oil seal portion on the opening for the jack, which is provided in the center of the buffer base 16 c , is removed. The plunger 3 is pulled up together with the car 1 by the winch, and is lifted up above the jack 4 . A pair of rope stoppers 3 a are connected to the plunger 3 by bolts 3 b so that the rope stoppers 3 a face and sandwich the plunger 3 .
Subsequently, similarly to the first embodiment, the counterweight guide rails 5 , the weight buffers 9 , the counterweights 6 , and the return pulleys 7 are mounted. The hoisting ropes 13 a pass through one of the rope stoppers 3 a of the plunger 3 , one of the first return pulleys 11 , the second return pulley 13 , and further the return pulley 7 on the top of the counterweight guide rail 5 to be connected to one of the counterweight 6 . On the opposite side, the hoisting ropes 13 a pass through another of the rope stoppers 3 a of the plunger, another of the return pulleys 11 , a sheave 19 a of the hoisting machine 19 , and further the return pulley 7 on the top of another of the counterweight guide rails 5 in a similar manner to be connected to another of the counterweights 6 . By providing the hoisting ropes 13 a in this manner, the car 1 can be raised and lowered by a driving force of the hoisting machine 19 .
Further, as in the case of the first embodiment, the emergency stop device and associated components, the governor, the tension sheave, and the governor rope are mounted. Finally, as in the case of the first embodiment, after the new control board 25 is carried into the hoistway 15 and is mounted to the car guide rail 16 a through the fittings, various wirings are provided. Then, after adjustment of mounting of various types of hoistway switches and various types of adjustment for operating the elevator are performed, the renovation to the rope-type elevator is completed.
Even according to the second embodiment described above, similarly to the first embodiment, when the existing hydraulic elevator is renovated to the rope-type elevator, the renovation period can be reduced, while the space can be efficiently used.
Third Embodiment
Next, as a third embodiment of the present invention, a of renovating a hydraulic direct plunger type elevator to a pressure-driven elevator is described referring to FIGS. 16 to 23 . FIGS. 16 and 17 are diagrams equivalent to FIGS. 1 and 2 , respectively. FIG. 18 is a front view illustrating a state in which pressure-driving belt devices are mounted to the plunger provided in the pit portion of the hoistway, and FIG. 19 is a perspective view of FIG. 18 . Further, FIG. 20 is a diagram illustrating a first mode of a rough surface provided to the plunger, FIG. 21 is a diagram illustrating a second mode of the rough surface provided to the plunger, FIG. 22 is a diagram illustrating a third mode of the rough surface provided to the plunger, and FIG. 23 is a diagram illustrating a fourth mode of the rough surface provided to the plunger. The third embodiment is the same as the first embodiment described above except for a part to be described below.
As illustrated in FIGS. 18 and 19 , at least two pressure-driving belt devices 21 are provided to the buffer base 16 c (buffer is not shown) provided in the pit. The pressure-driving belt devices 21 are prepared as an example of a driving device for generating a driving force for raising the car. The pressure-driving belt devices 21 move up the plunger by a friction force.
In the illustrated example, the two pressure-driving belt devices 21 are mounted so as to be pressed against the plunger 3 from the opposite sides. Each of the pressure-driving belt devices 21 includes a neck portion 21 d at one end portion of an elongated arm 21 c (end portion on the side closer to the plunger 3 ). Each of the neck portions 21 d stands obliquely upward toward the plunger 3 . A driving belt 21 a (having a cogged-belt shape) is rockably supported by each of the neck portions 21 d . A driving motor 21 b is connected to each of the driving belts 21 a . Each of the driving belts 21 a is driven to be circulated by a driving force of the driving motor 21 b , which is transferred through a reduction gear 21 g and a cogged gear 21 f . A spring 21 j is provided to a lower surface of another end portion of each of the arms 21 c . Further, a supporting portion 21 e is provided to a portion of each of the arms 21 c , which is closer to the one end. Each of the arms 21 c is supported by the corresponding supporting portion 21 e so as to be inclined in a seesaw-like fashion.
With the configuration described above, the pressure-driving belt devices 21 can press the driving belts 21 a so as to bring the driving belts 21 a in pressure contact with the pressure-driving belt devices 21 with a strong force based on the principle of leverage. Moreover, each of the driving belts 21 a has the cogged belt-like shape, and therefore does not slip against the cogged gear 21 f . Further, rough surfaces are provided on portions of a surface of the plunger 3 , which are to be held in pressure contact with the driving belts 21 a . Specifically, as a first mode of the rough surface, an adhesive 3 c is applied onto the portions of the surface of the plunger 3 , which are to be held in pressure contact with the driving belts 21 a . Then, vertically extending band-like sheets of abrasive paper 3 d are bonded thereon. By the abrasive paper 3 d , the friction force between the driving belts 21 a and the plunger 3 is increased to reduce the slippage between the driving belts 21 a and the plunger 3 . By the above-mentioned manner, the driving force of the pressure-driving belt devices 21 can be economically and reliably transferred to the plunger 3 to raise and lower the plunger 3 , that is, to raise and lower the car 1 .
The rough surfaces provided to the portions of the surface of the plunger 3 , which are to be held in pressure contact with the driving belts 21 a , are not limited to the mode using the abrasive paper 3 d . Thus, the following modes can be described as other examples. As a second mode of the rough surface as illustrated in FIG. 21 , the adhesive 3 c is applied onto the portions of the surface of the plunger 3 , which are to be held in pressure contact with the driving belts 21 a . Then, sand particles 3 e are sprayed to adhere thereon by using a spray 3 f . Alternatively, as a third embodiment of the rough surface, as illustrated in FIG. 22 , sander lines 3 g may be formed on the portions of the surface, which are to be held in pressure contact with the driving belts 21 a , by a sander 3 h . Further, alternatively, as a fourth mode of the rough surface, as illustrated in FIG. 23 , a knurling pattern 3 n may be formed on the portions of the surface, which are to be held in pressure contact with the driving belts 21 a , by using a knurling blade 3 j of a knurling tool 3 k.
The configuration other than that described above and the other removal and installation work and adjustment work are the same as those described in the above-mentioned first embodiment.
Even according to the third embodiment described above, similarly to the first embodiment, when the existing hydraulic elevator is renovated to the rope-type elevator, the renovation period can be reduced, while the space can be efficiently used.
Fourth Embodiment
The pressure-driven elevator obtained by the renovation of the hydraulic direct plunger type elevator is not limited to include the counterweights as described in the above-mentioned third embodiment. A configuration illustrated in FIGS. 24 and 25 as a fourth embodiment is an example thereof. As illustrated in FIGS. 24 and 25 , similarly to the above-mentioned third embodiment, the plunger 3 of the pressure-driven elevator is used, while the pressure-driving belt devices 21 are additionally provided in the fourth embodiment. However, the fourth embodiment differs from the third embodiment in that the configuration associated with the counterweights, such as the counterweights 6 , the counterweight guide rails 5 , the return pulleys 7 , the compensating ropes 8 , and the weight buffers 9 , is not installed. The remaining configuration, and the other removal and installation work and adjustment work are the same as those described in the above-mentioned first embodiment.
Even according to the fourth embodiment described above, similarly to the first embodiment, when the existing hydraulic elevator is renovated to the rope-type elevator, the renovation period can be reduced, while the space can be efficiently used.
The contents of the present invention have been specifically described above referring to the preferred embodiments. However, it is apparent that various modified modes are possible by those skilled in the art based on the basic technological thought and teaching of the present invention.
REFERENCE SIGNS LIST
1 car, 3 plunger, 4 jack, 6 counterweight, 8 compensating rope, 10 drum-type hoisting machine (driving device), 13 a hoisting rope, 15 hoistway, 21 pressure-driving belt device (driving device)
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An elevator renovation method, which is capable of reducing a renovation period and enabling effective use of a space when an existing hydraulic elevator is renovated to a non-hydraulic elevator. The elevator renovation method involves renovating a hydraulic elevator in which a plunger provided integrally with a car is hydraulically driven to a non-hydraulic elevator. The elevator renovation method includes; providing a driving device for generating a driving force for raising the car; leaving the plunger so that the plunger can be raised and lowered inside an existing jack; and obtaining the non-hydraulic elevator by exerting the driving force of the driving device in a direction in which the plunger is moved up to raise the car.
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BACKGROUND OF THE INVENTION
This invention generally relates to writing pens and more particularly to improved nib means for providing selective writing line widths.
Most commonly distributed fountain pens comprise writing nibs which provide writing having only one preselected line width. If a different line width is desired another nib laying down such different line width must be assembled into the pen or two pens must be used. Frequently individuals, such as accountants, desire to make inscriptions of at least two widths during one recording operation; a relatively fine line is desirable when ledger insertions are being made and a relatively wider line being useful for other general note-making and for signatures. At the present time two writing instruments are required in such a situation, each writing lines of distinct width. The disadvantages of using two pens are overcome when a single nib has the ability to write lines of two distinct widths with equal ease and exactness. Thus lines of two writing characteristics can be effected in an easy and smooth manner without major disturbance to the writer simply by rotating the pen.
SUMMARY OF THE INVENTION
It is a principal object of this invention to provide a simple and efficient nib assembly for a fountain pen.
A further object of this invention is to provide improved means for readily writing lines of two distinct widths.
Yet another object of this invention is to provide a nib affording considerable advantages over known constructions.
It is also an object of this invention to provide an improved pen nib having a plurality of paper-contacting portions whereby rotation of the nib produces lines of different width and character.
A still further object of this invention is to provide a simple and efficient writing implement, readily constructed and assembled yet providing an effective means for allowing a writer to choose and alter his writing stroke.
A feature of this invention is to provide a nib having a contoured pellet cooperating with improved supporting means for freely laying down lines of different widths depending upon which side of the nib faces the writing surface.
Another object of this invention is to provide a pen nib which combines simplicity and durability in construction with ease, convenience and efficiency in operation.
Further objects and features as well as advantages of this invention will become apparent as the following description of an illustrated embodiment thereof proceeds and is given for the purpose of disclosure and is taken in conjunction with the accompanying drawings in which like character references designate like parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIGS. 1 and 1a are a broken, vertical sectional view through a fountain pen incorporating the principles of this invention;
FIGS. 2 and 2a are a broken, enlarged elevational view partially broken away and having a portion removed therefrom of a nib and feed assembly incorporating the principles of this invention;
FIG. 3 is a foreshortened top plan view, partially broken away of the nib and feed assembly shown in FIG. 2;
FIG. 4 is an end view taken along the line 4--4 of FIG. 2 looking in the direction indicated by the arrows; and
FIG. 5 is an enlarged top plan view of a nib retainer incorporating the principles of this invention.
DETAILED DESCRIPTION
Referring now to the several figures and first to FIG. 1 there is shown a complete fountain pen 10 which includes a cap assembly 12 covering a writing end of the pen; the cap assembly is shown connected to a barrel assembly 14 but is removable therefrom for writing with the pen. A nib and feed assembly 16 comprising this invention is shown at the writing end of the pen.
The cap assembly 12 includes an outer, open-ended, generally cylindrically-shaped shell 18 formed of a metal, such as stainless steel, or some other suitable material. The shell 18 contains a tubular inner cap 19 which is internally proportioned to snugly receive a nib collar 20 at the writing end of the writing instrument for holding the cap assembly 12 and barrel assembly 14 together at such times when the pen is not being used, such as when it is being carried in a pocket or purse and it is desired to cover or protect the writing end of the pen. A clip rivet is fixed to the inner cap 19 for attaching a clip 22 to the cap assembly and for holding the shell 18 and inner cap 19 together.
The barrel assembly includes a generally open-ended barrel 25 formed of a metal, such as stainless steel, or some other suitable material. The barrel 25 connects to a generally tubular collector shell 26 by a shell connector 27. The inner wall of the collector shell 26 is proportioned to receive one end of the shell connector 27 and a suitable cement is used to bond the shell and connector together. The other end of the shell connector 27 is threaded to engage in a threaded end of a cylindrical barrel connector 28 which is cemented interiorally of one end of the barrel 25. In this manner, when the threaded portions of the barrel connector 28 and the shell connector 27 are connected, the barrel 25 is removably joined to the collector shell 26. A barrel tassie 24 is riveted across the other end of the barrel 25 for closing that end of the barrel.
Fitted within the collector shell 26 and held in place by ultrasonic bonding is a collector 29 having a number of radial fins 30 forming therebetween a number of capillary ink storage cells for receiving and thereafter feeding out any excess ink which may collect therein. The nib collar 20 is cemented into the collector shell 26 for connecting the cap assembly 12 and the barrel assembly 14 as hereinbefore described.
The inner dimensions of the barrel 25 are proportioned to receive and hold a replaceable ink reservoir or cartridge 33. It should be understood that the barrel 25 is adapted to receive a similarly, externally configured refillable ink reservoir (not shown). A collar 34 forms one end wall of the reservoir 33. To accomplish the mounting and connection of the reservoir 33 to the collector 29, the collector includes a centrally disposed, axially extending tubular portion having a rearward end 36 oriented at an angle to the axis of the pen for providing a sharp, knifelike surface to cut through the collar 34 which after being penetrated by the tubular portion 35 fits snugly around and over the tubular portion 35 preventing escape of ink from the reservoir along the outside wall of portion 35 yet providing communication wih the ink supply in the reservoir 33.
The collector 29 and nib collar 20 have aligned, centrally located bores therethrough which are proportioned to receive a feed 40 that serves to mount a nib 41 in the pen and to couple the nib to the ink supply contained in the reservoir 33 as well as to provide passage of replacement air from the atmosphere into the reservoir 33 as the ink supply is used up. The feed includes a collar 47 which stops the nib and feed assembly 16 against a shoulder formed internally of the nib collar 20 for exactly aligning the assembly 16 with respect to the collector 29. It should be pointed out that no rotational alignment is necessary because no radial orientation is necessary inside the collector. The nib and feed assembly 16 is freely rotatable within the collector bore and it will operatively function from any radial position therewithin. The feed 40 includes a longitudinally extending capillary feed groove 42 (FIG. 3) along which the ink flows from the reservoir 33 to the nib 41 and above which, in a space between the feed and the bore through the nib collar 20 and collector 29, replacement air flows into the cartridge. The feed 40 includes a tapered portion 43 at its front end which underlies the nib 41 and extends outwardly from the nib collar when the nib and feed assembly 16 is operatively assembled in the nib collar and collector bores. The tapered portion 43 becomes gradually less wide and less high as it approaches the writing end of the pen. The feed groove 42 in the feed 40 extends into the tapered portion 43 thereof for carrying ink to a slit 44 formed in the nib 41. The slit 44 defines a pair of adjacent, juxtaposed nib tines 45 having a pellet 46 attached to their outer ends. The slit 44 continues through the pellet for laying down ink on a writing surface. Looking toward the pellet 46, as in FIG. 4, it is shown that the pellet is substantially oval or egg-shaped with the larger or broader portion thereof being on the side of the nib toward the tapered portion 43 of the feed 40. A nib having a pellet configured in this manner can provide two distinct types of writing with the broader portion producing a broader line or stroke than the narrower portion of the pellet which is positioned toward the top of the nib. It should be understood that the sides of the pellet are not usually used in writing operations because they have no feed slit associated therewith for laying down ink on a writing surface.
A nib retainer 50 overlies the top of the nib 41. The external appearance of the exposed portion of the nib retainer 50 is similar to that of the exposed end of the feed in that it includes a tapered portion 51 which overlies the nib 41 and extends outwardly from the nib collar 20 when the nib 41, feed 40 and nib retainer 50 are operatively assembled into the writing end of the pen. The tapered portion 51 of the nib retainer 50 becomes gradually less wide and less high toward its free end. The tapered portion 51 of the nib retainer 50 is hollow and includes a T-shaped slot which provides communication between the atmosphere and the hollow interior of retainer 50.
The top of the feed 40 includes a raised rectangular nib lock lug 54 which fits through a rectangular hole 55 in the nib to position the nib on the feed and a raised post 56 which fits through an associated circular hole in the nib; said post 56 being suitably deformed or mushroomed over to lock the nib to the feed. The mushroomed post 56 prevents the nib from moving away from the feed when the force of writing pressure is exerted against the nib from the side of the nib adjacent the feed. The nib lock lug 54 has a post 60 extending therefrom which fits through an associated circular hole 61 formed in a relatively flat tail portion 62 of the retainer 50. The post 60 is suitably deformed or mushroomed to lock the nib retainer to the nib and feed.
The feed 40 also includes a plurality of circumferentially positioned, externally extending lugs 48 (one shown in FIG. 2) which provide a tight pressure fitting for the nib and feed assembly 16 against an inner circumferential wall of the nib collar 20. These lugs 48 also cooperate with the tail portion 62 of the nib retainer 50 for providing this snug fit.
The nib 41 is generally flat-appearing, however, as best seen in FIG. 4 the nib tines 45 are two planes which extend away from the horizontal approximately 8° thereby forming an approximately 164° included angle on the side of the nib toward the broader portion of the pellet. During a writing operation when the broader portion of the pellet touches the paper, a wider, wetter line is provided because the force acting against the broad portion of the pellet and the 8° orientation of the tines results in vector forces tending to force the tines apart and force open the slit; when the pen is rotated and the narrower portion of the pellet touches the paper, a finer, drier line is laid down, because the writing force acting against the narrow portion of the pellet and the 8° orientation of the tines results in vector forces tending to urge the tines together thereby reducing the width of the slit between the tines. As best seen in FIGS. 1 and 2 the free end of the nib retainer 50 is further away from the pellet of the nib than is the free end of the feed 40. Thus the fulcrum provided against the bending of the nib toward either the retainer 50 or the feed 40 is differently located. In that way a force applied against the broad portion of the pellet would meet less resistance to bending of the nib than an equal force applied against the narrower portion of the pellet.
As mentioned before, the nib retainer 50 is effectively hollow and includes the T-shaped slot 52 which forms the outside entrance for getting atmospheric air into the reservoir 33 to replace the ink therefrom which is written out during the writing process. In operation the air enters through T-shaped slot 52 and enters the hollow interior of nib retainer 50. From here the air passes around the post 60 between the retainer and the nib and then through a notch 58 in the feed. From the notch 58 the air enters and flows around a circumferential void 59 which is effectively a space between the front end of the collector 29 and the inner end of the nib collar 20. The circumferential void communicates with a notch 65 in the underside of the feed. It is appropriate to point out here that the notch 65 is normally full of air. The notch communicates with a wier 66 which is a circumferential space between the feed 40 and the internal bore through the collector 29. The wier 66 is normally full of ink, however when it is necessary to equalize the pressure in the reservoir, the air in the notch 65 passes around the wier 66 from bottom to top and then passes along a channel 67 above the feed into the reservoir. The circumferential void 59 also communicates with the spaces between the collector fins through a notch 70. The fins of the collector are normally full of air, that is, empty of ink, but if the collector is required to temporarily store a supply of ink, the air from the collector has egress to the atmosphere through the notch 70, into circumferential void 59 and through notch 58 into the interior of retainer 50 and out of slot 52.
Thus, it will be appreciated that all of the recited objects, advantages and features of the present invention have been demonstrated as obtainable in a highly practical fountain pen and one that is not only simple and positive in operation, but one that is relatively inexpensive and easy to manufacture.
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A fountain pen comprising a multipurpose writing nib having a contoured paper contacting portion or pellet attached to a forward portion thereof and two opposed, generally flat faces, each face being distinctly supported against flexure for providing variations in writing line breadth from using one or the other face of the nib against a writing surface.
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CROSS REFERENCE TO CO-PENDING APPLICATIONS
The present application is related to U.S. patent application Ser. No. 08/579,683, filed Dec. 28, 1995, entitled "Muti-Processor Data Processing System With Multiple, now U.S. Pat. No. 5,680,571, Separate Instruction and Operand Second Level Caches", U.S. patent application Ser. No. 08/288,651, which is a continuation of Ser. No. 07/762,282, filed Sep. 19, 1991, entitled "Cooperative Hardware and Microcode Control System for Pipelined Instruction Execution", now U.S. Pat. No. 5,577,259, and U.S. patent application Ser. No. 08/235,196, which is a continuation of Ser. No. 07/762,276, filed Sep. 19, 1991, entitled "Data Coherency Protocol for Multi-Level Cached High Performance Multiprocessor System", all assigned to the assignee of the present invention and all incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to general purpose digital data processing systems, and more particularly to such systems that employ shared memories accessed simultaneously by a plurality of users.
2. Description of the Prior Art
In most general purpose digital computers, it is desirable to have a computer storage system which can efficiently return data from a main memory. The computer storage system may be comprised of a shared memory resource. The concept of using a shared memory resource results from the design of general purpose digital computers, wherein often times additional memory resources, such as memory modules, are added at later points in time. In multi-processor computing systems, multiple requestors can request access to the same shared memory resource. Typically, these memories are divided into segments wherein the segments are mapped contiguously throughout the address space. Each of the multiple requestors can request access to the same memory segment simultaneously. As a result, requests not able to be serviced must be queued until they can be processed by a memory controller managing the requests. This can have the unfortunate result of decreasing overall system performance. It is desirable therefore to minimize queuing times to ensure maximum overall system performance.
One approach to solve this problem is to add additional queuing structures to support a plurality of requests. For example, if several instruction processors executing programs are utilizing the shared memory resource, adding additional queuing structures would reduce the backlog of queued requests. In one example, in a system utilizing a shared memory resource of 128 megawords of memory, four separate queuing structures may be added, each associated with a particular segment. Of the 27 bits necessary to access the 128 megaword shared memory resource, the two most significant bits, bits 26 and 27, may be used to select between the four segments, and the remaining bits, bits 1-25, used to address a particular word. If the 26th and 27th bit select between the four segments, a separate queuing structure is associated with each 32 megaword memory segment. Utilizing four queuing structures rather than one can increase system throughput by minimizing queuing or wait time. However, the additional queuing structures still do not prevent a backlog of queued requests if several instruction processors, for example, are executing programs resident in the same memory segment. This is because a disproportionate percentage of the requests will be directed at the same segment. That is, if two separate instruction processors are executing programs resident in the same 32 megaword memory segment, a backlog of queued requests could result since only one queuing structure serves the 32 megaword memory segment. This backlog of queued requests would therefore decrease overall system performance.
Another approach which has been used is to associate a cache memory with each individual queuing structure. While this approach can improve system performance by increasing the cache hit rate, a backlog of queued requests can still result if a disproportionate percentage of the requests are directed at the same memory segment. Thus associating the cache memory with each individual queuing structure would still not improve overall system performance.
Another disadvantage is that within the shared memory resource, multiple bit failures can occur. When the address space is mapped contiguously, as with the above approach, these multiple bit errors can be difficult to correct with known parity checking algorithms. This can be especially problematic with the very small feature sizes of the Dynamic Random Access Memories (DRAMs) and Static Random Access Memories (SRAMs) currently used in these memory resources. With minimum feature sizes approaching 0.5 microns or less, failures are more likely to cluster within a particular physical area in the DRAM or SRAM, thus affecting several adjacent memory bit storage cells and causing multiple bit errors.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages found in the prior art by providing a method and apparatus which utilizes an interleaved addressing scheme wherein each memory segment is associated with a separate queuing structure and the memory is mapped noncontiguously within a same segment so that all segments are accessed equally. Cache memory throughput is maximized as the plurality of requestors are queued evenly throughout the system.
In an exemplary embodiment of the present invention, the 128 megaword shared memory is divided into four segments, each having its own queuing structure. With 128 megawords, a 27-bit address is necessary to access the total memory address space. Multiple requestors in a multi-processor computing system can request access to the same memory segment simultaneously. The address mapping is selected to be the entry-level (EC) mode with two-way interleaved, addressing. Two scannable bits, a configuration bit and an interleave bit, select the configuration. mode. In addition to the EC mode with two-way interleave, the configuration mode can include the EC mode without interleave, the maximum-level (MC) configuration without interleave, and the MC configuration with four-way interleave. In the exemplary embodiment the configuration bit is equal to a logical 0, and the interleave bit is equal to a logical 1, thus selecting the EC configuration with two-way interleave. The segment select bits, defined within the memory address space, select a new segment after every 8 word block. Each segment is not mapped contiguously since each segment contains 64 megawords. The instruction cache set address and instruction word address are defined within the 15 least significant bits of the memory address. Thus when interleave is selected, the 10 address bits defining the instruction cache set address must each be shifted one position to the next most significant bit position to accommodate to the segment select bit. The five address bits defining the instruction cache word address are the five least significant bits of the memory address, thus only the two most significant of these five least significant bits must be shifted one position to the next most significant bit position to accommodate the segment select bit. If the operand cache is being addressed, the 10 address bits defining the operand cache set address must each be shifted one position to the next most significant bit position to accommodate to the segment select bit. The operand cache word address occupies the three least significant bit positions of the memory address and are not shifted if two-way interleave is selected.
The exemplary embodiment further includes a segment select associated with each segment to select a particular segment and to associate an instruction cache and operand cache, and a queue, with each particular segment. The segment select includes a segment multiplexer and a word multiplexer, both coupled to the plurality of requesters or instruction processors to decode the selection for a particular segment and select the proper address bits for the segment queue. The segment queue stacks address requests for access of data from the instruction cache and operand cache, and the memory storage units. Depending on whether instruction or operand data is being accessed, if the requested data is not available in the instruction cache or operand cache, the access to either of the two memory storage units will be completed. An instruction cache address decode decodes the instruction cache set address and instruction cache word address corresponding with the selected configuration, here the EC configuration with two-way interleave. The instruction cache receives the instruction cache set address and the instruction cache word address and determines if the requested data is available. If the operand cache is accessed, the operand cache address decode decodes the operand cache set address and operand cache word address corresponding to the EC configuration with two-way interleave. The operand cache tag directory receives the operand cache set address and operand cache word address and determines if the requested data is available. If the data is not available within the instruction cache or operand cache, the requested data is retrieved from either of the two memory storage units.
In a preferred embodiment of the present invention, the 128 megaword shared memory is divided into four segments, each having its own queuing structure. The address mapping is selected to be the MC configuration with four-way interleaved addressing. Two scannable bits, a configuration bit and an interleave bit, select the MC configuration. In the preferred embodiment the configuration bit is equal to a logical 1, and the interleave bit is equal to a logical 1, thus selecting the DC configuration with four-way interleave. The segment select bits, defined within the memory address space, select a new segment after every 8 word block. Each segment is not mapped contiguously since each segment contains 32 megawords. The instruction cache set address and instruction word address are defined within the 15 least significant bits of the memory address. Thus when fodr-way interleave is selected, the 10 address bits defining the instruction cache set address must each be shifted two positions to the next two most significant bit positions to accommodate to the segment select bits. The five address bits defining the instruction cache word address are the five least significant bits of the memory address, and only the two most significant of these five least significant bits must be shifted two positions to the next two most significant bit positions to accommodate the segment select bit. If the operand cache is being addressed, the 10 address bits defining the operand cache set address must each be shifted two positions to the next two most significant bit positions to accommodate to the two segment select bits. The operand cache word address occupies the three least significant bit positions of the memory address and are not shifted if two-way interleave is selected.
The preferred embodiment further includes a segment select associated with each segment to select a particular segment and to associate the instruction cache and operand cache, and the queue, with a particular segment. The segment select includes a segment multiplexer and a word multiplexer, both coupled to the plurality of requesters-or instruction processors to decode the selection for a particular segment and select the proper address bits for a segment queue. The segment queue stacks address requests for access of data from the instruction cache and operand cache and the memory storage units. Depending on whether an instruction or operand is being accessed, if the requested data is not available in the instruction cache or operand cache, the access to either of the two memory storage units will be completed. An instruction cache address decode decodes the instruction cache set address and instruction cache word address corresponding to the selected configuration, here the MC configuration with four-way interleave. The instruction cache tag directory receives the instruction cache set address and the instruction cache word address and determines if the requested data is available. If the operand cache is accessed, the operand cache address decode decodes the operand cache set address and operand cache word address corresponding to the MC configuration with four-way interleave. The operand cache receives the operand cache set address and operand cache word address and determines if the requested data is available. If the data is not available within the instruction cache or operand cache , the requested data is retrieved from either of the two memory storage units.
The description given herein does not limit the scope of the invention to any particular interleave configuration. As apparent from the description above, the elements described can accommodate any particular interleave configuration desired.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is a schematic diagram of a fully populated data processing system incorporating the present invention;
FIG. 2 is a pictorial diagram showing the packaging arrangement of the data processing system of FIG. 1;
FIG. 3 is a schematic diagram of the levels of storage for a single instruction processor;
FIG. 4 is a schematic diagram showing the entry-level (EC) configuration;
FIG. 5 is a schematic diagram showing the maximum-level (MC) configuration;
FIG. 6 is a simplified block diagram showing the major elements of the instruction processor;
FIG. 7 is a detailed block diagram of the instruction processor;
FIG. 8 shows the fields of a typical 36-bit machine instruction both extended mode and basic mode format;
FIG. 9 shows an exemplary base register stack;
FIG. 10 shows a typical base register entry;
FIG. 11 shows the address mapping for the entry-level (EC) configuration without interleave;
FIG. 12 shows the address mapping for the entry-level (EC) configuration with interleave;
FIG. 13 shows the address mapping for the maximum-level (MC) configuration without interleave;
FIG. 14 shows the address mapping for the maximum-level (MC) configuration with interleave;
FIG. 15 shows a segment address interleave map;
FIG. 16 is a block diagram showing the segment select;
FIG. 17 is a block diagram showing the instruction cache address decode;
FIG. 18 is a block diagram showing the operand cache address decode; and
FIG. 19A and FIG. 19B are a flow diagram showing an exemplary method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an overall diagram of fully populated data processing system according to the present invention. Data processing system 10 includes two individual processing clusters each contained within its own power domain. Furthermore, each individual processing cluster has its own storage controller and point-to-point communication with the other cluster via a storage controller-to-storage controller interface.
Storage controller 12 is contained within power domain 0-14, and storage controller 16 is contained within power domain 1-18. Storage controller 12 is coupled to storage controller 16 via interface 20. Storage controller 12 is fully populated with instruction processor 22, instruction processor 24, instruction processor 26, instruction processor 28, main memory module 32 and main memory module 34. Storage controller 16 is fully populated with instruction processor 36, instruction processor 38, instruction processor 40, instruction processor 42, main memory module 46 and main memory module 48. Storage controller 12 is coupled to common I/O bus 50 via path 52, and Storage controller 16 is coupled to common I/O bus 54 via path 56. Main memory module 32 is coupled to main memory module 34 vial path 60. Main memory module 46 is coupled to main memory module 48 via path 62. Each of instruction processors 22, 24, 26 and 28 (along with similar instruction processors 36, 38, 40, and 42) has internal dedicated cache resources in the form of an instruction cache and an operand cache. These elements, along with the associated data invalidity logic, are described in more detail below. A more general description of the construction and operation of instruction processors 22, 24, 26 and 28 (along with similar instruction processors 36, 38, 40, and 42) may be found in the above-referenced and commonly assigned co-pending U.S. patent application Ser. No. 07/762,276, filed Sep. 19, 1991 which has been incorporated by reference.
FIG. 2 is a schematic diagram showing the packaging of a portion of data processing system 10. A major physical element of data processing system 10 is Processing Complex Cabinet, PCC 70. Within fully populated PCC 70 is located instruction processors 22, 24, 26 and 28 (i.e., IP1, IP2, IP3 and IP4). In the preferred mode, each of these instruction processors is packaged on a single high density circuit board. The memory storage units 32 and 34 are coupled to storage controller 12 as explained above.
Network interface module (i.e., NIM) 72 provide an interface to the operator console via cable 74. Cable 76 couples an input/output processor (not shown) to storage controller 12. Input/output processor is physically packaged in an Input/output Complex Cabinet (i.e., ICC) which is not shown for clarity. Other referenced elements are as previously described.
FIG. 3 is a diagram 80 showing the hierarchical arrangement of the three levels of storage within data processing system 10. Instruction processor 22 is within the first level of storage and contains an instruction cache 82 and an operand cache 84, each storing 8k of 36-bit words. These are internal to instruction processor 22 and dedicated to the operations undertaken therein. By partitioning the internal dedicated cache resources in this manner, there is a certain concurrence of cache accesses associated with normal instruction execution.
Upon the request of instruction processor 22 to access a particular data element as either an instruction or operand, the directory of instruction cache 82 or operand cache 84, respectively, is queried to determine if the required data element is present within the associated cache resource. If the data element is present and valid, the access is completed at that level. If not, access is made to storage controller 12 via interface 86 for the block of eight 36-bit words containing the desired data element. A more detailed explanation of the operation of instruction cache 82 and operand cache 84 is found below.
Storage controller 12 is within the second level of storage. The storage controller contains multiple segments wherein each segment contains a 128k 36-bit word instruction cache and a 32k 36-bit words operand cache. In the present illustration, segment 0-88 has instruction cache 90 and operand cache 92, segment 1-94 has instruction cache 96 and operand cache 98, segment 2-100 has instruction cache 102 and operand cache 104, and segment 3-106 has instruction cache 108 and operand cache 110. These cache resources are shared by all users of the two memory storage units within the cluster to include both local and remote users. Any memory request to storage controller 12 is routed to the appropriate directory of instruction cache 90 or operand cache 92 in segment 0-88, instruction cache 96 or operand cache 98 in segment 1-94, instruction cache 102 or operand cache 104 in segment 2-100, or instruction cache 108 or operand cache 110 in segment 3-106 to determine if the desired data element is present and valid. Each of the instruction and operand cache memories within segment 0-88, segment 1-94, segment 2-100 or segment 3-106 are partitioned in address space to correspond to a particular address space within memory storage unit 32 or memory storage unit 34. As this routing is based upon the address requested, a particular second level instruction or operand cache resource within a particular segment will be accessed to determine if a requested data element is present before requesting the data element from memory storage unit 32 or memory storage unit 34 within the third level of storage.
If present and valid, the requested data element is supplied as an eight word block. If the requested data element is not validly present in either of instruction cache 90 or operand cache 92 in segment 0-88, instruction cache 96 or operand cache 98 in segment 1-94, instruction cache 102 or operand cache 104 in segment 2-100, or instruction cache 108 or operand cache 110 in segment 3-106 (depending upon the requested address), the data will then be requested from the third level of storage. Storage controller 12 is coupled to memory storage units 32 and 34 in the third level of storage via interface 112. In the preferred mode, memory storage units 32 and 34 each contain up to 256 megawords of storage.
Each data element request to storage controller 12 is made through a separate interface. For a fully populated system, this includes four instruction processors, one input/output processor, and one other storage controller (see also, FIG. 1). The two configurations typically used are the entry-level (EC) configuration (see, also FIG. 4) and the maximum-level (MC) configuration (see also, FIG. 5). In addition there are four address interleave choices available. These are the EC configuration with and without address interleave (see also, FIG. 11 and FIG. 12), and the MC configuration with and without address interleave (see also, FIG. 13 and FIG. 14). Each data element request as discussed above is divided between instruction cache 90 or operand cache 92 in segment 0-88, instruction cache 96 or operand cache 98 in segment 1-94, instruction cache 102 or operand cache 104 in segment 2-100, or instruction cache 108 or operand cache 110 in segment 3-106, depending upon the requested address. Only if the requested data element is not validly present in the appropriate second level cache resource is an access request made to the third level of storage to memory storage units 32 or 34.
FIG. 4 is a diagram 114 showing the entry-level (DEC) configuration of the three levels of storage within data processing system 10. Instruction processor 22 which contains instruction cache 82 and an operand cache 84, and instruction processor 24 which contains instruction cache 116 and operand cache 118, are within the first level of storage. Instruction cache 82 and operand cache 84, as well as instruction cache 116 and operand cache 118, each store 8k of 36-bit words. These are internal to instruction processor 22 and instruction processor 24 and are dedicated to the operations undertaken therein. Thus by partitioning the internal dedicated cache resources in this manner, there is a certain concurrence of cache accesses associated with normal instruction execution.
Upon the request of either instruction processor 22 or instruction processor 24 to access a particular data element as either an instruction or operand, the directory of instruction cache 82 or operand cache 84 in the case of instruction processor 22, or instruction cache 116 or operand cache 118 in the case of instruction processor 24 is queried to determine if the required data element is present within the associated cache resource. If the data element is present and valid, the access is completed at that level. If not, access is made to storage controller 12 via interface 86 for the block of eight 36-bit words containing the desired data element.
Storage controller 12 is within the second level of storage. The storage controller contains two segments in the EC mode which can support up to two instruction processors. Each segment contains a 128k 36-bit word instruction cache and a 32k 36-bit words operand cache. In the EC configuration, segment 0-88 has instruction cache 90 and operand cache 92, and segment 1-94 has instruction cache 96 and operand cache 98. Thesescache resources are shared by all users of the two memory storage units within the cluster to include both local and remote users. Any memory request to storage controller 12 is routed to the appropriate directory of instruction cache 90 or operand cache 92 in segment 0-88, or instruction cache 96 or operand cache 98 in segment 1-94 to determine if the desired data element is present and valid. Each of the instruction and operand cache memories within segment 0-88 or segment 1-94 are partitioned in address space to correspond to a particular address space within memory storage unit 32 or memory storage unit 34. As this routing is based upon the address requested, a particular second level instruction or operand cache resource within a particular segment will be accessed to determine if a requested data element is present before requesting the data element from memory storage unit 32 or memory storage unit 34 within the third level of storage.
If present and valid, the requested data element is supplied as an eight word block. If the requested data element is not validly present in either of instruction cache 90 or operand cache 92 in segment 0-88, or instruction cache 96 or operand cache 98 in segment 1-94, (depending upon the requested address), the data will then be requested from the third level of storage. Storage controller 12 is coupled to memory storage units 32 and 34 in the third level of storage via interface 112. In the EC mode, the total address space partitioned within memory storage units 32 and 34 to correspond to the instruction and operand cache memories within segment 0-88 or segment 1-94, is the same as the total address space partitioned to correspond to the instruction and operand cache memories within the four segments of the maximum-level (MC) configuration (see FIG. 5).
FIG. 5 is a diagram 120 showing the maximum-level (MC) configuration of the three levels of storage within data processing system 10. Instruction processor 22 which contains instruction cache 82 and an operand cache 84, instruction processor 24 which contains instruction cache 116 and operand cache 118, instruction processor 26 which contains instruction cache 122 and operand cache 124, and instruction processor 28 which contains instruction cache 126 and operand cache 128, are each within the first level of storage. Each instruction cache 82, 116, 122 and 126, as well as each operand cache 84, 118, 124 and 128, can store 8k of 36-bit words. Each instruction or operand cache within a particular instruction processor are internal to that instruction processor (e.g. instruction processor 22, 24, 26 or 28) and are dedicated to the operations undertaken therein. Thus by partitioning the internal dedicated cache resources in this manner, there is a certain concurrence of cache accesses associated with normal instruction execution.
Upon the request of either instruction processor 22, instruction processor 24, instruction processor 26 or instruction processor 28 to access a particular data element as either an instruction or operand, the directory of instruction cache 82 or operand cache 84 in the case of instruction processor 22, instruction cache 116 or operand cache 118 in the case of instruction processor 24, instruction cache 122 or operand cache 124 in the case of instruction processor 26, or instruction cache 126 or operand cache 128 in the case of instruction processor 28, are queried to determine if the required data element is present within the associated cache resource. If the data element is present and valid, the access is completed at that level. If not, access is made to storage controller 12 via interface 86 for the block of eight 36-bit words containing the desired data element.
Storage controller 12 is within the second level of storage. The storage controller contains four segments in the MC mode which can support up to four instruction processors. Each segment contains a 128k 36-bit word instruction cache and a 32k 36-bit word operand cache. In the MC configuration, segment 0-88 has instruction cache 90 and operand cache 92, segment 1-94 has instruction cache 96 and operand cache 98, segment 2-100 has instruction cache 102 and operand cache 104, and segment 3-106 has instruction cache 108 and operand cache 110. These cache resources are shared by all users of the two memory storage units within the cluster to include both local and remote users. Any memory request to storage controller 12 is routed to the appropriate directory of instruction cache 90 or operand cache 92 in segment 0-88, instruction cache 96 or operand cache 98 in segment 1-94, instruction cache 102 or operand cache 104 in segment 2-100, or instruction cache 108 or operand cache 110 in segment 3-106, to determine if the desired data element is present and valid. Each of the instruction and operand cache memories within segment 0-88, segment 1-94, segment 2-100 or segment 3-106 are partitioned in address space to correspond to a particular address space within memory storage unit 32 or memory storage unit 34. As this routing is based upon the address requested, a particular second level instruction or operand cache resource within a particular segment will be accessed to determine if a requested data element is present before requesting the data element from memory storage unit 32 or memory storage unit 34 within the third level of storage.
If present and valid, the requested data element is supplied as an eight word block. If the requested data element is not validly present in either instruction cache 90 or operand cache 92 in segment 0-88, instruction cache 96 or operand cache 98 in segment 1-94, instruction cache 102 or operand cache 104 in segment 2-100, or instruction cache 108 or operand cache 110 in segment 3-106, (depending upon the requested address), the data will then be requested from the third level of storage. Storage controller 12 is coupled to memory storage units 32 and 34 in the third level of storage via interface 112. In the MC mode, the total address space partitioned within memory storage units 32 and 34 to correspond to the instruction and operand cache memories within segment 0-88, segment 1-94, segment 2-100 or segment 3-106 is the same as the total address space partitioned to correspond to the instruction and operand cache memories within the two segments of the entry-level (EC) configuration.
FIG. 6 is a simplified block diagram of instruction processor 22 showing the major data and control paths. Interface 86, providing the data transfer path between storage controller 12 and instruction processor 22, is actually a two-way path. Data is accessed by storage controller 12 and routed to either instruction cache 82 or operand cache 84 depending upon whether the initial request was for instruction data or operand data. In accordance with usual local cache operation, instruction cache 82 and operand cache 84 temporarily store the data for use by instruction processor 22. Interface 86 also couples write data from write stack 130 to storage controller 12 for longer term storage. Priority for this shared interface is ordinarily given to read data requests requiring write data to be queued in write stack 130. The exception to giving priority to read data is whenever data is to be read from a location for which a write access has been queued.
Instructions from instruction cache 82 are provided via path 132 to control section 134 for decoding via microcode controller and hardwired control logic. Arithmetic execution logic 136 receives operand data via path 138 and performs the specified operation using a combination of microcode control and hardwired control as explained in greater detail below.
Most arithmetic instructions operate upon data which is temporarily stored in general register stack 140. This permits most rapid access to the data, because that data is directly accessed from an extremely fast storage stack. Similarly, arithmetic results are often returned to general register stack 140 for temporary storage until further arithmetic processing. Data is routed to general register stack 140 by path 142. Data from general register stack 140 is routed back to arithmetic execution logic 136 via path 144 and to write stack 130 via path 145. The data transferred to write stack 130 is queued for storage by storage controller 12 as discussed above.
FIG. 7 is a more detailed block diagram of instruction processor 22. The major data paths are shown, with the solid line paths signifying 72 bit, double word, transfer paths; and addressing paths; and the dotted lines indicating data paths of no greater than 36 bits. Control line paths are not shown for clarity.
The interface to storage controller 12 is via interface 86, as described above. It consists of write interface 146 and read interface 148. Each of these data paths couples a 36-bit word in parallel fashion. The function of write stack 130 (see also FIG. 6) is incorporated within store interface 150 which also provides the request/acknowledge synchronization logic. Addressing information for store interface 150 is sent from instruction cache 82 via interface 152 and operand cache 84 via interface 154 for a corresponding cache miss. Instructions are sent to instruction cache 82 via path 156. Because instructions are 36-bit words, path 156 has a width of 36 bits. Operand data read by storage controller 12 is transferred from store interface 150 to operand cache 84 by path 158. Similarly, write operand data is sent from operand cache 84 to store interface 150 via path 160. Both path 158 and path 160 have a width of 72 bits to accommodate double word operands.
Instructions to be executed are addressed by instruction read 162. The addresses are computed using one of the base registers located within address environment 164. If the instruction is the next sequential instruction, its address is determined by incrementing the program address counter. If the instruction to be executed is addressed by a branch or jump instruction, the address may be computed by address generator 166 and supplied via path 168. Alternatively, the address may be supplied by jump prediction 170 via path 172 during operation in the jump prediction mode as explained in detail below. The address of the next instruction is provided to instruction cache 82 via path 174.
The next addressed instruction is fetched from instruction cache 82 if a match is found. If the request results in a cache miss, storage controller 12 is requested to read the memory block containing the instruction as discussed above. In either case, the instruction is provided to instruction decoder 176 via path 178. The instruction is decoded through the use of a microcode controller by instruction decode 176, and the operand address is computed by address generator 166 from the data received via path 180.
Operand cache 84 contains general register stack 140 (see also, FIG. 6). The cache is addressed by the output of address generator 166 received from path 182. Direct operands are received on path 184. If a match is not made in operand cache 84, a read request is made of storage controller 12 through store interface 150 as explained above. If a match is found in operand cache 84 or if the instruction specifies a direct operand received on path 184, the operand data is more immediately produced. In either case, the operand data is routed in accordance with the operation to be performed as specified by the instruction. Indirect operands cause the new operand address to be transferred to address generator 166 via path 186. Operands are transferred to binary arithmetic 188 for mathematical computation via path 190 or to address environment 164 via path 192.
Binary arithmetic 188 provides the basic control for all arithmetic operations to be performed on data received via path 190. Floating point operations are scaled and controlled by floating point logic 194 which receives operand data on path 196. Floating point results are returned to binary arithmetic 188 by path 198. Mult./div. 200 performs the basic multiplication and division operations for fixed point instructions. Operand data is received via path 202 and the products/quotients returned via path 204 and floating point logic 194. Decimal arithmetic 206 receives operand data on path 208 and returns results via path 210. Decimal arithmetic performs special purpose decimal operations.
Another category of instructions involves a change to the base registers within the addressing environment 164. The data is supplied to addressing environment 164 via path 192. Base register contents are supplied to interrupt control 212 via paths 214 and 216. Interrupt control 212 provides the interrupt data to operand cache 84 via path 218. Control section 220 provides the overall microcode control.
The operation of instruction processor 22 is intended to occur in the pipelined mode whenever feasible. The preferred mode utilizes a three stage pipeline. The operation of this pipeline may be found in U.S. patent application Ser. No. 07/762,276, entitled "Data Coherency Protocol for Multi-Level Cached High Performance Multiprocessor System", referenced co-pending application which has been incorporated herein by reference. The remaining referenced components are as previously discussed.
FIG. 8 shows the field format of a typical 36-bit machine instruction in both extended mode and basic mode format. The diagram is generally shown at 228. The F-field 230 or Function Code, including bits 0 through 5, specifies the operation to be performed by the instruction. The J-field 232, including bits 6 through 9, is sometimes combined with the F-field 230 to act as part of the Function Code, but usually represents an instruction operand qualifier indicating whether the instruction operand is the entire 36-bit word specified by the instruction operand address, a subfield of that word or the instruction operand address itself (immediate operand). The A-field 234, located at bits 10 through 13, is usually the register operand address specifying the address of the register containing the operand. However, for some instructions the A-field 234 acts as part of the Function Code 230. The X-field 236, at bits 14 through 17, is the index register (X-register) address specifying an index register to be used in the indexing operation to form the instruction operand address. The H-bit 238 at bit 18 is used to control index incrementation when the J-field of the instruction is non zero. The I-bit 240 at bit 19 indicates indirect addressing in basic mode unless the instruction specifies an immediate operand.
Generally, the "basic mode" denotes a basic set of machine instructions and capabilities, and "extended mode" denotes a set of machine instructions that includes the basic mode instructions plus a set of additional instructions, thereby providing extended operational capability. In extended mode, the I-bit 240 is used either as an extension to the B-field 242 or to indicate whether 18-bit or 24-bit relative addressing will be used. The B-field 242 at bits 20 through 23 in extended mode format is the base register selector which specifies a base register describing the bank containing the instruction operand. The displacement address in extended mode is specified by the D-field 244 (bits 24 through 35) and in basic mode by the U-field 246 (bits 20 through 35). Those fields contain a displacement value that is used in conjunction with the modifier portion of the index register specified by the X-field 236 to form an instruction operand relative address. A further discussion of the instruction format and the operation thereof can be found in the above-referenced U.S. patent application Ser. No. 07/762,282, entitled "Cooperative Hardware and Microcode Control System for Pipelined Instruction Execution".
FIG. 9 shows an exemplary base register stack. The diagram is generally shown at 248. The base register stack comprises a number of addressable base registers 250, 252, and 254. In a preferred embodiment, base register stack 248 comprises 15 base registers as shown. During initialization of an applications program, a selected set of base registers are loaded with a number of fields including a base register address field.
The base register stack 248 is used to allocate memory to each application program running on the data processing system. This is accomplished by using a virtual addressing scheme, wherein each base register contains a base address which may be used to calculate an absolute address. A further discussion of absolute address generation may be found in the above-referenced U.S. patent application Ser. No. 07/762,282, filed Sep. 19, 1991, entitled "Cooperative Hardware and Microcode Control System for Pipelined Instruction Execution", which is incorporated herein by reference.
FIG. 10 shows the format for one entry 256 in one of the 15 user base registers. Each entry consists of four 36-bit words (i.e., words 258, 260, 262 and 264), wherein each word has lower quarter 266, second quarter 268, and upper half 270. Word 258 has a number of control bits 272 within lower quarter 266 and second quarter 268. Upper half 270 of word 258 contains access lock 274.
Lower limit 276 is located in lower quarter 266 of word 260. Upper limit 278 is located in upper half 270 of word 260. Upper limit 278 and lower limit 276 are used to set the security limits on user program access to the associated data segment.
The base address consists of portion 280 located in upper half 270 of word 262 and portion 282 located in the entire 36 bits of word 264. In this manner, an absolute storage space of 252 words of 36 bits each can be uniquely addressed by the absolute address.
FIG. 11 shows the address mapping for the open entry (EC) configuration without interleave. In the EC configuration, the address is divided into two independently operating segments (see also, FIG. 4). Thus, with both storage controller 12 and storage controller 16 (see also, FIG. 1), there is a total of 4 segments or servers which operate in parallel with each segment being dedicated to two instruction processors. The address mapping for the EC configuration without interleave is shown generally at 284. Segment select bit 286 is address bit A27 which defines the segment selected. A27 is selected because it is the most significant address bit within the minimum memory range available and results in toggling between the two segments every 64 megawords. Since address bit A27 is the most significant address bit and selects between one of two available segments, mapping occurs contiguously within a segment. Address 284 is a write through address and contains the instruction cache and operand cache address bits. The instruction cache address is divided into an instruction cache set address 288 which include address bits A39 through A48, and an instruction cache word address 290 which includes address bits A49 through A53. The operand cache address is divided into an operand cache set address 292 which includes address bits A41 through A50, and an operand cache word address 294 which includes address bits A51 through A53.
FIG. 12 shows the address mapping for the entry level (EC) configuration with interleave. The address mapping for the EC configuration with interleave is shown generally at 296. With the EC configuration, the address is divided into two independently operating segments (see also, FIG. 4). Segment select bit 298, which is address bit A50, defines the segment selected and selects a new segment after every 8 word block. Thus, a segment does not contain a contiguous address range. Address bits A51 through A53 are contiguous bits and define the segment address field. Each combination of address bits A51 through A53 corresponds to one of eight address words or locations mapped contiguously within the selected segment. The maximum addressable range of A51 through A53 defines the number of address words mapped contiguously within the selected segment and thus is eight.
When interleave is selected for the EC mode, the instruction cache set address 300 is provided by A38 through A47 and is shifted left one bit from the EC mode without interleave (see also, FIG. 11). The instruction cache word address is defined by address bits A48 through A49 and A51 through A53. Here, instruction cache word address bits A48 and A49 are shifted left one bit from the EC mode without interleave to allow address bit A50 to perform the segment selection. Operand cache set address 304 is provided by address bits A40 through A49, which are shifted left one bit from the EC mode without interleave (see also, FIG. 11). Operand cache word address 306 is provided by address bits A51 through A53.
FIG. 13 shows the address mapping for the maximum-level (MC) configuration without interleave. In the MC configuration, each of two storage controls divides the memory address into four segments (see also, FIG. 5). Each segment operates independently which means that with two storage controls, there are a total of eight segments that operate in parallel, wherein each storage control is dedicated to a cluster of four instruction processors (see also, FIG. 5). The address mapping for the MC configuration without interleave is shown generally at 308. Segment select bits 310 are provided by address bits A27 and A28, which define the segment selected. A27 and A28 reside within the minimum memory range, wherein every 32 megawords will route to a different segment on the 0-3 basis. Thus, as address bits A27 and A28 select between one of four available segments, the memory mapping occurs contiguously within a segment. Instruction cache set address 312 is provided by address bits A39 through A48. Instruction cache word address 314 is provided by address bits A49 through A53. Operand cache set address 316 is provided by address bits A41 through A50. Operand cache word address 318 is provided by address bits A51 through A53.
FIG. 14 shows the address mapping for the maximum level (MC) configuration with interleave. The address map for the MC configuration with interleave is shown generally at 320. In the MC configuration with interleave, segment select bits 322 are provided by address bits A49 and A50. Address bits A49 and A50 select between one of four available segments so that a new segment is selected after every eight word block. Thus, a segment does not contain a contiguous-address range. Address bits A51 through A53 are contiguous bits and define the segment address field. Each combination of address bits A51 through A53 corresponds to one of eight address words or locations mapped contiguously within the selected segment. The maximum addressable range of A51 through A53 defines the number of address words mapped contiguously within the selected segment and thus is eight.
When interleave is selected for the MC mode, the instruction cache set address 324 is provided by address bits A37 through A46 which are shifted left two bits from the MC configuration without interleave (see also, FIG. 13). This allows bits A49 and A50 to perform the segment selection. Instruction cache word address 326 is provided by address bits A47 and A48 which are shifted left two bits as well, and by address bits A51 through A53. Operand cache set address 328 is provided by address bits A39 through A48 which are shifted left two bits over the MC configuration without interleave (see also, FIG. 13). The operand cache word address 350 is provided by address bits A51 through A53.
FIG. 15 shows a segment address interleave map. The segment interleave map is shown generally at 322. When interleave is selected for either the entry-level (EC) or maximum-level (MC) mode, the instruction cache set address and operand cache set address and a portion of the instruction cache word address must be shifted left by one bit for the EC mode, or two bits for the MC mode. The instruction cache set address, instruction cache word address, operand cache set address, and operand cache word address inputs must be multiplexed (see also, FIGS. 17 and 18). The multiplexer selection is provided by two scannable interleave scan bits 334 which are configuration bit 336 and interleave bit 338. Configuration bit 336 and interleave bit 338 select one of four. If configuration bit 336 and interleave bit 338 are both zero, EC configuration without interleave is selected. If configuration bit 336 is zero and interleave bit 338 equals one, the EC configuration with two-way interleave is selected. If the configuration bit 336 equals 1 and the interleave bit 338 equals 0, the MC configuration without interleave is selected. If the configuration bit 336 equals 1 and the interleave bit 338 equals 1, the MC configuration with four-way interleave is selected. The segment selection for the EC and MC modes is provided by requestor address 340 through address bits A27, A28, A49 or A50, depending upon the configuration selected (see also, FIGS. 11-14). If configuration bit 336 and interleave bit 338 are both equal to 0, the EC mode without interleave is selected as indicated at 342 and 344. At 342, requester address 340 address bit A27 is 0 and segment 0 is selected as shown at segment selection 366. At configuration 344, requester address 340 address bit A27 equals 1 and segment selection 366 shows segment 2 is selected. At 346, configuration bit 336 is equal to 0 and interleave bit 338 equals 1, and the EC configuration with two-way interleave is selected. Requestor address 340 address bit A50 equals 0, thus, segment 0 is selected. At configuration 348, configuration bit 336 equals 0 and interleave bit 338 equals 1, and the EC mode with two-way interleave is selected. Requestor address 340 address bit A50 equals 1, thus, segment selection 366 indicates segment 2 is selected. At configuration 350, configuration bit 336 equals 1 and interleave bit 338 equals 0, and the MC mode with no interleave is selected. Requestor address 340 shows four combinations of address bits A27 and A28, while the MC configuration without interleave is selected. Thus, at configuration 350 when A27 equals 0 and A28 equals 0, segment selection 366 indicates segment 0 is selected. At configuration 352, when A27 equals 0 and A28 equals 1, segment selection 366 indicates segment 1 is selected. At configuration 354, when A27 equals 1 and A28 equals 0, segment selection 366 indicates segment 2 is selected. At configuration 356, when A27 equals 1 and A28 equals 1, segment selection 366 indicates segment 3 is selected. When configuration bit 336 and interleave bit 338 are both equal to 1, the MC mode with four-way interleave is selected. At configuration 358, address bit A49 equals 0 and address bit A50 equals 0 and segment selection 366 indicates segment 0 is selected. At configuration 360, A49 equals 0 and A50 equals 1, and segment selection 366 indicates segment 1 is selected. At configuration 362, A49 equals 1 and A50 equals 0, and segment selection 366 indicates segment 2 is selected. At configuration 364, A49 equals 1 and A50 equals 1, and segment selection 366 indicates segment 3 is selected.
FIG. 16 is a block diagram showing the major elements of the segment select. Each of segments 0 88, segment 1 94, segment 2 100, or segment 3 106 within storage controller 12 (as well as storage controller 16) contains segment select 368. Segment mux 370 and word mux 372 both couple to instruction processor 22, instruction processor 24, instruction processor 26 and instruction processor 28. Segment mux 370 has address bit A27 at 374, address bit A50 at 376, address bits A27 through A28 at 378, and address bits A49 through A50 at 380, all as inputs.
Segment select 368 performs the segment selection illustrated in FIG. 15. Each instance of segment select 368 corresponds with the number of segments available for selection. Thus, with the EC configuration with no interleave or two-way interleave, two segments are selected and two instances of segment select 368 are available. With the MC configuration without interleave or with four-way interleave, four segments are selected from and four instances, one corresponding to each segment, of segment select 368 are available. If segment select 368 is associated with segment 0 88, segment select 368 is selected when segment mux 370 decodes a segment select address corresponding to segment 0 88. Thus, if configuration bit 336 and interleave bit 338 of scan bits 344 are both equal to 0, the EC configuration without interleave is selected, and a 0 is decoded at address bit 27 at 374. If configuration bit 336 is equal to 0 and interleave bit 338 is equal to 1, the EC configuration with two-way interleave is selected and a 0 is decoded at address bit A50 at 376 to select segment select 368. If configuration bit 336 is equal to 0 and interleave bit 338 is equal to 1, the EC configuration with two-way interleave is selected and a zero is decoded at address bit A50 at 376 to select segment select 368. If configuration bit 336 is equal to 1 and interleave bit 338 is equal to 0, the MC configuration without interleave is selected. Address bit A27 equals 0 and address bit A28 equals 0 is decoded at 378 to select segment select 368. If configuration bit 336 equals 1 and interleave bit 338 equals 1, the MC mode with four-way interleave is selected. Address bit A49 equals 0 and address bit A50 equals 0 is decoded at 380 to select segment select 368. Once segment select 368 is decoded in any of the four modes, the segment select bits are passed as the most significant bits to segment queue 382 via path 384. In addition, word mux 372 is enabled through path 386 to multiplex the main address bits for access of memory storage unit 0 32 or memory storage unit 1 34. Thus, if configuration bit 336 is equal to 0 and interleave bit 338 is equal to 0, the EC configuration without interleave is selected and word mux 372 selects address bits A28 through A53 at 388 and multiplexes them to segment queue 382 via path 396. If configuration bit 336 is equal to 0 and interleave bit 338 equals 1, the EC configuration with no interleave is selected and word mux 372 selects address bits A27 through A49 and A50 through A53 and provides them to segment queue 382 via path 396. If configuration bit 336 is equal to 1 and interleave bit 338 is equal to 0, the MC configuration without interleave is selected and word mux 372 multiplexes address bits A29 through A53 via path 392 to segment queue 382 via path 396. If configuration bit 336 equals 1 and interleave bit 338 equals 1, the MC configuration with interleave is selected and address bits A27 through A48 and A51 through A53 at 394 are multiplexed by segment queue 382 via path 396. Segment queue performs an address write through to instruction cache 90 and operand cache 92 when accessing memory storage unit 0 332 and memory storage unit 1 334. In addition, segment queue 382 stacks address requests for access of data from memory storage unit 0 332 or memory storage unit 1 334. Depending on whether and instruction or operand is being accessed, if the requested data is not available and instruction cache 90 or operand cache 92 the access to memory storage unit 0 32 and memory storage unit 1 34 will be completed. Instruction cache address decode 400 decodes the instruction cache set address and instruction cache word address corresponding to the EC configuration without interleave, the EC configuration with two-way interleave, the MC configuration without interleave, or the MC configuration with four-way interleave (see, FIGS. 11-14). Instruction cache 90 receives the instruction cache set address via path 402 and the instruction cache word address via path 404 and determines if the requested data is available. If operand cache 92 is accessed, operand cache address decode 406 decodes the operand cache set address and operand cache word address corresponding to either the EC configuration without interleave, the EC configuration with two-way interleave, the MC configuration without interleave, or the MC configuration with four-way interleave. Depending upon the configuration selected, operand cache 92 receives the operand cache set address via path 408 and the operand cache word address via path 410 and determines if the requested data is available. and determines if the data is available. If the data is not available within instruction cache 90 or operand cache 92, the requested data is retrieved from memory storage unit 0 32 or memory storage unit 1 34 via path 112.
FIG. 17 is a block diagram showing the instruction cache address decode. The instruction cache address decode is shown generally at 412 and couples to instruction cache 90 via paths 402 and 404. Set address mux 414 has address bits A39 through A48 at 416, address bits A38 through A47 at 418, address bit A39 through A48 at 420, and has address bits A37 through A46 at 422. Address bit inputs 416, 418, 420 and 422 of said address mux 414 correspond respectively with instruction cache set address 288 in FIG. 11, instruction cache set address 300 in FIG. 12, instruction cache set address 312 in FIG. 13, and instruction cache set address 324 in FIG. 14. Word address mux 424 has address bits A49 through A50 at 426, address bits A48 through A49 at 428, address bits A49 through A50 at 430, and address bits A47 through A48 at 432. Address bits A51 through A53 are presented to instruction cache 90 directly via 433 without passing through word address mux 424. Address inputs 426, 428, 430 and 432 of word address mux 424 correspond respectively with instruction cache word address 290 of FIG. 11, instruction cache word address 302 of FIG. 12, instruction cache word address 314 of FIG. 13, and instruction cache word address 326 of FIG. 14. Instruction cache address decode also has scannable flip-flops 434 and 436 which couple to decode logic 438 through paths 440 and 442. Scannable flip-flops 434 and 436 have outputs 440 and 442 which correspond to configuration bit 336 and interleave bit 338 in FIG. 15. Thus, depending upon the configuration selected, scannable flip-flops 434 and 436 select through decode logic 438, either the EC configuration without interleave at 444, the EC configuration with two-way interleave at 446, the MC configuration without interleave at 448, and the MC configuration with four-way interleave at 450. Thus, depending upon the configuration selected via scannable flip-flops 434 and 436, set address mux 414 passes the corresponding 10-bit set address, and word address mux 424 passes the corresponding 5-bit word address (i.e. 2 multiplexed bits and 3 bits from 433), to instruction cache 90. Thus, if the EC mode without interleave is selected, set address mux 414 passes the address bits at 416 and word address mux 424 passes the address bits at 426, respectively, to instruction cache 90 via paths 402 and 404. If the EC mode with two-way interleave is selected, set address mux 414 passes address bit at 418 and word address mux 424 passes the address bits at 428 to instruction cache 90. If the MC mode without interleave is selected, set address mux 414 passes the address bits at 420 and the word address mux 424 passes the address bits at 430 to the instruction cache 90. If the MC configuration with four-way interleave is selected, set address mux 414 passes the address bits at 422 and the word address must 424 passes the address bits at 432 to the instruction cache 90.
FIG. 18 is a block diagram showing the operand cache address decode. The operand cache address decode is shown generally at 452 and is coupled to operand cache 92 through path 408 and path 410. Set address mux 454 has address bits A41 through A50 at 456 as inputs, address bits A40 through A49 at 458 as inputs, address bits A41 through A50 at 460 as inputs, and address bits A39 through A48 at 462 as inputs. The address inputs at 456, 458, 460 and 462 of set address mux 454 correspond with the operand cache set address 292 in FIG. 11, the operand cache set address 304 in FIG. 12, the operand cache set address 316 in FIG. 13, and the operand cache set address 328 in FIG. 14, respectively. The set address mux 454 selects one of the inputs of 456, 458, 460 or 462 and couples the selected input to the operand cache 92 via path 408. Word address bits A51 through A53 are coupled to operand cache 92 via path 410. Scannable flip-flops perform the configuration selection. Configuration flip-flop 474 and interleave flip-flop 476 via paths 480 and 482, respectively, couple to decode logic 478 to perform the configuration selection. Output 480 of configuration flip-flop 474 corresponds to configuration bit 336 of FIG. 15, and output 482 of interleave flip-flop 476 corresponds to interleave bit 338 of FIG. 15. Decode logic 478 depending upon the inputs at 480 and 482, select either the EC mode without interleave at 484, the EC mode with two-way interleave at 486, the MC mode without interleave at 488, or the MC mode with four-way interleave at 490. If the EC mode without interleave is selected at 484, set address mux 454 passes the address bits at 456 to operand cache 92 via path 408, and word address mux 406 passes the address bits at 466 to operand cache 92 via path 410. The address bits at 408 and 410 are a 10-bit set address and 3-bit word address, respectively. If the EC mode with two-way interleave is selected, set address mux 454 passes the address bits at 458 to operand cache 92. If the MC mode without interleave is selected, set address mux 454 passes the address bits at 460 to operand cache 92. If the MC mode with four-way interleave is selected, set address mux 454 passes the address bits at 462 to operand cache 92.
FIG. 19 is a flow diagram showing an exemplary method of the present invention. The diagram is generally shown at 492. The flow diagram is entered at element 494, wherein control is passed to element 496 via interface 498. Element 496 provides a plurality of segment multiplexers. Control is then passed to element 500 via interface 502. Element 500 provides a plurality of word multiplexers. Control is then passed to element 504 via interface 506. Element 504 provides a plurality of segment queues, wherein each particular one of said plurality of segment queues is coupled to a particular one of said plurality of segment multiplexers and a particular one of said plurality of word multiplexers. Control is then passed to element 508 via interface 510. Element 508 receives a plurality of scan bits to select a particular one of a plurality of positions of a one or more contiguous segment select bits. Control is then passed to element 512 via interface 514. Element 512 receives said plurality of scan bits to select a particular one of the plurality of positions of a plurality of word address. Control is then passed to element 516 via interface 518. Element 516 decodes a particular one of a plurality of segment select addresses, and enables a corresponding one of the plurality of word multiplexers when a correct said particular one of the plurality of segment select addresses is received, said one or more contiguous segment select bits comprising said segment select address. Control is then passed to element 520 via interface 522. If the condition of a particular one of the plurality of requestors contending for access to the shared memory accessing an operand cache is not satisfied, control is passed to element 524 via interface 526. Element 524 receives said plurality of scan bits to select a particular one of a plurality of instruction cache set address bits and a particular one of a plurality of instruction cache word address bits. Control is then passed to element 528 via interface 530. Element 528 provides said particular one of said plurality of instruction cache set address bits and said particular one of said plurality of instruction cache word address bits to a particular one of a plurality of instruction cache memories to access, an instruction cache storage location within said particular one of said plurality of instruction cache memories. Control is then passed to element 532 via interface 534. Element 532 provides said decoded one or more contiguous segment select bits and said plurality of word address bits to the shared memory if said instruction cache storage location or said operand cache storage location does not contain requested data. Control is then passed to element 536 via interface 538 where the algorithm is exited.
If the condition at element 520 of a particular one of the plurality requestors contending for access to the shared memory accessing an operand cache is satisfied, control is passed to element 540 via interface 542. Element 540 receives said plurality of scanned bits to select a particular one of a plurality of operand cache set address bits and a particular one of a plurality of operand cache word address bits. Control is then passed to element 544 via interface 546. Element 544 provides said particular one of said plurality of operand cache set address bits and said particular one of said plurality of operand cache word address bits to a particular one of a plurality of operand cache memories to access an operand cache storage location within said particular one of said plurality of operand cache memories. Control is then passed to element 532 via interface 548. Element 532 provides said decoded one or more of contiguous segment select bits and said plurality of word address bits to the shared memory if said instruction cache storage location or said operand cache storage location does not contain requested data. Control is then passed to element 536 via interface 538 where the algorithm is exited.
Having thus described the preferred embodiments of the present invention, those of skill in the art will readily appreciate that the teachings found herein may be applied to yet other embodiments within the scope of the claims hereto attached.
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Method and apparatus for maximizing cache memory throughput in a system where a plurality of requesters may contend for access to a same memory simultaneously. The memory utilizes an interleaved addressing scheme wherein each memory segment is associated with a separate queuing structure and the memory is mapped noncontiguously within the same segment so that all segments are accessed equally. Throughput is maximized as the plurality of requesters are queued evenly throughout the system.
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FIELD OF THE INVENTION
[0001] The present invention relates to recognizing sprites in animated sequences.
BACKGROUND
[0002] Animation involves the production of consecutive images, which when displayed, convey a perception of motion. The most common form of two-dimensional animation is sprite animation. A sprite is a bitmap image or a set of images that are composited over a background, producing the illusion of motion. Sprite animation is relatively fast and easy with modern computers. Also, sprites are typically selected from a library of suitable images. Consequently, if in an animation sequence the sprite can be identified, the sprite can be searched for within the library and the results used in further inferring the animation sequence, its context and other details.
[0003] Sprites for encoding video data is the focus of U.S. Pat. No. 5,943,445 issued Aug. 24, 1999 and assigned to Digital Equipment Corporation and entitled “Dynamic Sprites for Encoding Video Data”. U.S. Pat. No. 5,943,445 describes segmenting frames into rigid and non-rigid bodies, and identifying these bodies as sprites. Some suitable techniques for such encoding are presented in U.S. Pat. No. 4,853,775 issued Aug. 1, 1989 and assigned to Thomson-CSF and entitled “Method and Device to Estimate Motion in a Sequence of Moving Pictures”. Both these United States patents relate to estimating local motion vectors by performing gradient operations.
[0004] Sprite-based encoding is described in the U.S. Pat. No. 6,205,260 issued Mar. 20, 2001 and assigned to Sharp Laboratories of America, Inc and entitled “Sprite-based Video Coding System with Automatic Segmentation Integrated into Coding and Sprite-building Process”. This reference describes analysing MPEG video and disassociating the foreground from the background, with no restrictions on the moving objects etc. Complex mathematical transformations, such as affine transformations, perspective transformations, warping operations etc, are extensively used to separate a sprite from its background.
[0005] The above-described two references describe techniques that are relatively complicated, and involve complex mathematical operations.
[0006] In view of the above observations, a need clearly exists for techniques that are able to identify sprites against a background.
SUMMARY
[0007] Certain 2D animation sequences, especially cartoon animations, have a constant background image, while sprites (for example, actors or objects of the animation) are moving in the foreground to create the animation effect. Once created, the animation is streamed as a sequence of images with the background and the sprites seamlessly integrated.
[0008] Described herein are techniques for identifying sprites when a sequence of animation images is provided. Techniques of this sort can be usefully provided for compressing animation sequences for storage and transmission. Animation sequences can be stored in a format in which the background and the sprites are separately identified.
[0009] Other applications exist in the fields of surveillance, image understanding, sprite-based video search and sprite-based video conferencing. The relative simplicity of the geometric operations used in the described technique allows further refinements to be added by those skilled in the art.
[0010] The described techniques use relatively simple geometric operations and binary bit manipulation operations to identify sprites in animation sequences.
[0011] The described techniques involve three separate but related procedures, namely (i) identification of the sprite, (ii) identification of the background and (iii) identification of the identified sprite's translation path. By analysing a sequence of given images (also referred to as frames), sprite definition is first established. Then, using the definition of the sprite, a determination is made of the background image and translation path taken.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a flowchart of separate processing stages involved in the techniques described herein.
[0013] FIG. 2 comprises six individual images (labelled F 1 to F 6 ) that constitute frames of an example animation sequence, from which the frames of FIGS. 3 to 21 are each derived.
[0014] FIG. 3 comprises three frames (labelled A, B and C) that in combination illustrate horizontal and vertical “flip” operations performed on a source frame.
[0015] FIG. 4 comprises three frames (labelled F 1 , F 2 and X) that in combination illustrate an “XOR” operation performed on two source frames.
[0016] FIG. 5 comprises three frames (labelled F 1 , F 2 and X) that in combination illustrate an “XNOR” operation performed on two source frames.
[0017] FIG. 6 is a representation that illustrates a “bounds” operation performed on a source frame.
[0018] FIG. 7 comprises two images (labelled X and M) that in combination illustrate a “mask” operation performed on a source frame.
[0019] FIG. 8 comprises two images (labelled X and M) that in combination illustrate an “inverse mask” operation performed on a source frame.
[0020] FIG. 9 comprises three frames (labelled A, B and X) that in combination illustrate an “addition” operation performed on two source frames.
[0021] FIG. 10 comprises three images (labelled F 1 , F 2 , F 3 ) from the sequence of FIG. 1 , which are used in FIGS. 10 to 10 to illustrate a “FlipUnit” operation.
[0022] FIG. 11 is a frame that represents the result of an “XOR” operation on frames F 1 and F 2 Of FIG. 10 .
[0023] FIG. 12 is an image that represents the result of a “bounds” operation on the image of FIG. 11 .
[0024] FIG. 13 comprises three images that each represent the respective results of “bounds” operations performed on combinations of “XOR” operations involving the three frames of FIG. 10 .
[0025] FIG. 14 comprises two images (labelled F 2 and F 2M ) that represent the source (F 2 ) and result (F 2M ) of a “mask” operation.
[0026] FIG. 15 comprises two images (labelled F 2M and T 1 ) that represent the source (F 2M ) and result (T 1 ) of a horizontal “flip” operation.
[0027] FIG. 16 comprises two images (labelled T 1 and T 2 ) that represent the source (T 1 ) and result (T 2 ) of a vertical “flip” operation.
[0028] FIG. 17 comprises two images (labelled T 2 and T 2M ) that represent the source (T 2 ) and result (T 2M ) of a “mask” operation.
[0029] FIG. 18 comprises two images (labelled T 2M and T 3 ) that represent the source (T 2M ) and result (T 3 ) of a horizontal “flip” operation.
[0030] FIG. 19 comprises two images (labelled T 3 and T 4 ) that represent the source (T 3 ) and result (T 4 ) of a vertical “flip” operation.
[0031] FIG. 20 comprises two images (labelled T 4 and T 4M ) that represent the source (T 4 ) and result (T 4M ) of a “mask” operation.
[0032] FIG. 21 comprises three images (labelled T 4M , F 1 , F Result ) which illustrate the result of an “XNOR” operation involving two source images.
[0033] FIG. 22 is a representation of a co-ordinate system used to orient an identified sprite.
[0034] FIG. 23 is a flowchart of a “FlipUnit” operation described with reference to FIGS. 10 to 21 .
[0035] FIG. 24 is a flowchart of an algorithm for identifying a sprite in an animated sequence such as represented in FIG. 2 , as per step 110 in FIG. 1 .
[0036] FIG. 25 is a flowchart of an algorithm for identifying a translation path in an animated sequence such as represented in FIG. 2 , as per step 120 in FIG. 1 .
[0037] FIG. 26 is a flowchart of an algorithm for identifying a backgound in an animated sequence such as represented in FIG. 2 , as per step 130 in FIG. 1 .
[0038] FIG. 27 is a schematic representation of a computer system suitable for performing the techniques described with reference to FIGS. 1 to 26 .
DETAILED DESCRIPTION
[0039] There are three distinct stages involved in the described techniques, namely: (i) sprite identification, (ii) translation path identification and (iii) background identification. Each of these stages is described in turn following description of particular operations involved in these stages. FIG. 1 flowcharts these three respective steps 110 , 120 and 130 .
[0040] Techniques described herein algorithmically identify the sprite and get the sprite definition (that is, the sprite pixels) from this animation sequence. If this identification is possible, then the animation sequence of frames can be compressed into one background image, one sprite image and the translation route that the sprite takes. This can save a lot of storage space and transmission time. Compression of this sort can also assist in analysing image sequences.
[0000] Assumptions
[0041] Consider a sequence of images (that is, an animation sequence) that satisfies the following criteria listed below.
1. There is a single sprite in the animation. That is, only one object is moving in the animation sequence. 2. The background does not change throughout the animation. That is, all the images provided in the animation sequence will have the same background image. 3. The sprite only translates during the animation. The sprite does not change shape, size or orientation during the animation. That is, there is no rotation or scaling. 4. The sprite's boundary pixels are of a different colour than the background. The internal pixels of the sprite can have the same colours as that of the background. 5. At least three frames are given in the animation sequence.
Sample Animation
[0047] FIG. 2 represents a sample animation sequence having 6 frames, each labelled F 1 to F 6 using respective reference numberals 210 to 260 . Observe that the sprite is the boat and that the boat is only translating across the “frame”, from left to right. The background image does not change. The boundary pixels of the sprite are of a different color than the background, represented here in greyscale. Hence this animation sequence satisfies all the constraints listed above.
[0000] Flip Operation
[0048] There are two different kinds of flip operation used in the described techniques, namely Horizontal Flip (h-Flip) and the Vertical Flip (v-Flip) operations. These flipping operations are done on an image (or frame) with respect to a rectangle inside that frame. The h-Flip operation results in the exchange of pixel-columns inside the rectangle of the target image. The v-Flip operation results in the exchange of pixel-rows inside the rectangle of the target image.
[0049] FIG. 3 schematically represents frames A 310 , B 320 and C 330 that depict these flip operations. Consider frame A 310 represented in FIG. 3 . This is the source frame and a rectangle designated R 340 is shown inside frame A 310 . The frames B 320 and C 330 are a result of respectively performing h-Flip and v-Flip operations on A 310 with respect to rectangle R 340 .
[0050] These two flip operations are represented as B=h-Flip(A, R) and C=v-Flip(A, R).
[0000] XOR Operation
[0051] An XOR operation is a binary operation whose behaviour is indicated in the truth table of Table 1. This operation is represented herein as X=A/B. Note that A and B are two input frames and the resulting frame is referred to as X.
TABLE 1 Pixel(p, q) in A Pixel(p, q) in B Output Pixel(p, q) in X w w White w v Black
[0052] FIG. 4 schematically represents frames that illustrate the described XOR operation.
[0053] Consider frames F 1 210 and F 2 220 . If corresponding pixels in frames F 1 210 and F 2 220 are of the same colour, then the output frame, which is X(1,2) 430 , has a white pixel at the corresponding pixel location. Otherwise, the output frame X(1,2) 430 has a black pixel at that location. Observe that only differences between the two input frames are retained in the output frame.
[0000] XNOR Operation
[0054] An XNOR operation is a binary operation whose behaviour is indicated by the truth table at Table 2. This operation is represented herein as X=AΦB. Note that A and B are two input frames and the resulting frame is referred to as X.
TABLE 2 Pixel(p, q) in A Pixel(p, q) in B Output Pixel(p, q) in X w w W w v White
[0055] Consider two frames F 1 210 and F 2 220 represented in FIG. 5 . If the corresponding pixels in frames F 1 210 and F 2 220 are of the same colour, then the output frame, which is X(1,2) 530 has a pixel of the same colour in the corresponding pixel location. Otherwise, the output frame X(1,2) 530 has a white pixel in that location. Observe that only differences between the two input frames are removed in the output frame, and similar pixels are retained.
[0000] Bounds Operation
[0056] FIG. 6 schematically represents a frame X 610 in which dashed rectangle R 620 is the bounding rectangle of the objects depicted in frame X 610 .
[0057] Bounding rectangle R 620 for a frame X 610 is obtained using the following sequence of steps.
1. Scan from the top of X 610 , each row of pixels, until a row with at least one non-white pixel is obtained. Name that row as ‘top’. 2. Scan from the bottom of X 610 , each row of pixels, until a row with at least one non-white pixel is obtained. Name that row as bottom. 3. Scan from the left of X 610 , each column of pixels, until a column with at least one non-white pixel is obtained. Name that column as left. 4. Scan from the right of X 610 , each column of pixels, until a column with at least one non-white pixel is obtained. Name that column as right.
[0062] The rectangle defined by the points (left, top) and (right, bottom) is called as the bounding rectangle R 620 . Several enhancements can be made to the above-listed steps to reduce iterations, that's not the focus of this work. This bounding operation is represented herein as R=Bounds(X).
[0000] Mask Operation
[0063] FIG. 7 schematically represents frames X 710 , in which a bounding rectangle R 720 is specified. Frame M 730 is the result of the mask operation, in which M=Mask(X, R).
[0064] In a mask operation, an operand frame X 710 is assumed and a mask rectangle is referred to as rectangle R 720 . The output of the operation is a new frame that retains the colors of the pixels inside the mask rectangle, but the pixels outside the mask rectangle are rendered as white. A psuedocode representation of this mask operation is presented in Table 3.
TABLE 3 colour of pixel (p,q) in output frame = colour of pixel (p,q) in input frame if (p,q) is inside R else colour of pixel (p,q) in output frame = white
Inverse Mask Operation
[0065] FIG. 8 schematically represents frames X 810 and bounding rectangle R 820 involved in an inverse mask operation. Frame M is the result of the inverse mask operation, in which M=InverseMask(X, R).
[0066] In this operation, an operand a frame X 810 is assumed and a mask rectangle is referred to as rectangle R 820 . The output of the operation is a new frame that retains the colors of the pixels outside the mask rectangle, but the pixels inside the mask rectangle are rendered as white. A psuedocode representation of this inverse mask operation is presented in Table 4.
TABLE 4 colour of pixel (p,q) in output frame = white if (p,q) is inside R else colour of pixel (p,q) in output frame = colour of pixel (p,q) in input frame
Addition Operation
[0067] FIG. 9 schematically represents operand frames A 910 and B 920 , and output frame X 930 of an addition operation.
[0068] Given two frames A 910 and B 920 , an addition operation produces an output frame that white pixels in frame A 910 replaced by the colors of the corresponding pixels in frame B 920 . This addition operation is represented as X=A+B. A pseudocode representation of this addition operation is presented in Table 5.
TABLE 5 colour of pixel(p,q) in X = colour of pixel(p,q) in A if (p,q) is non-white else colour of pixel(p,q) in X = colour of pixel(p,q) in B.
Sprite Identification
[0069] To understand the process of sprite identification, a sequence of operations referred to as FlipUnit is first defined. FlipUnit is a sequence of operations performed on three different frames to extract maximum information about the sprite from these three given frames. Once FlipUnit operations are understood, FlipUnit can be treated as a single operation, and is used to identify the sprite from the sequence of frames supplied.
[0000] FlipUnit Operation
[0070] A sequence of operations, referred to herein as a FlipUnit operation, is performed on three frames. An animation sequence consists of n frames. This FlipUnit operation applies to any three different frames taken from the sequence of n frames.
[0071] FIG. 10 schematically represents three different frames F 1 210 , F 2 220 , and F 3 230 . The sprite is in different positions in the three respective frames. Once the FlipUnit is understood, the technique used to extract the complete sprite definition from the given n frames can be described in further detail.
[0072] FIG. 23 flowcharts steps performed for the FlipUnit operation, each of which is described below with reference to correspondingly numbered steps.
Step 2305 XOR the first two frames, F 1 210 and F 2 220 , to obtain a third frame called X(1,2) 1340 . That is, perform the operation X(1,2)=F 1 /F 2 . FIG. 11 schematically represents the result of this XOR operation, X(1,2) 1340 . Step 2310 Once X(1,2) 1340 is obtained, get the bounding rectangle R(1,2) 1370 for X(1,2) 1340 . That is, perform the operation R(1,2)=Bounds(X(1,2)). FIG. 12 schematically represents the bounding rectangle R(1,2) 1370 .
[0075] Step 2305 & 2310 Similar to the way in which X(1,2) 1340 and R(1,2) 1370 is obtained as explained in the above steps 1 and 2, obtain the following operations indicated in Table 6 below. FIG. 13 schematically represents the results of these three different XOR and bounding operations.
TABLE 6 X(2, 3) = F 2 /F 3 X(1, 3) = F 1 /F 3 R(2, 3) = Bounds(X(2, 3)) R(1, 3) = Bounds(X(1, 3))
Step 2315 Mask frame F 2 220 with respect to R(2,3) 1380 . That is, let F 2M =Mask(F 2 , R(2,3)). FIG. 14 schematically represents the source frame F 2 220 and target frame F 2M 1430 . Step 2320 Flip horizontally F 2M 1430 with respect to the rectangle R(2,3) 1380 . The resulting frame is referred to as T 1 1540 . That is, perform the operation T 1 =h-Flip(F 2M , R(2,3)). FIG. 15 schematically represents source frame F 2M and target frame T 1 1540 . Step 2325 Flip vertically T 1 1540 with respect to the rectangle R(2,3) 1380 . The resulting frame is referred to as T 2 1650 . That is, perform the operation T 2 =v-Flip(T 1 , R(2,3)). FIG. 16 schematically represents source frame T 1 and target T 2 1650 . Step 2330 Mask T 2 1650 with respect to R(1,3) 1390 . That is, let T 2M =Mask(T 2 , R(1,3)). FIG. 17 schematically represents the source frame T 2 1650 and target frame T 2M 1760 . Step 2335 Flip horizontally T 2M 1760 with respect to the rectangle R(1,3) 1390 . The resulting frame is referred to as T 3 1870 . That is, perform the operation T 3 =h-Flip(T 2M , R(1,3)). FIG. 18 schematically represents source frame T 2M 1760 and target frame T 3 1870 . Step 2340 Flip vertically T 3 1870 with respect to the rectangle R(1,3) 1390 . The resulting frame is referred to as T 4 1980 . That is, perform the operation T 4 =v-Flip(T 3 , R(1,3)). FIG. 19 schematically represents source frame T 3 1870 and target frame T 4 1980 . Step 2345 Mask frame T 4 1980 with respect to rectangle R(1,2) 1370 . That is, T 4M =Mask(T 4 , R(1,2)). FIG. 20 schematically represents source frame T 4 1980 and target frame T 4M 2090 . Step 2310 XNOR frame F 1 210 with T 4M 2090 . The output frame F Result 2130 is the result of the FlipUnit. That is, F Result =F 1 ΦT 4M . FIG. 21 schematically represents source frame F 1 210 and T 4M 2090 , and target frame F Result 2130 .
[0084] The above-described steps of the FlipUnit operation return F Result 2130 as the resulting frame of the operations performed. The FlipUnit operation takes any three frames (for example, F 1 210 , F 2 220 and F 3 230 ) as input and provides an output frame that translates the sprite in a second frame to the sprite position in a first frame using a third frame. The output frame has the sprite in the position of the sprite in the first frame. Pseudocode for FlipUnit using the operations described herein is presented in Table 7.
[0085] The FlipUnit operation is used to extract a maximum definition of the sprite using three operand frames from an animation sequence, as described directly below.
TABLE 7 /* FlipUnit procedure */ procedure FlipUnit(F 1 , F 2 , F 3 ) X(1,2)=F 1 /F 2 ; X(1,3)=F 1 /F 3 ; X(2,3)=F 2 /F 3 ; R(1,2)=Bounds(X(1,2)); R(2,3)=Bounds(X(2,3)); R(1,3)=Bounds(X(1,3)); F 2M =Mask(F 2 , R(2,3)); T 1 =h−Flip(F 2M , R(2,3)); T 2 =v−Flip(T 1 , R(2,3)); T 2M =Mask(T 2 , R(1,3)); T 3 =h−Flip(T 2M , R(1,3)); T 4 =v−Flip(T 3 , R(1,3)); T 4M =Mask(T 4 , R(1,2)); F Resu1t =F 1 ΦT 4M ; Return F Result end procedure
Algorithm for Sprite Identification
[0086] A call to the FlipUnit operation is made in the following manner: F Result =FlipUnit(F i , F j , F k ). The FlipUnit operation translates the sprite in F j to the position of the sprite in F i using F k . The F Result has the intermediary definition of the sprite in position of F i .
[0087] Consider n frames in an animation sequence. A minimum of three frames are used that is (n≧3) in this technique.
[0088] Consider the pseudocode presented in Table 8.
TABLE 8 Sprite=FlipUnit(F 1 , F n , F 2 ); for i=2 to n−1 do Result=FlipUnit(F 1 , F i , F i +1); Sprite=Sprite Φ Result; end for
[0089] At the end of the execution of the for loop presented in Table 8, a definition of the sprite from the given n frames is available in the frame referred to as “Sprite”. The described techniques attempt to determine algorithmically from the frames of the animation sequence, a sprite definition that essentially agrees with what is quite clearly perceived to be the sprite, when viewing the animation.
[0090] In the first instruction given above, the sprite in frame F n is translated to the position of sprite in frame F 1 using F 2 as the intermediary frame. The output serves as the starting point for the sprite definition.
[0091] In each iteration of the loop, the sprite in frame F i is translated to the sprite position in F 1 using F i+1 as the intermediary frame. This procedure is for frames F 2 to F n−1 . In each iteration, the result from the FlipUnit operation is accumulated in the “Sprite” frame by XNOR-ing the output with the latest definition of the “Sprite” frame. That is, the FlipUnit operation updates the “Sprite” frame using the XNOR operation. This procedural loop completes the sprite identification process. By the end of this algorithm, one obtains a definition of the sprite and also the sprite's position in the frame F 1 .
[0000] Translation Path Identification
[0092] Assume that the translation path is to be stored in a path vector P, in which the positions of the sprite in frames F 1 to F n is stored in variables P 1 to P n . Further, assume that each P i is a rectangle indicating the position of the sprite in the frame. From the above-described process of sprite identification, P 1 is known. A determination action can thus be made of the other values of P by using the following algorithm. FIG. 22 schematically represents this co-ordinate system. P i (left) gives the x coordinate of the top left point 2210 , and P i (bottom) gives the Y coordinate of the bottom right point.
[0093] In this coordinate system, the origin is the top left corner of the screen and the right direction is positive for x-axis, and the down direction is positive for y-axis.
[0094] Table 9 presents pseudocode for determining path vector P.
TABLE 9 P1=Bounds(Sprite); for i=2 to n do pi=findNext(P1, F1, Fi); end for
[0095] The findNext procedure used in the algorithm of Table 9 is defined in the psuedocode presented in Table 10.
TABLE 10 procedure findNext(P, A, B) T=A/B; Temp=Bounds(T); R(left)=P(left)+(Temp(left)−P(left)); R(right)=P(right)+(Temp(right)−P(right)); R(top)=P(top)+(Temp(top)−P(top)); R(bottom)=P(bottom)+(Temp(bottom)−P(bottom)); return R; end procedure
[0096] The position of the sprite in F 1 is first determined. The bounding rectangle for the XOR-ed output of F 1 and the frame F i of the current iteration is then obtained. Then, using this bounding rectangle, and the position of sprite in F 1 , a determination is made of the position rectangle for the sprite in F i using calculations presented in Table 10. After execution of this pseudocode, the translation path of the sprite is established. The last item to be established is the definition of the background, which is described directly below.
[0000] Background Identification
[0097] With the definition of the sprite and the positions of the sprite in the different frames already established, the background is determined using pseudocode presented in Table 11.
TABLE 11 Background=InverseMask(F1, P1); for i=2 to n do temp=InverseMask(Fi, Pi); Background=Background+temp; end for
[0098] After the execution of the loop, the “Background” frame contains the maximum background information that is necessary to correctly reproduce the animation.
[0099] After these above-described three steps of (i) sprite identification, (ii) translation path identification and (iii) background identification, the described procedure is completed. The entire animation is represented by a single background image, a single sprite image and a path vector.
[0100] This canonical representation can be used to suitably compress the animation sequence. The identified sprite can be searched in a database of images and matched with appropriate entries.
[0000] Computer Hardware and Software
[0101] FIG. 27 is a schematic representation of a computer system 2700 that can be used to perform steps in a process that implement the techniques described herein. The computer system 2700 is provided for executing computer software that is programmed to assist in performing the described techniques. This computer software executes under a suitable operating system installed on the computer system 2700 .
[0102] The computer software involves a set of programmed logic instructions that are able to be interpreted by the computer system 2700 for instructing the computer system 2700 to perform predetermined functions specified by those instructions. The computer software can be an expression recorded in any language, code or notation, comprising a set of instructions intended to cause a compatible information processing system to perform particular functions, either directly or after conversion to another language, code or notation.
[0103] The computer software is programmed by a computer program comprising statements in an appropriate computer language. The computer program is processed using a compiler into computer software that has a binary format suitable for execution by the operating system. The computer software is programmed in a manner that involves various software components, or code means, that perform particular steps in the process of the described techniques.
[0104] The components of the computer system 2700 include: a computer 2720 , input devices 2710 , 2715 and video display 2790 . The computer 2720 includes: processor 2740 , memory module 2750 , input/output (I/O) interfaces 2760 , 2765 , video interface 2745 , and storage device 2755 .
[0105] The processor 2740 is a central processing unit (CPU) that executes the operating system and the computer software executing under the operating system. The memory module 2750 includes random access memory (RAM) and read-only memory (ROM), and is used under direction of the processor 2740 .
[0106] The video interface 2745 is connected to video display 2790 and provides video signals for display on the video display 2790 . User input to operate the computer 2720 is provided from input devices 2710 , 2715 consisting of keyboard 2710 and mouse 2715 .
[0107] The storage device 2755 can include a disk drive or any other suitable non-volatile storage medium.
[0108] Each of the components of the computer 2720 is connected to a bus 2730 that includes data, address, and control buses, to allow these components to communicate with each other via the bus 2730 .
[0109] The computer system 2700 can be connected to one or more other similar computers via a input/output (I/O) interface 2765 using a communication channel 2785 to a network 2780 , represented as the Internet.
[0110] The computer software program may be provided as a computer program product, and recorded on a portable storage medium. In this case, the computer software program is accessed by the computer system 2700 from the storage device 2755 . Alternatively, the computer software can be accessed directly from the network 2780 by the computer 2720 . In either case, a user can interact with the computer system 2700 using the keyboard 2710 and mouse 2715 to operate the programmed computer software executing on the computer 2720 .
[0111] The computer system 2700 is described for illustrative purposes: other configurations or types of computer systems can be equally well used to implement the described techniques. The foregoing is only an example of a particular type of computer system suitable for implementing the described techniques.
CONCLUSION
[0112] A method, a computer system and computer software are described herein in the context of sprite recognition for translating sprites that do not scale or shear etc.
[0113] Techniques are described herein only with reference to the above-described constraints that the boundary pixels of the sprite are of a different colour from the background pixel at that location. The described techniques can, for example, be appropriately modified to handle relatively minor changes in the colours of the sprite and the background.
[0114] Various alterations and modifications can be made to the techniques and arrangements described herein, as would be apparent to one skilled in the relevant art.
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Sprite identification in animated sequences is achieved by performing three separate but related procedures, namely (i) identification of the sprite, (ii) identification of the background and (iii) identification of the identified sprite's translation path. By analysing a sequence of frames, sprite definition is first established. Then, using the definition of the sprite, a determination is made of the background image and translation path taken. This analysis allows the animated sequence to be compressed in a format in which the background and the sprites are separately identified.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an electrical circuit for the control of a plurality of electrical loads and of the functions thereof.
[0003] It is particularly suitable for upgrading existing electrical circuits in buildings such as, for instance, of ventilation fans and lighting systems which cannot easily be supplemented without extensive measures in terms of the structure and electrical installations.
[0004] 2. The Prior Art
[0005] A circuit for controlling an electrical load (for instance, the circuit of a chandelier with a plurality of electric current circuits) is known which by repeatedly actuating one switch allows a few functions to be performed, as by repeated on and off switching and evaluation of the number switching intervals or switching pulses by electronic circuitry.
[0006] Its disadvantage is that the electric load must be provided with such electronic circuitry and that switching five times or more for attaining one state or another is unacceptable.
[0007] Also known is a circuit in which different frequencies or pulse length modulations can be realized by modulating the mains voltage between active line and neutral line or by additional modulation when the phase is at zero. The drawback of such an arrangement is that active and neutral lines must always be present at the switch, which is not the case in simple existing on/off switches in alternating current circuits.
[0008] Furthermore, infrared remote switching circuits are known for the remote control of electrical loads.
[0009] Their disadvantage resides on the one hand in a relatively complex internal or external receiver installed at the apparatus or load and, on the other hand, in the need for a transmitter with a battery as a separate current supply.
[0010] Also, a cable-connected electrical circuit is known for the control of several functions of an electrical load and its functions within a low current net circuit with an active and a neutral line, having, for the control of an electrical load in the active line, a switching unit with several function keys series-connected with one or more electrical loads, with a further switching unit being present ahead of each electrical load.
[0011] Its disadvantage is that in order to energize the diodes for a modulation, active and neutral lines must either be present or they must be installed. This, in turn, requires, for instance during installation of such circuits and, more so, during upgrading existing mains circuits in living, business and function rooms significant time and effort for installing the neutral line. Moreover, such a circuit suffers from a relatively long reaction time. At a minimum signal-to-noise ratio this may result in safety problems and may lead to transmission failure from general net failures. In illumination equipment connected in this manner, for instance, large signal-to-noise ratios may result in flickering (EP 1 066 690 B1).
[0012] Moreover, a system for the zero point data transmission is known for power lines.
[0013] The disadvantage of such circuits is that they require uninterrupted active and neutral lines which cannot be provided in a number of special applications, as, for instance, where simple on/off circuits are present which depend on phase interruptions and which have no neutral line (EP 1,134,910 A2).
[0014] Also, a burst signal transmission system is known for providing electrical circuits.
[0015] Its disadvantage is that for rendering the circuit functional, the transmitters integrated in the circuit always require an EMK by way of an active and a neutral line or battery (EP 0 370 943 A2).
[0016] Furthermore, a cable-connected lamp control system is known in which signals are transmitted by changing the supply voltage.
[0017] Here, too, it is disadvantageous that the signal-modulating current circuit is connected to the active and neutral lines and that for this reason the system is unsuitable for circuits lacking a neutral line (WO 91/030093 A1).
[0018] Finally, a load control system with cable-connected signaling is known.
[0019] Its drawback is that to modulate signals in these systems, there must always be present an active and a neutral line which makes this system unsuitable for circuits without neutral line (GB 2 050 662 A).
OBJECT OF THE INVENTION
[0020] It is an object of the invention to provide a cable-connected circuit for the control of a plurality of different electrical loads and/or for the control of several different functions thereof in a single alternating current circuit.
[0021] In this connection, the operating unit for controlling the functions is to be integrated solely in the voltage-carrying line, with neither additional EMK by battery or transformer being required for the function of the operating unit nor the need for connecting a neutral line.
SUMMARY OF THE INVENTION
[0022] In the accomplishment of these and other objects the invention provides for an electrical circuit in which, for the control of at least one electrical load 28 , at least one modulation switching unit 21 with a plurality of function keys 12 , 13 , 14 , 15 , 16 , 17 is series-connected, by means of terminals A and B to one or more electrical loads 28 , 28 a, in an alternating current circuit having an active line 26 b and a neutral line 26 a, and a demodulation switching unit 22 is provided ahead of the electrical loads.
[0023] The modulating switching unit 21 with terminals A and B and at least two function keys 12 , 13 , 14 , 15 , 16 , 17 is structured such that
[0024] a) within it, between active line 26 b connected to terminal A and line 26 c connected to terminal B, there is provided a diode 3 the cathode of which is connected to line 26 b and the anode of which is connected to a modulating line 26 c, and
[0025] b) in parallel therewith, between line 26 b and modulating line 26 c there are provided a plurality of series-connected homo-poled fast diodes constituting diode group 1 and diode group 2 poled opposite to diode 3 , and
[0026] c) parallel therewith, between diode group 1 and the other diode group 2 as well as the modulating line 26 c, there is provided a field effect transistor 4 which is by a line 29 is connected to terminals C of double diodes of function keys 12 , 13 , 14 , 15 , 16 , 17 as well as to a code generator 8 at one of the contacts PIN 014 thereof such that the field effect transistor 4 is connected in parallel to diode group 2 , with the source being connected to the last cathode of diode group 2 , the drain being connected to the anode thereof and the gate being connected to the function keys 12 - 17 via the double diodes C, D thereof for decoupling, and
[0027] d) a modulation field effect transistor 5 is present between line 26 b and line 26 c and also connected, by a line 11 , to the code generator 8 at one of its code output contact PIN 011 such that the modulation field effect transistor 5 is connected parallel to the diode groups 1 and 2 with its source connected to the last cathode of diode group 2 , its gate connected to the data output of the code generator 8 at one of the code output terminals PIN 011 thereof, and
[0028] e) a rectifier diode being provided in line 26 b, its cathode being connected to a feed line 32 of the code generator 8 , and
[0029] f) a capacitor 7 is present between voltage feed line 32 of the code generator 8 and line 26 c, and
[0030] g) the voltage feed line 32 is connected to the code generator 8 at one of the positive supply voltage terminals PIN 010 thereof, and
[0031] h) line 26 c is connected to the function keys 12 , 13 , 14 , 15 , 16 , 17 and, by a line 31 , to the code generator 8 at the negative supply voltage contact PIN 09 thereof, and
[0032] i) that, for decoupling, the double diodes of the function keys 12 , 13 , 14 , 15 , 16 , 17 are connected, by their contacts D, via lines to the code generator 8 at at least two or more of the control input terminals PIN 06 , 07 , 08 , 09 , 016 , 017 , 018 thereof, and
[0033] j) that the voltage feed line 32 is connected to one of the terminals PIN 010 and another one of the code generator terminals PIN 014 of the code generator 8 by way of a pull up resistor 9 and line 29 , and
[0034] k) external oscillator connection terminals PIN 012 and PIN 013 of the code generator 8 are connected to each other by an external oscillator resistor 10 .
[0035] The demodulation switching unit 22 ahead of the electrical loads 28 , 28 a and provided with a power supply unit 23 for maintaining a minimum current for a stand-by function is connected to the neutral line 26 a and to the modulation line 26 c from terminal B of the modulation switching unit 21 .
[0036] Within the demodulation switching unit 22 an electronic decoder 24 functioning as a micro processor is connected downstream from the power supply unit 23 . The micro processor is also directly connected to the neutral line 26 a and, by way of a high-pass filter 25 and/or by a zero point recognition 30 to line 26 c from terminal B of modulation switching unit 21 .
[0037] At least one electronic or electromechanical power switch 27 , 27 a is arranged downstream from the decoder 24 , the power switch 27 , 27 a being directly connected in parallel to the neutral line 26 a and the modulation line 26 c.
[0038] The power switch or switches 27 , 27 a are connected to the electrical load or loads 28 , 28 a by means of terminals E, F and/or G, H.
[0039] Several modulation switching units 21 may also be interconnected in series.
[0040] The advantages of the invention are that, at relatively low complexity, various further loads and/or functions can be connected to a simple alternating current circuit provided with series-connected on/off switches or two-way switches to an electrical load. The technical complexity in terms of material and labor may thus be significantly minimized. The pole terminals A and B of the lines may be interchanged or exchanged without damaging the system of the electrical circuit. This facilitates installation. It is especially easy to install the circuit in accordance with the invention into existing electrical installations in buildings by leaving the entire simple net in a building unchanged and by only exchanging on/off switches or two-way switches for modulation switching units of the same size and to equip even ceiling vents and/or illumination systems with such a demodulation switching unit. This is of particular advantage, for instance, where a ceiling fan with integrated illumination is to replace an existing fixture since in this manner the illuminating means may be dimmed or switched at different levels of brightness and/or in different numbers and/or where ceiling fans may be simultaneously or separately switched on or off, or where they may be operated at different levels of power or rotational directions. It is also possible to integrate a plurality of switching units in accordance with the invention. To carry out a modulation of bursts on the half-waves of the amplitudes ensures significant immunity from general net malfunctions or other functional failures, such as, for instance, light flickering. The circuit in accordance with the invention is characterized by extremely short reaction times.
DESCRIPTION OF THE SEVERAL DRAWINGS
[0041] The novel features which are considered to be characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its structure, construction and lay-out, as well as manufacturing techniques, together with other objects and advantages thereof, will be best understood from the following description when read with reference to the drawings, in which:
[0042] FIG. 1 is a circuit diagram of the modulation switching unit 21 of the function key;
[0043] FIG. 2 is a circuit block diagram of the demodulation circuit unit integrated into the load; and
[0044] FIG. 3 is a schematically shown modulation curve with bursts for switching pulses.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] A ceiling-mounted air exhaust fan combined with lamps is to be connected with active and neutral line to the net by a simple electric system mounted under plaster. Initially, the inventive modulation switching unit 21 with function keys 12 - 17 is series-connected in the line between the ceiling fan as one electrical load 28 and the lamps 28 a and the net to replace the switch originally provided as an on/off switch. Appropriately associated function keys may be actuated to control several different functions, such as on/of and different revolutions of the ceiling exhaust fan and/or different levels of illumination of the lamp and/or the switching of different numbers of lamps. For this purpose the combination ceiling-mounted air exhaust fan and lamp is provided with a demodulation switching unit 22 and is connected to the existing two-lead net.
[0046] During operation of the circuit electrical power may be switched from 1 W at stand-by operation to several hundred Watts. In a series circuit currents from about 1 mA to several A may result. During a half-wave a low voltage drop is affected across the diode group 1 which feeds the code generator 8 and renders the field effect transistor 4 conductive which shunts the diode group 2 . The diode 6 and the capacitor 7 serve to decouple and buffering of energy. The diode 3 serves to let the opposite half-wave pass.
[0047] FIG. 3 graphically depicts the modulation of the alternating current during signal transmission.
[0048] One or more function keys 12 to 17 are actuated for transmitting a function control signal from the function key switch i.e. the modulation switch unit 21 to the loads 28 and 28 a. The associated double diode C thus lowers the gate voltage of the field effect transistor 4 by way of the resistor 9 which causes the field effect transistor 4 to open. At the same time the clock system of the code generator 8 (pin 014 ) begins to resonate, with the frequency of the base pulse being determined by the size of the external oscillator resistor 10 . The code generator 8 receives the information about which key or keys have been actuated from contact D of the double diode associated with the respective actuated function key or keys 12 to 17 . The generated code diagrams emitted from the output terminal 011 of the code generator 8 thus control the gate of the field effect transistor 5 which in synchronism with the code signal electrically shunts the diodes of diode group 1 and of diode group 2 . Following the control operation, the diodes of diode group 2 will be shunted by the field effect transistor 4 in order to keep the loss of power as small as possible. On the other hand, the diodes of diode group 2 are required if necessary to increase the degree of modulation or signal-to-noise ratio. Code diagrams appear at pin 011 of the code generator 8 which correspond to a given actuated function key 12 to 17 . The optimum chronological interaction between frequency of the main current circuit, the length of the code and the synchronous gap between the modulation bursts 20 is depicted in the upper half-wave in FIG. 3 . As a rule, the lower half-wave is not modulated and passes unaltered through the diode 3 .
[0049] To demodulate the modulated half-wave in the demodulation switching unit 22 , the code signal is split by the high pass filter 25 from the low-frequency alternating current and is fed to the decoder 24 which ignores incomplete and faulty modulation bursts 20 . To increase the functionality there will be a succession of several modulation bursts 20 . The decoder 24 will then evaluate several complete transmitted modulation bursts 20 and examine them for uniformity. The electrical power switches 27 , 27 a will switch and/or dim individual loads 28 , 28 a with dimming resulting from the zero-crossing recognition 30 .
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An electrical circuit for controlling at least one electrical load and at least one function thereof by providing, in the active line of an AC circuit, a modulation switching circuit and a plurality of function keys series-connected with at least with the at least one electrical load and a demodulation unit upstream thereof.
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FIELD OF THE INVENTION
The invention relates to bodies structured as one or more helically wound runners around which one or more conductive wires may be wound, electrical devices and/or systems configured to include such bodies, and agricultural applications thereof.
BACKGROUND OF THE INVENTION
It is known that spirally wound electrical conductors exhibit certain electromagnetic properties and/or can be used, e.g., to generate particular electromagnetic fields. For example, it is known that an electromagnetic coil may act as an inductor and/or part of a transformer, and has many established useful applications in electrical circuits. Applications of an electromagnetic coil may exploit the electromagnetic field that is created when, e.g., an active current source is operatively coupled to the coil.
SUMMARY
One aspect of the invention relates to an electrical system for promoting growth of life stock, fish, and/or other animals. The system includes one or more bodies, one or more runners, one or more conductive wires, one or more current sources, and/or other components. Individual bodies may include one or more runners arranged in a helical shape having at least two complete revolutions per runner. Individual bodies may have a periphery. Individual bodies may be installed around and/or near one or more animals. Individual wires may be carried by individual runners. Individual wires may be conductive. Individual current sources may be arranged to electrically couple with one or more wires causing one or more currents through one or more wires. The one or more current sources may be configured to cause currents through wires such that one or more electromagnetic effects, e.g. electromagnetic fields, are created in and/or around individual bodies. The one or more electromagnetic effects may promote growth of the one or more animals disposed within and/or near the one or more bodies.
One aspect of the invention relates to a method for promoting growth of life stock, fish, and/or other animals. The method may include installing one or more bodies around and/or near one or more animals and supplying one or more currents to the one or more bodies such that one or more electromagnetic effects, e.g. electromagnetic fields, are created within and/or near the body. The one or more electromagnetic effects may promote of growth of the one or more animals within and/or near the one or more bodies. Individual bodies may include one or more runners, one or more wires, and/or other components. Individual runners may be arranged in at least two complete revolutions per runner. Individual wires may be carried by individual runners. Individual wires may be conductive. The one or more current sources may be configured to supply currents through individual wires such that one or more electromagnetic effects, e.g. electromagnetic fields, are created in and/or around one or more bodies.
These and other objects, features, and characteristics of the present disclosure, as well as the methods of operation and functions of the related components of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the any limits. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a system for promoting growth of an animal, according to one or more implementations.
FIG. 2 illustrates a method for promoting growth of an animal, according to one or more implementations.
FIG. 3 illustrates a system for promoting growth of one or more animals, according to one or more implementations.
FIG. 4 illustrates a system for promoting growth of one or more animals, according to one or more implementations.
DETAILED DESCRIPTION
FIG. 1 illustrates a system 10 for promoting growth of an animal 14 , according to one or more implementations. System 10 includes a body 85 , a first wire 86 , a current source 11 , and/or other components. The depiction of animal 14 as a single entity is not meant to be limiting. Animal 14 may include one or more animals and/or other organisms. As used herein, the term “animal” may refer to any organism of the kingdom Animalia except humans. In some implementations, system 10 may be configured to promote growth in livestock, fish, and/or other animals. In some implementations, system 10 may be configured to promote growth of animals that are raised, bred, grown, or produced in captivity and/or under human control. In some implementations, system 10 may be configured to promote growth of animals for a commercial purpose, including but not limited to the purpose of human consumption. In some implementations, the term animal may include genetically modified and/or synthetic organisms. In some implementations, an animal may include, by way of non-limiting example, a chicken, a cow, a pig, a lamb, a goat, a bird, a fish, a crustacean, a mollusk, a reptile, and/or other animals.
By way of non-limiting example, additional structures and/or features of body 85 , runners 88 and 89 , current source 11 , and/or processing component described herein, may be described in U.S. Pat. No. 8,653,925, entitled “Double Helix Conductor,” which issued Feb. 18, 2014, which is hereby incorporated into this disclosure by reference in its entirety. This patent may also be referred to as “the '925 patent” herein.
By way of non-limiting example, additional structures and/or features of body 85 , runners 88 and 89 , current source 11 , and/or processing component described herein, may be described in U.S. Pat. No. 8,919,035, entitled “Agricultural Applications of a Double Helix Conductor,” which issued Dec. 30, 2014, which is hereby incorporated into this disclosure by reference in its entirety. This patent may also be referred to as “the '035 patent” herein.
By way of non-limiting example, additional structures and/or features of body 85 , runners 88 and 89 , current source 11 , and/or processing component described herein, may be described in U.S. patent application Ser. No. 14/194,412, entitled “HEALTH APPLICATIONS FOR USING BIO-FEEDBACK TO CONTROL AN ELECTRO-MAGNETIC FIELD,” which was filed Feb. 28, 2014, which is hereby incorporated into this disclosure by reference in its entirety. This patent may also be referred to as “the '412 application” herein.
Body 85 of system 10 in FIG. 1 may include one or more helically wound runners. As depicted in FIG. 1 by way of non-limiting example, body 85 may include two intertwined helically wound runners—runner 88 and runner 89 —sharing the same (circular) axis. Runner 88 and runner 89 may be arranged in the shape of a double helix. Individual runners may be coupled by struts 90 to other runners. Individual ones of the runners may have one or more conductive wires spirally wound therearound. Runner 88 and runner 89 of body 85 may form cores around which wire 86 and wire 87 are spirally wound, respectively. As depicted in FIG. 1 , body 85 includes two wires: wire 86 and wire 87 . In some implementations, system 10 includes one runner, three runners, and/or another number of runners. In some implementations, system 10 includes one wire, three wires, and/or another number of wires. In some implementations, system 10 includes one current source, three current sources, and/or another number of current sources.
Wire 86 , as any wire listed in any figure included in this description, may be insulated, uninsulated, or partially insulated and partially uninsulated. As used herein, any “wire” may include a set of twisted wires (which may interchangeably be referred to as a “twisted wire” or a “pair of twisted wires”), including but not limited to a set of two twisted wires. The number of turns of a set of twisted wires per inch and/or per helical revolution of a runner may be characteristic measurements/features of the system. In some implementations, the number of twists per inch of a twisted wire may be about 2, about 5, about 10, about 20, about 100, about 150, about 200, about 250, and/or another suitable number of twists. In some implementations, the number of twists per inch of a twisted wire may be 144 twists.
System 10 may include one or more current sources. As depicted in FIG. 1 , system 10 may include two current sources, current source 11 and current source 12 . Individual ones of the current sources may be configured to induce one or more currents through one or more wires and/or across electrical leads, including but not limited to the electrical leads of the one or more wires wound around the one or more runners of body 85 . In some implementations, the one or more currents may include one or more alternating currents. In some implementations, one or more induced currents may correspond to one or more sensor-generated output signals. In some implementations, the one or more induced currents may correspond to one or more signals generated by a transducer, a signal generator, an (audio) amplifier, and/or other components, including but not limited to the components described in the '925 patent, the '035 patent, and/or the '412 application. In some implementations, the one or more current sources 12 may be configured to induce two independent currents to the two (twisted) wires that are spirally wound around the first runner and the second runner, respectively.
Runner 88 and runner 89 of body 85 and system 10 in FIG. 1 may be arranged in the shape of a three-dimensional curve similar to or substantially the same as a (double) helix, bend with its ends arranged together (e.g., in a toroidal shape). It is noted that the shape of body 85 resembles the general shape of DNA. The shape of the cross-section of a runner may include one or more of a circle, an oval, a square, a triangle, a rectangle, an angular shape, a polygon, and/or other shapes. The width and height of the cross-section of a runner may be limited for practical purposes. For example, for the purposes described herein, in some implementations, it may be preferred arrange body 85 such that there is available space within the periphery of body 85 , as shown, e.g., in FIG. 1 . As depicted in FIG. 1 , the shape of the cross-section of runner 88 and runner 89 is a circle. Note that implementations of this disclosure are not intended to be limited by any of the given examples.
In some implementations, individual wires may be arranged around individual runners such that the individual wire is arranged at a fixed and/or constant distance from the individual runner and/or the surface of the individual runner, at least for one or more individual ones of the revolutions of the helical shape of the individual runner. In some implementations, the individual wire is arranged in continuous contact with the individual runner and/or the surface of the individual runner, at least for one or more individual ones of the revolutions of the helical shape of the individual runner.
Runner 88 , runner 89 and/or struts 90 of system 10 in FIG. 1 may be manufactured from one or more of plastic, plastic plated with metals including copper, nickel, iron, soft iron, nickel alloys, and/or other metals and alloys, and/or other materials. In some implementations, runner 88 , runner 89 and struts 90 may be manufactured from non-conductive material. Runner 88 , runner 89 , and struts 90 may be manufactured from different materials. Runner 88 , runner 89 , and struts 90 may be manufactured through integral construction or formed separately prior to being assembled. The preceding statement is not intended to limit the (process of) manufacture of bodies similar to or substantially the same as body 85 in any way. In some implementations, a body similar to body 85 may have no struts.
The shape of body 85 of system 10 in FIG. 1 may be generally toroidal. In some implementations, the body of system 10 may be arranged in any planar shape, including circular, polygonal, and/or other shapes. Alternatively, and/or simultaneously, a body such as body 85 may be arranged in a three-dimensional curve (a.k.a. space curve). Runner 88 and runner 89 of body 85 may form cores around which wire 86 and wire 87 are spirally wound, respectively. As such, wire 86 and wire 87 may be arranged in a helical shape having axes that coincide with runner 88 and runner 89 , respectively. As shown in FIG. 1 , wire 86 and 87 may be wound such that they go around any of struts 90 of body 85 and/or around any points of engagement between one of struts 90 and one of runners 88 and 89 . The number of wire turns per complete revolution of a runner and/or the number of wire turns between adjacent struts may be characteristic measurements/features of body 85 . In FIG. 1 , wire 86 and wire 87 are arranged to make approximately three to five turns between adjacent struts associated with runner 88 and runner 89 , respectively, and/or some other number of turns. The depiction of FIG. 1 is intended to be exemplary, and in no way limiting.
Wire 86 may include two or more leads—as depicted, lead 86 a and lead 86 b . Wire 87 may include two or more leads—as depicted, lead 87 a and lead 87 b . By way of non-limiting example, a twisted wire may have four leads. In system 10 , body 85 is electrically coupled with one or more power sources and/or current sources, such as, e.g., current source 11 and/or a current source 12 , arranged such that electrical coupling with one or both of wire 86 and wire 87 may be established, e.g. through coupling of current source 11 with lead 86 a and 86 b of wire 86 and through coupling of current source 12 with lead 87 a and 87 b of wire 87 . The current supplied to wire 86 may be a direct current or an alternating current. The current supplied to wire 87 may be a direct current or an alternating current. The currents supplied to wire 86 and wire 87 may flow in the same direction or the opposite direction.
For alternating currents, operating frequencies ranging from 0 Hz to 100 GHz are contemplated. Operating currents ranging from 1 pA to 10 A are contemplated. Operating voltages ranging from 1 mV to 20 kV are contemplated. In some implementations, a root mean square voltage of about 12 V is supplied to wire 86 and/or wire 87 . In a preferred implementation, the frequency of the alternating current supplied to wire 86 and/or wire 87 may be between 0 Hz and 20 kHz. In some implementations, the current is less than about 1 pA, 1 nA, 1 mA, 100 mA, 250 mA, 500 mA, and/or other amounts of current. The operating frequencies for wire 86 and wire 87 may be the same or different. Other electrical operating characteristics of current supplied to wire 86 and wire 87 , such as phase, may be the same or different. System 10 may be used to exploit the electromagnetic effect and/or field that may be created in and/or around body 85 when electrical power is supplied to one or more wires of body 85 . The electromagnetic effect may promote growth of animal 14 disposed within and/or near body 85 and/or the periphery of body 85 .
Some implementations of a system including a body similar to or substantially the same as body 85 in FIG. 1 , thus including wire 86 and wire 87 , may be configured to have a current in wire 86 flowing in the opposite direction as the current in wire 87 . In some implementations the current supplied to one wire may be a direct current, whereas the current supplied to another wire may be an alternating current.
In some implementations, one or more currents flowing through a body similar to body 85 may be controlled to correspond to one or more signals. By way of non-limiting example, FIG. 3 illustrates a system 10 A for promoting growth of one or more animals. System 10 A may be the same as or similar to system 10 depicted in FIG. 1 . System 10 A may include a body 85 A, a current source 11 , one or more processors 110 , a processing component 113 , a playback component 112 , an input component 111 , a user interface 120 , electronic storage 130 , and/or other components. In some implementations, one or more components of system 10 A may correspond to one or more processors, computer program components, user interfaces, electronic storage, and/or other components, including but not limited to the components described in the '925 patent, the '035 patent, and/or the '412 application.
System 10 A may include a body 85 A that is the same as or similar to body 85 depicted in FIG. 1 . Body 85 A may be suspended above the one or more animals 14 , placed around the one or more animals 14 , placed underneath an area for the one or more animals 14 (e.g. underneath a pen or other enclosure), and/or otherwise arranged in proximity of the one or more animals 14 . In some implementations, body 85 A may be installed around an area having a width between 10 and 500 feet, and having a length between 10 and 500 feet. In some implementations, the width may be about 4 feet, 6 feet, 8 feet, 10 feet, 15 feet, 20 feet, 25 feet, 30 feet, 40 feet, 50 feet, 75 feet, 100 feet, 150 feet, 200 feet, 250 feet, 300 feet, 400 feet, 500 feet, and/or another appropriate length that is suitable for the number and kind of animals disposed within and/or near body 85 A. In some implementations, the length may be about 4 feet, 6 feet, 8 feet, 10 feet, 15 feet, 20 feet, 25 feet, 30 feet, 40 feet, 50 feet, 75 feet, 100 feet, 150 feet, 200 feet, 250 feet, 300 feet, 400 feet, 500 feet, and/or another appropriate length that is suitable for the number and kind of animals disposed within and/or near body 85 A.
In some implementations, the one or more processors 110 may be configured to provide information-processing capabilities and/or execute computer program components, including but not limited to input component 111 , playback component 112 , processing component 113 , and/or other components. Processor 110 may include one or more of a digital processor, an analog processor, a digital circuit designed to process information, a central processing unit, a graphics processing unit, an analog circuit designed to process information, and/or other mechanisms for electronically processing information. Although processor 110 is shown in FIG. 3 as a single entity, this is for illustrative purposes only. In some implementations, processor 110 may include a plurality of processing units.
In some implementations, an alternating current supplied to body 85 A may include a carrier signal and a modulating signal. In some implementations, carrier signals used for the alternating current may be radio-frequency signals. As used herein, radio frequency may refer to frequencies between about 30 kHz and about 30 GHz. In some implementations, the modulating signal for the alternating current may be modulated through one or more of amplitude modulation, frequency modulation, phase modulation, digital modulation, and/or other types of modulation.
In some implementations, the one or more frequencies included in the alternating current may be based on audio recordings of a note, tone, or chord, generated by a frequency generator, a function generator, and/or a (musical) instrument. In some implementations, a first frequency may be used for the first runner, and a second frequency may be used for the second runner. For example, a first frequency may be based on the sound of an instrument, e.g. a piano, playing an A above middle C (also referred to as A 4 , which may include sound having a frequency of about 432 Hz, depending on the tuning system used). For example, a second frequency may be based on the sound of some instrument, e.g. a piano, playing a note forming a harmonious interval with A 4 , e.g. E 5 , which may include sound having a frequency of about 648 Hz. For example, a third frequency, if used, may be based on the sound of some instrument, e.g. a piano, playing a note forming a harmonious interval with A 4 , e.g. A 5 , which may include sound having a frequency of about 864 Hz. The particular tuning used in some implementations may be referred to as Pythagorean tuning. Mathematically perfect tuning may combine notes having a 3:2 ratio. Different types of tuning (or tuning systems), including but not limited to equal tempered tuning, may be used and considered within the scope of this disclosure.
It should be appreciated that although components 111 - 113 are illustrated in FIG. 3 as being co-located within a single processing unit, in implementations in which processor 110 includes multiple processing units, one or more of components 111 - 113 may be located remotely from the other components. The description of the functionality provided by the different components 111 - 113 described herein is for illustrative purposes, and is not intended to be limiting, as any of components 111 - 113 may provide more or less functionality than is described. For example, one or more of components 111 - 113 may be eliminated, and some or all of its functionality may be incorporated, shared, integrated into, and/or otherwise provided by other ones of components 111 - 113 . Note that processor 110 may be configured to execute one or more additional components that may perform some or all of the functionality attributed below to one of components 111 - 113 .
Input component 111 may be configured to obtain information, e.g. from one or more digital audio files, or, alternatively and/or simultaneously, based on sensor-generate output signals. In some implementations, the information may be obtained from storage, e.g. from electronic storage. Information obtained from storage may include electronic audio files in any format, including but not limited to MP3, WMA, WAV, AIFF, and/or other audio formats. In some implementations, information may be obtained from sound sources including frequency generators, function generators, phonographs, CD-players, DVD players, AM radio, FM radio, and/or other sound sources. In some implementations, the information obtained by input component 111 may be streaming data (e.g. streaming audio) from a particular website.
Processing component 113 may be configured to process the obtained information from input component 111 . In some implementations, processing component 113 may be configured to generate a processed signal based on the obtained information from input component 111 . For example, processing component 113 may convert, filter, modify, and/or otherwise transform information or signals from input component 111 to generate the processed signal.
Playback component 112 may be configured to produce sound signals based on one or more of the obtained information from input component 111 and/or the processed signal from processing component 113 . The sound signals produced by playback component 112 may be coupled electrically to the leads of one or more conductive wires wound around one or more runners of body 85 A such that the induced current may correspond to and/or be based on the sound signals. Alternatively, and/or simultaneously, the induced current may be controlled by and/or based on the sound signals produced by playback component 112 . In some implementations, the sound signals produced by playback component 112 may be amplified by an amplifier (not shown) before being electrically coupled to the leads of one or more conductive wires. In some preferred implementations, the amplifier may be an audio amplifier ranging between 100 W and 400 W. Other types of amplifiers and/or amplifiers having a different power range are also contemplated.
Electronic storage 130 of system 10 A in FIG. 3 may include electronic storage media that electronically stores information. The electronic storage media of electronic storage 130 may include one or both of system storage that is provided integrally (i.e., substantially non-removable) with its electrical system and/or removable storage that is connectable to its electrical system via, for example, a port (e.g., a USB port, a Firewire port, etc.) or a drive (e.g., a disk drive, etc.). Electronic storage 130 may include one or more of optically readable storage media (e.g., optical disks, etc.), magnetically readable storage media (e.g., magnetic tape, magnetic hard drive, floppy drive, etc.), electrical charge-based storage media (e.g., EPROM, EEPROM, RAM, etc.), solid-state storage media (e.g., flash drive, etc.), and/or other electronically readable storage media. Electronic storage 130 may store software algorithms, information determined by processor 110 , information received via user interface 120 , and/or other information that enables system 10 A or another system described in this disclosure to function properly. For example, electronic storage 130 may store sound information and/or electronic audio files (as discussed elsewhere herein), and/or other information. Electronic storage 130 may be a separate component within its electrical system, or electronic storage 130 may be provided integrally with one or more other components of its electrical system (e.g., processor 110 ).
User interface 120 of system 10 A in FIG. 3 may be configured to provide an interface between the system and a user through which the user can provide information to and receive information from the system. This enables data, results, and/or instructions and any other communicable items, collectively referred to as “information,” to be communicated between a user and the system. An example of information that may be conveyed to a user is an indication of the volume and/or intensity of the sound signals produced by playback component 112 . Examples of interface devices suitable for inclusion in user interface 120 include a keypad, buttons, switches, a keyboard, knobs, levers, a display screen, a touch screen, speakers, a microphone, an indicator light, an audible alarm, and a printer. Information may be provided to a user by user interface 120 in the form of auditory signals, visual signals, tactile signals, and/or other sensory signals.
It is to be understood that other communication techniques, either hard-wired or wireless, are also contemplated herein as user interface 120 . For example, in one implementation, user interface 120 may be integrated with a removable storage interface provided by electronic storage 130 . In this example, information is loaded into system 10 A in FIG. 3 from removable storage (e.g., a smart card, a flash drive, a removable disk, etc.) that enables the user(s) to customize the system 10 A. Other exemplary input devices and techniques adapted for use with system 10 A may include, but are not limited to, an RS-232 port, RF link, an IR link, modem (telephone, cable, Ethernet, internet or other). In short, any technique for communicating information with system 10 A FIG. 3 is contemplated as user interface 120 .
In some implementations, system 10 may include multiple bodies similar to or substantially the same as body 85 . Currents for these multiple bodies may be supplied by one or more power sources and/or current sources. In some implementations, a system may include a combination of one or more bodies similar to or substantially the same as body 85 and one or more bodies similar to or substantially the same as body 85 . By way of non-limiting example, FIG. 4 illustrates a system 10 B for promoting growth of one or more animals. System 10 B may be the same as or similar to system 10 A depicted in FIG. 3 . System 10 B may include a set 85 C of bodies 85 B, and/or other components. By way of non-limiting example, one or more current sources, processors, computer program components, user interfaces, electronic storage, and/or other components are not depicted in FIG. 4 .
Applications for any of the described systems herein, such as, e.g., system 10 , system 10 A, and system 10 B, herein may include affecting growth and/or growth rate of animals and/or other organisms. For example, a particular type of animal may have a typical growth rate, or range of typical growth rates, under growing conditions that lack a significant electromagnetic effect and/or field. For the purposes of this description, a significant electromagnetic field may be determined as an electromagnetic field of at least a predetermined threshold level of tesla. The predetermined threshold may be 1 pT, 1 nT, 1 mT, 10 mT, 100 mT, and/or another threshold. Using any of the electrical systems described herein, the growth rate, or range of typical growth rates, of the particular type of animal may be increased to a higher growth rate, or higher range of growth rates, for the particular animal. A unit of growth rate may be inch/day, or another unit expressing some length, area, volume, or size per unit of time, and/or another appropriate unit.
For example, a specific type of animal may have a typical maximum growth level, under growing conditions that lack a significant electromagnetic field. Using any of the electrical systems described herein, the maximum growth level, or range of typical maximum growth levels, of the specific type of animal may be increased to a higher maximum growth level, or higher range of maximum growth levels, for the specific animal. Maximum growth level may be expressed in inches, square inches, liters, kilograms, lipid content, and/or another unit expressing some length, area, volume, weight, or size, and/or another appropriate unit.
For example, a particular type of animal may have a typical maximum yield, under growing conditions that lack a significant electromagnetic field. Using any of the electrical systems described herein, the maximum yield, or range of typical maximum yields, of the particular type of animal may be increased to a higher maximum yield, or higher range of maximum yields, for the particular animal. Maximum yield may be expressed in volume or weight per area and/or period, such as kilogram/square feet, or pounds per acre per week, and/or other units as appropriate.
For example, a particular type of animal may have a typical duration to reach maturity, under growing conditions that lack a significant electromagnetic field. Using any of the electrical systems described herein, the duration to reach maturity, or range of typical durations to reach maturity, of the particular type of animal may be decreased to a shorter duration to reach maturity, or shorter range of duration to reach maturity, for the particular animal. Duration to reach maturity may be expressed in hours, days, weeks, and/or other units as appropriate.
FIG. 2 illustrates a method 200 for promoting growth of one or more animals. The operations of method 200 presented below are intended to be illustrative. In certain implementations, method 200 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 200 are illustrated in FIG. 2 and described below is not intended to be limiting.
In certain implementations, method 200 may be implemented in one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The one or more processing devices may include one or more devices executing some or all of the operations of method 200 in response to instructions stored electronically on an electronic storage medium. The one or more processing devices may include one or more devices configured through hardware, firmware, and/or software to be specifically designed for execution of one or more of the operations of method 300 .
At an operation 202 , a body is installed around and/or near one or more animals. The body includes at least one runner, a wire, and one or more current sources. The runner is arranged in a helical shape having at least two complete revolutions. The wire is carried by the first runner. The wire is conductive. The one or more current sources are arranged to electrically couple with the wire. In one implementation, operation 202 is performed by a user of system 10 (shown in FIG. 1 and described above).
At an operation 204 , an alternating current is supplied through the wire such that an electromagnetic effect (e.g. an electromagnetic field) is created in and/or around the body that promotes growth of the one or more animals disposed within and/or near the body. In one implementation, operation 204 is performed by one or more current sources similar to or substantially the same as current source 11 (shown in FIG. 1 and described above).
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.
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An electrical system having an underlying structure having a helical shape is used to produce useful electromagnetic effects for agricultural applications, including promoting growth of animals.
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BACKGROUND OF THE INVENTION
Many prior workers have sought to increase the sorbency of fibrous web products by addition of "super absorbent" particles, e.g., modified starch or other polymeric particles which sorb and retain under pressure large volumes of liquids, especially aqueous liquids. The previous products prepared by such additions all have had significant limitations. For example, one commercial product, which comprises sorbent particles adhered between two sheets of tissue paper, decomposes in use, whereupon the sorbent particles are washed out of the product and into liquid being treated. Another commercial product, comprising a rather stiff open-mesh fabric or cheese cloth to which essentially a single layer of sorbent particles is adhered, sorbs only limited amounts of liquid.
A different product taught in U.S. Pat. No. 4,103,062 is made by dispersing particles in an air-laid cellulosic fiber web and densifying the web with heat and pressure to increase its strength. However, this product sorbs only a limited amount of liquid, because of the nonexpansible nature of the densified web, and because sorbent particles at the edge of the web swell upon initial liquid intake and prevent permeation of additional liquid into internal parts of the web. U.S. Pat. No. 4,105,033 seeks to avoid such edge blockage by distributing the sorbent particles in spaced layers separated by layers of fibers, but such a construction requires added processing steps and is subject to delamination. In other products sorbent particles are simply cascaded into a loose fibrous web (see U.S. Pat. No. 3,670,731), but both U.S. Pat. Nos. 4,103,062 and 4,105,033 note that it is difficult to deposit the particles uniformly, and the particles tend to move within the web during subsequent processing, storage, shipment or use of the web and thereby develop nonuniform properties.
U.S. Pat. No. 4,235,237 teaches a different approach in which a fibrous web is sprayed, immersed or otherwise contacted with sorbent material dispersed in a volatile liquid. Vaporization of the volatile liquid leaves a web in which sorbent particles envelop the fibers, principally at fiber intersections. Disadvantages of this approach include the need for multiple steps to prepare the product, limitations on amount of sorbent that can be added to the web, brittleness of the dried webs, and the tendency for sorbent material to be concentrated at the web surface.
SUMMARY OF THE INVENTION
The present invention provides a new sorbent sheet product with unique capabilities beyond those of any known prior-art product. Briefly, this new sheet product comprises a coherent web of blown fibers, and an array of solid high-sorbency liquid-sorbent polymeric particles dispersed within the web. The blown fibers are prepared by extruding liquid fiber-forming material into a high-velocity gaseous stream, where the extruded material is attenuated and drawn into fibers. A stream of fibers is formed, which is collected, e.g., on a screen disposed in the stream, as an entangled coherent mass. According to the invention sorbent particles may be introduced into the stream of fibers, e.g., in the manner taught in U.S. Pat. No. 3,971,373, and the mixture of fibers and particles is collected as an entangled coherent mass in which the sorbent particles are entrapped or otherwise physically held. A particle-filled fibrous web is formed in essentially one step, and the only further processing required may be simply cutting to size and packaging for use.
A sheet product of the invention is integral and handleable both before and after immersion in liquid, because the collected blown fibers are extensively tangled or snarled and form a strong coherent web, and the sorbent particles are lastingly held and retained within this web.
Large quantities of liquid can be sorbed, with the amount dependent principally on the sorption capacity of the individual sorbent particles. Liquid is sorbed by sorbent particles located in even the inner parts of the sheet product, apparently because the sorbent particles are held apart by the web structure, allowing liquid to surround individual particles before swelling occurs. The fibers of the web are preferably wet by the liquid being sorbed, e.g., as a result of use of a fiber-forming material that is wet by the liquid or by addition of a surfactant during the web-forming process, which further assists sorption.
The sorbent particles swell and expand in size during sorption, and although the blown fibers are extensively entangled, the web of fibers expands as the particles expand and the sorbed liquid tends to be retained in the product even when the product is subjected to pressure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of apparatus used in practicing the present invention;
FIG. 2 is a greatly enlarged sectional view of a portion of a sheet product of the invention; and
FIGS. 3A and 3B are side views of a sheet product of the invention, FIG. 3A showing the sheet product before use and FIG. 3B showing the sheet product after it has been used to sorb a substantial amount of liquid.
DETAILED DESCRIPTION
A representative apparatus useful for preparing sheet product of the invention is shown schematically in FIG. 1. The apparatus is generally similar to that taught in U.S. Pat. No. 3,971,373 for preparing a particle-loaded web of melt-blown fibers. Part of the apparatus for forming melt-blown fibers is described in Wente, Van A., "Superfine Thermoplastic Fibers" in Industrial Engineering Chemistry, Vol. 48, p. 1342 et seq. (1956), or in Report No 4364 of the Naval Research Laboratories, published May 25, 1954, entitled "Manufacture of Superfine Organic Fibers," by Wente, V. A.; Boone, C. D.; and Fluharty, E. L. The illustrated apparatus includes two dies 10 and 11 which include a set of aligned parallel die orifices 12 through which the molten polymer is extruded, and cooperating air orifices 13 through which heated air is forced at a very high velocity. The air draws out and attenuates the extruded polymeric material, and after a short travel in the gaseous stream, the extruded material solidifies as a mass of fibers. According to the present invention, two dies are preferably used and arranged so that the streams 14 and 15 of fibers issuing from them intersect to form one stream 16 that continues to a collector 17. The latter may take the form of a finely perforated cylindrical screen or drum, or a moving belt. The collected web 18 of microfibers is then removed from the collector and wound in a storage roll. Gas-withdrawal apparatus may be positioned behind the collector to assist in deposition of fibers and removal of gas.
The apparatus shown in FiG. 1 also includes apparatus for introducing sorbent particles into the sheet product of the invention. Desirably this apparatus introduces a stream 20 of the sorbent particles which intercepts the two streams of melt-blown fibers at the latter's point of intersection. Such an arrangement is believed to be capable of providing a maximum loading of particles into the collected fibrous web. Alternatively a single die may be used with one or more particle streams arranged to intersect the stream of fibers issuing from the die. The streams of fibers and sorbing particles may travel in horizontal paths as shown in FIG. 1, or they may travel vertically so as to generally parallel the force of gravity.
In the representative apparatus illustrated in FIG. 1, the apparatus for feeding sorbent particles into the stream of fibers comprises a hopper 22 for storing the particles; a metering device 23, such as a magnetic valve or metering device described in U.S. Pat. No. 3,661,302, which meters particles into a conduit 24 at a predetermined rate; an air impeller 25 which forces air through a second conduit 26 and which accordingly draws particles from the conduit 24 into the second conduit 26; and a nozzle 27 through which the particles are ejected as the particle stream 20. The nozzle 27 may be formed, for example, by flattening the end of a cylindrical tube to form a wide-mouthed thin orifice. The amount of particles in the particle stream 20 is controlled by the rate of air flow through the conduit 26 and by the rate of particles passed by the metering device 23.
Melt-blown fibers are greatly preferred for sheet products of the invention, but solution-blown fibers in which the fiber-forming material is made liquid by inclusion of a volatile solvent can also be used. U.S. Pat. No. 4,011,067 describes useful apparatus and procedures for preparing a web of such fibers; however, in preparing sheet products of this invention fiber-forming material is generally extruded through a plurality of adjacent orifices rather than the single orifice shown in the patent.
The particles are preferably introduced into the fiber stream at a point where the fibers have solidified sufficiently that the fibers will form only a point contact with the particles (as taught in U.S. Pat. No. 3,971,373). However, the particles can be mixed with the fibers under conditions that will produce an area contact with the particles.
Once the sorbent particles have been intercepted in the fiber stream, a process for making the sheet product of the invention is generally the same as the process for making other blown fiber webs; and the collectors, methods of collecting, and methods of handling collected webs are generally the same as those for making non-particle-loaded blown fiber webs.
The layer of fibers and particles formed in any one revolution, and a completed sheet product of the invention may vary widely in thickness. For most uses of sheet products of the invention, a thickness between about 0.05 and 2 centimeters is used. For some applications, two or more separately formed sheet products of the invention may be assembled as one thicker sheet product. Also sheet products of the invention may be prepared by depositing the stream of fibers and sorbent particles onto another sheet material such as a porous nonwoven web which is to form part of the eventual sheet product. Other structures, such as impermeable films, can be laminated to a sheet product of the invention through mechanical engagement, heat bonding, or adhesives.
Sheet products of the invention may be further processed after collection, e.g., compacting through heat and pressure to control sheet caliper, to give the sheet product a pattern or to increase the retention of sorbent particles. Other fibers besides blown fibers may be introduced into the sheet product in the manner taught in U.S. Pat. No. 4,118,531. For example, crimped bulking fibers as described in that patent may be mixed with blown fibers together with sorbent particles to prepare a more lofty or lightweight sheet product.
The blown fibers are preferably microfibers, averaging less than about 10 micrometers in diameter, since such fibers offer more points of contact with the particles per unit volume of fiber. Very small fibers, averaging less than 5 or even 1 micrometer in diameter, may be used, especially with sorbent particles of very small size. Solution-blown fibers have the advantage that they may be made in very fine diameters, including less than one micrometer. Larger fibers, e.g., averaging 25 micrometers or more in diameter, may also be prepared, especially by the melt-blowing process.
Blown fibrous webs are characterized by an extreme entanglement of the fibers, which provides coherency and strength to a web and also adapts the web to contain and retain particulate matter. The aspect ratio (ratio of length to diameter) of blown fibers approaches infinity, though the fibers have been reported to be discontinuous. The fibers are long and entangled sufficiently that it is generally impossible to remove one complete fiber from the mass of fibers or to trace one fiber from beginning to end. Despite such entanglement, a sheet product as represented by the sheet 28 in FIG. 3A will expand greatly in size during sorption, as represented in FIG. 3B. Sheet products of the invention generally can expand at least 3 times their original thickness during sorption, and more typically expand 5 or 10 or more times their original thickness.
The fibers may be formed from a wide variety of fiber-forming materials. Representative polymers for forming melt-blown fibers include polypropylene, polyethylene, polyethylene terephthalate, and polyamides. Representative polymers for forming solution-blown fibers include polymers or copolymers of vinyl acetate, vinyl chloride, and vinylidene fluoride. Inorganic materials also form useful fibers. Fibers of different fiber-forming materials may be used in the same sheet product in some embodiments of the invention, either in mixture in one layer or in different layers.
Many of the fiber-forming materials form hydrophobic fibers, which can be undesirable in water-sorbing sheet products. To improve the sheet product for such a use, a surfactant in powder or liquid form may be introduced into the sheet product, as by mixing powders with the sorbent particles before they are introduced into the web or spraying liquids onto the web after it is formed. Useful surfactants, which typically comprise molecules having oleophilic and hydrophilic moieties, include dioctyl ester of sodium sulfosuccinate and alkylaryl polyether alcohol. A small amount of the surfactant, such as 0.05 to 1 weight-percent of the sheet product, will generally provide adequate hydrophilicity, but larger amounts can be used. Use of oleophilic fibers together with water-sorbing particles can have the advantage of dual absorption, in that the fibrous web sorbs organic liquids such as oils while the particles sorb water.
As indicated above, the sorbent particles used in the invention are generally super absorbent particles, which rapidly absorb and retain under pressure larger quantities of liquids. The preferred particles for sorbing water comprise modified starches, examples of which are described in U.S. Pat. No. 3,981,100, and high-molecular-weight acrylic polymers containing hydrophilic groups. A wide variety of such water-insoluble water-sorbing particles are available commercially, and they typically sorb 20 or more times their weight of water and preferably 100 or more times their weight of water. The amount of water sorbed declines as impurities are included in the water. Alkylstyrene sorbent particles (such as marketed by Dow Chemical Company under the trademark "Imbiber Beads") are useful for sorbing liquids other than water. They tend to sorb 5 or 10 times or more their weight of such liquids. In general the sorbent particles should sorb at least their own weight of liquid.
The sorbent particles may vary in size, at least from 50 to 3000 micrometers in average diameter. Preferably, the particles are between 75 and 1500 micrometers in average diameter.
The volume of sorbent particles included in a sheet product of the invention will depend on the particular use to be made of the product and will involve balancing the amount of sorbency desired with properties such as integrity or strength of the web, or desired web thickness. Generally sorbent particles account for at least 1, and more typically at least 20, volume-percent of the solid content of the sheet product ("solid content" is used to contrast with bulk volume and refers to the physical components of the sheet product and not the voids or interstices between those components). However amounts under 10 or 20 volume-percent are useful and have the advantage that they are retained in the web even more completely than particles at higher loadings are retained. Where high sorbency is desired, the sorbent particles generally account for at least 50 volume-percent of the solid content of the sheet product. One of the advantages of the invention is that high particle-loadings can be achieved, though there is seldom need for particles in excess of 90 volume-percent.
Sheet material of the invention has a variety of uses, including uses listed in the prior art such as bandages, diapers, incontinent pads, and sanitary napkins.
The invention will be further illustrated by the following examples.
EXAMPLES 1 AND 2
Two sets of sheet product of the invention were prepared from polypropylene microfibers that averaged about 5 micrometers in diameter, sorbent particles comprising a synthetic high-molecular-weight acrylic polymer containing hydrophilic carboxylate groups ("Permasorb 29," supplied by National Starch and Chemical Corporation), and surfactant particles of dioctyl ester of sodium sulfosuccinate ("Aerosol OT-B" from American Cyanamid). The sorbent particles and surfactant particles (in the amounts stated below) were mixed together and introduced into a stream of the microfibers using apparatus as shown in FIG. 1. The die orifices of the two dies were separated from one another by 6 inches (15 centimeters), the dies were arranged to project fiber streams at an angle of 30° to the vertical, and the fiber streams intersected at a variable distance about 5-10 inches (12-25 centimeters) from the die orifices and continued to a collector surface located 12 inches (30 centimeters) from the die orifices. Polymer was extruded through the die orifices at a rate of about 4 pounds per hour per inch (0.7 kilogram/hour/centimeter) width of die, and air heated to 700° F. (370° C.) was forced through the hot air orifices of the dies.
The prepared sheet products were immersed in tap water and the sorbency of the products measured (weight of sheet product after immersion ("wet") minus weight before immersion ("dry") divided by weight before immersion). Results and proportions of components are given in Table I below.
TABLE I__________________________________________________________________________Amount of Sorbent Particles Amount of Surfactant Total Weight Thickness of Water Sorbency Volume-percent of solid Weight-percent of Sheet Product Ratio of weightWeight ratio content of web occupied of sheet product Product Dry Wet of water sorbedEx. of fibers by sorbent particles accounted for by surfactant (grams per Inches to weight ofNo. and particles (percent) (percent) square meter) (Centimeters) sheet__________________________________________________________________________ product1 1:2.9 62 0.8 510 0.12 0.7 33 (0.3) (1.8)2 1:4.4 71 0.8 700 0.1 1.4 59 (0.25) (3.6)__________________________________________________________________________
EXAMPLES 3-11
Sheet product of the invention was prepared comprising polypropylene microfibers averaging about 5 micrometers in diameter and two different varieties of sorbent particles, one being a modified starch ("Waterlock A-100" supplied by Grain Processing Corporation) and the second being a synthetic high-molecular-weight acrylic polymer containing hydrophilic carboxylate groups ("Permasorb 20," supplied by National Starch and Chemical Corporation). The sorbent particles were included in different amounts as shown in Table II below. The total amount of water sorbed by immersing each sample of sheet product in tap water for, respectively, 5 minutes and 20 minutes was measured and is reported in Table II as a ratio of grams of water sorbed per gram of sheet product. The amount of water sorbed and retained after the sheet product was immersed for, respectively, 5 minutes and 18 hours, and then laid on a cellulose paper towel for 30 seconds was also measured and is reported as a ratio of grams of water per grams of sheet product. A percent of theoretical sorption is also reported, which is a ratio of the water sorbed and retained (after 20 minute immersion and laying on a paper towel) to the amount of water which the sorbent particles will sorb when immersed in water by themselves.
TABLE II__________________________________________________________________________ Ratio of Weight Ratio of Weight of Water Sorbed of Water and Retained After Sheet Ratio of SorptionTotal Weight Weight-Percent Sorbed After Immersion Immersed for Time Shown by Sheet Product toof Sorbent for Time Shown to Laid on Paper Towel Sorption by SorbentExampleSheet Product Particles Weight of Sheet Product Weight of Sheet Product ParticlesNo. (grams/m.sup.2) (Percent) 5 Min 20 Min 20 Min 18 Hour (Percent)__________________________________________________________________________3 100 30 16 17 15 13 684 125 42 25 26 23 25 755 225 68 40 43 39 48 796 260 73 46 52 48 59 907 250 70 34 34 33 43 658 23 40 36 46 29 -- 699 27 50 42 46 37 31 7010 42 53 38 46 37 39 6611 140 85 41 45 41 -- 46__________________________________________________________________________
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New sorbent sheet products are prepared comprising a coherent web of entangled blown fibers prepared by extruding liquid fiber-forming material into a high-velocity gaseous stream and an array of super absorbent polymeric particles dispersed within the web.
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BACKGROUND OF THE INVENTION
Since airplanes were first constructed there has been a need to provide fasteners for the application of skin coverings to load carrying structures that would accommodate the shear tensile loading between a skin and its substructure. Over time the airplane industry has come to rely on mechanical fasteners to satisfy this need, particularly since evolution of airplane design and construction has resulted in airplanes manufactured almost entirely from metal.
Recent developments in aircraft design have produced a new genertion of aircraft constructed with as much as fifty percent or more advanced composite materials such as graphite/epoxy. Because of the complexity of the designs of these aircraft, today's aircraft manufacturers have come to rely on automation to economically manufacture and assemble their advanced composite parts. To date, however, a suitable means for automating the assembly of these parts has yet to be developed, causing manufacturers to continue to rely on mechanical fasteners for fastening composite structures to substructures. The use of mechanical fasteners, however, causes the cost of final assembly to be increased because of their special drilling and reinforcement requirements, and because of the need for such fasteners to be made from more expensive materials to avoid serious corrosion problems in service.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide an apparatus for stitching together composite airframe parts as an alternative to the use of other fastening techniques. Another object of the present invention is to provide a stitching apparatus that can stitch along the straight, bowed, twisted and highly contoured paths which are present in advanced composite structures. A further object of the present invention is to provide a microprocessor controlled stitching apparatus having six axes of motion to achieve the flexibility of motion required for stitching along the straight and complexly contoured paths present in advanced composite structures.
According to the present invention, a translaminar stitching module is provided which includes a stitching assembly housing a stitching mechanism, and a rack assembly used to support composite workpieces during stitching. The module is capable of stitching composite materials in both circumferential and/or longitudinal directions. For this purpose, the module is provided with six axes of movement, three translational axes and three rotational axes. The translational axes include an X axis of translation parallel to the composite workpieces being stitched, a Y axis of translation perpendicular to the composite workpieces, and a Z axis of translation perpendicular to the floor. The rotational axes include an alpha axis of rotation around an axis parallel to the Y axis, a beta axis of rotation around an axis parallel to the Z axis, and a gamma axis of rotation around an axis parallel to the X axis.
The X, Y, Z, alpha and gamma axes are controlled by a microprocessor-based control system using encoder feedback for position control. One encoder is provided for each of the five axes.
Movement along the Y, Z and alpha axes is implemented by translating and/or rotating various sub-assemblies of the stitching assembly, while movement along the X and gamma axes is implemented by translating and/or rotating the rack assembly.
The Z axis normally operates as a single servo controlled axis; however, it also functions as a split axis during stitching to enable the stitching assembly to avoid any obstructions which may be present on a workpiece.
The beta axis is a positional rotation axis. Motion along this axis can be implemented by rotating anyone of three sub-assemblies of the stitching assembly used directly in the stitching operation. Movement of each of these assemblies is also microprocessor controlled. However, unlike the other axes, positioning of the assemblies is sensed by the microprocessor through a series of photo-optical position switches.
The stitching module is also provided with a number of auxiliary mechanisms which allow it to access and stitch deep structure on workpieces, to exert pressure on workpieces to achieve tight stitch formation, to self-digitize for programming new stitch paths for new workpieces, and to heat workpieces to aid needle penetration for easier stitching.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the stitching module showing its six axes of motion.
FIG. 2a is a side elevational view of the stitching module.
FIG. 2b is a front elevational view of the stitching head assembly of the stitching module.
FIG. 3 is an overall block diagram of the stitching module control system.
FIG. 4a is a perspective view of the stitching module showing motion of the stitching assembly along the alpha axis.
FIG. 4b is a partial rear perspective view of the stitching module showing the sector gear used to move the stitching assembly along the alpha axis.
FIG. 5 is a perspective view of the rack assembly showing movement of the rack assembly along the gamma axis.
FIG. 6 is an enlarged perspective view of a needle extension arm and a pressure foot roller assembly of the stitching head assembly.
FIG. 7 is a front elevational view of the digitizing adaptor used to program the microprocessor of the control system with new stitching path information.
FIG. 8 is a general flowchart of the software routine for creating a new parts program file.
FIGS. 9a and 9b are a general flowchart of the software routine for editing an existing parts program file.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The stitching module of the present invention is a translaminar multi-axis stitcher that can move in both circumferential and/or longitudinal directions for stitching linear and curvilinear paths. FIG. 1 shows stitching module 1 and the six axes of motion used by the stitching module for circumferential and or longitudinal motion. These six axes include three translational axes and three rotational axes as follows: an X axis of translation 2 parallel to the composite workpieces being stitched, a Y axis of translation 3 perpendicular to the workpieces, a Z axis of translation 4 perpendicular to the floor, an alpha axis of rotation 5 around an axis parallel to the Y axis 3, a beta axis of rotation 6 around an axis parallel to the Z axis 4 and a gamma axis of rotation 7 around an axis parallel to the X axis 2.
Referring to FIGS. 2a, 2b and 3, the stitching module incorporates a commercially available stitching machine, a Landis model 88 single thread chain stitch machine, for the actual stitching function. Two major subassemblies of the Landis machine are used. These include a stitching head assembly 8, containing a needle 9 and its associated drive shafts and cams, and a stitching horn assembly 10, containing a twirler mechanism for wrapping thread around needle 9.
The stitching head assembly is mounted on a support structure 11 which is driven by an AC motor 12. For movement along the beta axis during stitching the stitching head assembly is rotated to one of four positions through rotation of the support structure. These positions are marked by photo-optical switches 13 positioned at 90° intervals along the beta axis. Motor 12 is activated by a microprocessor based controller 14 (FIG. 3) through a typical motor control logic circuit 15. The photo-optical switches sense the position of the stitching head at any given time, and feed this information back to the controller to allow it to position the stitching head during stitching.
During stitching, stitching horn assembly 10 normally operates in conjunction with stitching head assembly 8. However, it can be rotated independently when necessary. Horn assembly 10 is rotated by a DC motor 16, and can be rotated to any of one of four distinct positions. The positions are also marked by photo-optical position switches 17 positioned at 90° intervals. Motor 16 is also activated by controller 14 through motor control logic 15, while position switches 17 also feed back positional information to controller 14 to allow it to position stitching horn 10 during stitching.
The horn assembly and its motor are mounted on a support structure called a horn yoke assembly 18. This assembly is, in turn, rotated by an AC motor 19, and can be rotated to one of four positions. These positions are also marked by photo-optical position switches 20 positioned at 90° intervals. Like motor 16, motor 19 is also activated by controller 14 through motor control logic 15, while position switches 20 also feed back positional information to controller 14 to allow it to position horn yoke 18 during stitching.
The foregoing rotational arrangement provides stitching head assembly 8 and stitching horn assembly 10 with a high degree of flexibility in their movement along the beta axis. Each assembly can be rapidly moved to one of four positions, thereby giving the stitching module the capability of changing its direction of stitching in a minimum amount of time. Thus, stitching module 1 can readily stitch in any of four directions (plus or minus X and plus or minus Y), and yet quickly turn around and stitch in a return direction in adjacent paths. This minimizes the time required at the end of each stitching run to locate the system for the next stitching run.
Stitching head 8, support 11 and motor 12 are all supported by an upper yoke assembly 21, while stitching horn 10, motor 16 and horn yoke 18 are all supported by a lower yoke assembly 22. Acting together upper yoke assembly 21 and lower yoke assembly 22 form a complete yoke assembly 23 which is slidably mounted on a dove tail slide drive assembly 24 for translation along the Z axis.
Mounted on top of this slide drive assembly is a Z axis drive assembly 25 which translates yoke assembly 23, and in turn stitching head 8 and stitching horn 10 along the Z axis. For this purpose a DC servo motor 26 and gear box 26' turn an acme screw 27, best seen in FIG. 4a, by means of a belt 28 spanning two pulleys, one 29 attached to the output shaft of gear box 26, and a second 30 attached to an end of screw 27. As motor 26 and gear box 26' turn screw 27 either clockwise or counter clockwise, yoke 23, and thus the stitching head and horn, translate in either the plus or minus Z directions.
Servo motor 26 is part of a coordinate velocity servo loop used by the controller to implement and control velocity and position along the Z axis. Controller 14 uses a number of typical servo power amplifiers 31 to control the velocity of the servo motors used throughout the stitching module. For activation and velocity control of motor 26, controller 14 selects and energizes the particular servo power amplifier of amplifiers 31, which is connected to motor 26.
The distance which yoke 23 moves along the Z axis is measured by a Z axis encoder 32 mechanically linked to motor 26. The velocity information collected by this encoder is fed back to the controller to allow it to determine the position and speed of the stitching head with respect to a workpiece, and to adjust it accordingly. To protect yoke 23 from travelling too far in either direction along the Z axis over-travel limit switches 33 are provided.
Stitching module 1 is also capable of avoiding any obstructions which may be present on a given workpiece by splitting its Z axis. When an obstruction is approached, a cylinder 35 is extended by the controller activating a solenoid 36 through motor control logic 15. Extension of this cylinder causes the lower yoke 22, and in turn horn 10, to be lowered so as to avoid the obstruction. During this motion, the lower yoke slides down rails 37 which are secured to the sides of slide drive assembly 24. After the obstruction has been avoided, the solenoid is de-activated, causing cylinder 35 to retract, and the lower yoke and horn to slide up the rails. At this point the operation of the Z axis is resumed as a single servo controlled axis.
The positioning of cylinder 35 is sensed by two photo-optical position switches 38. One switch senses when the cylinder is retracted. The other senses when it is extended. This positional information is transmitted back to controller 14 for positioning control.
FIGS. 4a and 4b demonstrate movement of the stitching module along the alpha axis. This movement is implemented by an alpha axis drive assembly 40 which tilts yoke assembly 23, and in turn stitching head assembly 8 and stitching horn assembly 10. Because of the low speeds, power requiremements and positioning accuracy tolerance requirements for movement along this axis, the alpha drive utilizes a permanent magnet motor 41 which is controlled by the controller through a typical SCR motor control circuit 42. To tilt yoke 23, the shaft of this motor engages a curved sector gear 43, best seen in FIG. 4b, mounted on the back of the yoke at the bottom. Operating in conjunction with the alpha drive is a swivel axis assembly 44 on which yoke 23 is rotatably mounted through a shaft and bearing assembly so as to allow it to tilt and move along the alpha axis. The design of sector gear 43 permits an alpha axis rotation of the stitching head and horn of plus or minus 15 degrees. Movement along the alpha axis is measured by an alpha axis encoder 45 which transmits this information to controller 14 for tilt control. To prevent excessive tilt over-travel limit switches 46 are also provided.
Swivel axis assembly 44 has a truss-like construction, and is mounted on top of a platform shaped base assembly 50. Movement of the stitching module along the Y axis is implemented by a Y axis drive assembly 51 which translates base 50, and in turn, stitching head 8 and stitching horn 10, in either the plus or minus Y directions. For this purpose the base is mounted on a plurality of Thomson bearings 52, which in turn, slidably engage a pair of rails 53. These rails allow bearings 52, with base 50 mounted thereon, to translate in the plus and minus Y directions. The translation of base assembly 50 is effected through a servo motor 54 turning a ball bearing lead screw 55 linked to base 50 through an internally threaded sleeve 56.
Motor 54 is also controlled by microprocessor-based controller 14 via one of the servo power amplifiers 31. A Y axis encoder 57 measures the movement of base 50 along the Y axis, and feeds this information to the controller to allow it to control the velocity of motor 54 to properly move base 50 during stitching. Y over-travel limit switches 58 limit excessive movment of base 50 along the Y axis.
Stitching module 1 is also provided with a rack assembly 60 for supporting composite workpieces during stitching. This rack assembly is also used to implement movement along the X and gamma axes. Rack assembly 60 includes a stitching rack 61 which conforms in shape to the shape of the workpieces to provide optimum support. For this purpose the stitching rack is molded from fiber glass to the general shape of the workpieces. Thus, workpieces having any shape may be stitched merely by substituting for rack 61 a new rack which conforms to the shape of the new workpieces.
The construction and operation of rack assembly 60 can best be seen in FIG. 5. The stitching rack 61 shown in FIG. 5 is designed to support an aircraft inlet duct assembly (not shown). In this particular instance its shape is drum-like to accommodate the shape of the inlet duct assembly; however, as noted previously, if a different assembly having a different shape were to be stitched, a new rack conforming to the different assembly would be substituted.
Stitching rack 61 is also supported with transverse stiffening ribs 62 for torsional and lateral strength. On either side of these ribs are clearance slots 63 which are properly spaced to permit needle 9 to penetrate rack 61 during stitching. The bottom of the rack is open to allow access for horn 10 during stitching. The workpieces to be stitched are located on the stitching rack by means of locating pins 64 shown in FIG. 2a.
The movement of the stitching module along the X and gamma axes is achieved by appropriately translating and/or rotating rack assembly 60 along such axes.
To allow movement along the gamma axis, rack 61 is rotatably mounted at each end on a support frame 65 of a carriage 66 by means of a shaft and bearing assembly 67. Movement is implemented by means of a gamma axis drive assembly 68 which utilizes a DC servo motor 69 to rotate a pulley wheel 70 fitted to the shaft of motor 69. Pulley wheel 70, in turn, rotates a second pulley wheel 71, fitted to one of the shaft and bearing assemblies 67, by means of a drive belt 72 spanning both pulleys.
Motor 69 is also controlled by controller 14 through one of servo power amplifiers 31. For velocity and position control, gamma axis encoder 73 measures the movement of rack 61 along the gamma axis, after which it transmits such information to the controller.
For movement of rack assembly 60 along the X axis, carriage 66 is mounted on a plurality of Thomson bearings 75 which, in turn, slidably engage a pair of rails 76. Movement is implemented by means of an X axis drive assembly 80 which utilizes a DC servo motor 81 controlled by controller 14 through one of the servo power amplifiers 31. Motor 81 turns a ball bearing lead screw 82 which engages a threaded sleeve 83 attached to carriage 66. As screw 82 is rotated, carriage 66, and ultimately rack assembly 61, are translated in the positive or negative X directions.
Movement by rack assembly 60 along the X axis is measured by an X axis encoder 84, while a pair of over-travel limit switches 85 ensure that such movement does not exceed safe limits. The data measured by the encoder serves as feedback to controller 14 to allow it to properly control the movement of rack 60 during stitching.
It has been discovered that a number of auxiliary mechanisms enhance the module's versatility and speed and improve the quality of its stitch.
For example, as shown in FIGS. 2a and 2b, two controllable forced air heaters are provided which permit both top side and bottom side heating of the laminate workpieces being stitched prior to needle entry. For top side heating a tube 90 shown in FIG. 2b directs forced hot air to that area of a workpiece at which needle 9 of stitching head assembly 8 is about to penetrate. Tube 90 is mounted on stitching head assembly 8 parallel to needle 9.
For bottom side heating a second tube 91 adjacent to horn assembly 10 is provided. Tube 91 also directs forced hot air to the workpieces, but it is directed to the bottom side of the area where needle 9 is about to penetrate.
The temperature of the hot air directed by tubes 90 and 91 is adjusted so that the workpieces are moderately softened during stitching to minimize fiber breakout in the workpieces and to reduce thread friction and the build-up of resin present in the workpieces on the needle.
FIG. 6 shows a vertically disposed needle shaft extension 95 which gives stitching module 1 the capability of deep-structure reach during the stitching operation. It is an extension of the needle holder (not shown) of the basic Landis machine, and is connected on one end to such holder. Bolted to the other end is needle 9. The design of needle shaft extension 95 permits the close placement of needle 9 to a workpiece skin being stitched to high standing frame details (e.g., nine inches high), while still allowing stitching module 1 to utilize the needle stroke capabilities inherent in the design of the basic Landis machine.
FIG. 6 also shows a pressure-foot roller assembly 96 used to keep the skin of a workpiece in contact with stitching rack 61 during stitching to aid in the formation of tight stitches. Assembly 96 consists of a pressure roller 97 rotatably mounted on an axis assembly 98 which is bolted to one end of a vertically disposed, spring loaded shaft 99. Shaft 99 is spring loaded by means of a spring 100 which surrounds shaft 99 and is attached thereto by a sleeve 101 which also surrounds shaft 99. The pressure exerted by roller 97 on a given composite workpiece is achieved by microprocessor base controller 14 activating a pressure foot solenoid 102, and in turn, an air cylinder (not shown) attached to the top of shaft 99, so as to cause a vertical displacement downward of shaft 99 and pressure roller 97. Controller 14 is assured that pressure roller 97 is in proper position during stitching by means of a single photo-optical position switch 103. This switch senses whether or not the roller is in the proper extended position for stitching, and transmits this information back to controller 14.
During the stitching operation, roller assembly 96 works in conjunction with the stitching action of needle 9 by holding down the composite materials during the withdrawal of the needle. The roller also aids in the formation of tight stitches by embedding the thread used by the stitching module into the surface of the composite material of the workpieces. Kelvar thread is the type used in the preferred embodiment of the invention.
As noted previously, the twirler and needle assemblies of the basic Landis machine are incorporated in the present invention. However, unlike the arrangement used in the Landis machine where these assemblies are driven by a common shaft and motor, in the stitching module the two assemblies are separated and driven independently by separate DC motors.
Needle 9, which is mounted in stitching head assembly 8, is drivn by a DC servo motor 105 which is part of a servo loop controlled by controller 14 through one of the amplifiers 31. Two photo-optical position switches 106 sense whether needle 9 is in the full-up or full-down position, and transmit this information back to controller 14 for control purposes. Through this control arrangement stitching speeds of one stitch per second, or twenty inches per minute, can be achieved.
For rotation of the twirler (not shown), the mechanism which wraps thread around needle 9 as it penetrates the workpiece, a DC motor 107 is utilized. This motor is also controlled by controller 14, but through motor control logic 15. Four photo-optical position switches 108 positioned at 90° intervals provide controller 14 with the positioning information necessary to control the twirler's operation.
The photo-optical position switches used in stitching module 1 area of typical design, each consisting of a light emitting diode (LED) and a photo transistor. A single shutter, about 0.125 inches wide, is located on each rotating member of the stitching module operating in conjunction with the switches. As these shutters pass sequentially through the LED-photo transistor pairs of the various switches, pulses are generated which are monitored by controller 14 so as to enable it to determine the position of the mechanism being controlled.
The overall control system of the stitching module is shown in FIG. 3. The heart of the control system is microprocessor-based controller 14. Microprocessor-based controller 14's architecture consists of three single board microcomputers. These microcomputers include a master control microcomputer 109, a data control microcomputer 110 and a motor control microcomputer 111. In the preferred embodiment standard singleboard microcomputers, model 80/30 manufactured by Intel Corporation, are used; they employ the Intel 8085 microprocessor and 8K of on-board ROM and 16K of on-board RAM. However, it should be understood that equivalent computers or hard-wired circuits may also be used.
The master control microcomputer 109, which is responsible for supervising the sequence of control of the overall system, allows an operator to interface the control system via a system terminal 112.
The data control microcomputer 110 handles, and processes in real-time during stitching, all of the parts program data which is used to define the stitch paths for the various workpieces. This parts program data is stored on floppy discs mounted in a typical dual floppy disc drive 113. The data, when processed, is passed to the motor control microcomputer 111.
Motor control microcomputer 111 actuates the motors and solenoids used throughout the stitching module. Microcomputer 111 also monitors the photo-optical position and over travel limit switches used throughout the stitching module.
Microprocessor based controller 14 utilizes a bus architecture based upon Intel Corporation's multi-bus multi processor organization. The three microcomputers 109, 110 and 111, the system memory (8K ROM and 32K RAM not shown) and certain peripheral devices, such as the floppy disc, communicate with each other over this system bus. For critical applications, such as monitoring position or limit switches, typical I/O circuit cards, which do not pass data across the system bus but instead are wired directly to the particular microcomputer responsible for such function, are used.
System terminal 112 which is the main operator's interface for access to the control system, is a typical CRT terminal which communicates with the master control microcomputer through a typical interface circuit. In addition to system terminal 112, a small portable remote operator's control station 114 provides an operator with a convenient means of controlling the operation of the system from a remote position. Station 114 communicates with the master control microcomputer through a typical I/O circuit card which does not pass data across the system bus.
The executive operating system software for each microcomputer is located in on-board ROM. In the preferred embodiment this software is a package sold by Intel and is referred to as RMX-80. It can support a multitasking environment, real-time interrupt processing, system terminal communications, inter-task communications and disc file management. Because the functions performed by each microcomputer are different, slightly different versions of this package are used in each of the microcomputers.
Microprocessor based controller 14 is also capable of teaching itself the geometry and auxiliary motions necessary for stitching airplane parts which have not been previously stitched. For this self-digitizing function a digitizing control station 116 is provided to allow the operator to manually jog stitching head 8 along the paths on the workpieces to be stitched. Digitizing control station 116 is constructed with a number of function switches which when activated initiate through controller 14 the various functions associated with carrying out the self-digitizing function. In this mode of operation the stitching head is moved to various desired positions after which a digitizing program of the system operating through data control micro-processor 110 stores the coordinate values measured by the encoders of the X, Y, Z, alpha and gamma axes, and the positional information provided by the position switches of the beta axis and other functions.
Referring now to FIG. 7, to help the operator set up the stitching module during the digitizing function a visual aid in the form of a digitizing adaptor 120 is provided. Digitizing adaptor 120 is mounted on the same shaft 99 that mounts pressure roller 97. The adaptor has a pointer 121, attached to the end of shaft 99, which is used by an operator to position the stitching head 8. The adaptor also provides an operator with indications of stitching head normality to the surface of a workpiece and position with respect to the slots 63 of stitching rack 61. This information is used to position the stitching module for the self-digitizing function. The indication of normality is obtained through observing three small feet 122, each the size of a quarter, attached to the bottom of adaptor 120. By positioning all three feet on the surface of a workpiece simultaneously an operator can be reasonably assured that the stitching head is normal to the surface of the workpiece.
To compensate for an operator's positioning inaccuracies, digitizing adaptor 120 is also provided with a potentiometer 123 mounted in the middle thereof. Potentiometer 123 measures the height or elevation of the rack surface with respect to the stitching needle, and thereby provides a Z axis start position above the work surface for needle 9 prior to the start of the stitching operation.
For the digitizing function stitching module 1 is provided with a digitizing program. Through this program an operator is provided with the capability of easily generating new or editing existing part program files.
A flowchart showing the general routine followed by the digitizing program in creating a new parts program file is disclosed in FIG. 8. This routine is initiated as indicated at 130 by an operator request via digitizing control station 116 to create a new file. The CRT terminal is used to specify a particular name for the new file. In response to this request the master control microprocessor 109, which coordinates the execution of this routine, commands data control microprocessor 110 to create a new disc file, see 131. The data control microprocessor then creates a new file on one of the floppy discs of drive 113 for storing the parts program file. Thereafter, it informs the master control microprocessor of its completion (see 132). The master control microprocessor 109 then queries motor control microprocessor 111, as shown at 133, as to whether or not it is ready to begin the self-digitizing function. When motor control microprocessor 111 indicates it is ready, the operator manually jogs the coordinate position controlled axes to a new position, or alternatively positions the discrete axis via a manual jog function. When the operator is satisfied with the new position of the system, he commands the system to enter the new system position (see 134) by pressing a switch on control station 116 entitled "Enter Parts Program". The data control microprocessor 110 then enters the new position information into the new program file, after which data control microprocessor 110 indicates to master control microprocessor 109 that the information for that position has been stored and that it is ready to store the next position as shown in the flowchart at 135. At this point the operator can manually jog the system to the next position to be stored and repeat the storage request or he may end the routine.
A flowchart showing the general routine followed by the digitizing program in editing an existing parts program file is disclosed in FIGS. 9a and 9b. This routine is initiated by an operator request via system terminal 112 or control station 114 to edit a particular file (see entry at 140). In response to this request the master control microprocessor 109 commands the data control microprocessor 110 to open the existing disc file for reading and editing, and to create a new file area for the edited resulting file as indicated at 141. Data control microprocessor 110 then signals master control microprocessor 109 that the task is done (see 142). At this point the operator can start playing back the data in the file automatically by pressing a "Start" switch located on the digitizing control station. This causes master control microprocessor 109 to command data control microprocessor 110 to start removing data from the file, and to process and pass it to the motor control microprocessor (see block labled 143). The data controller continues to remove data from the file until it senses a stop command, identified at 144, from the operator issued via microprocessor 109. The operator enters this command when he has reached the point he wishes to edit, and he presses a "Stop" switch also located on control station 116. At this point the operator manually jogs the coordinate position controlled axes to a new position or, alternatively, positions the discrete axis via a manual jog function. Again, when the operator is satisfied with the new position of the system, he presses the "Enter Parts Program" switch on the control station to command the data control microprocessor to enter the new point into the file (see 145). Alternatively, he may remove the data just played back by pressing a "Remove Parts Program" switch on control station 116. Depressing the "Start" switch continues the play back sequence again as indicated at 146 in FIG. 9a. When the data control microcomputer reaches the last data point it indicates this to the operator (see 147, FIG. 9b). At this point the operator has the option of entering additional points (block 148) or closing the file (149) by pressing an "End" switch on station 116.
During the normal stitching operation the stitching module uses the data stored in a disc file during the digitizing steps described above. The stitching operation includes an automatic switch run wherein each point in a given file is taken out in order by the data control microprocessor 110. If the data is a jog function of a discrete position axis, the operation is performed by motor control microprocessor 111. If it is a position coordinate set, the data control microprocessor 110 does real-time calculations using a linear interpolation procedure to estimate the distance along the switching rack surface from its present position to the new coordinate location. This estimated distance is divided by a pitch length entered during the digitizing sequence. The resulting answer is the number of stitches to be placed between the present position and the next disc file position. The distance to be traveled by each axis is divided by the number of stitches just calculated. This results in an incremental motion requirement for each axis for each stitch. Repetitive application of the incremental values to all of the axes generates the positions of the stitches between the present location and the next digitized value. Using the two types of procedures, i.e., the jog functions for the discrete axis, or the real time stitch path calculations, an entire file is played back under control of the data control microprocessor 110, resulting in a workpiece being stitched according to the data stored in the disc file.
The above described embodiment of the invention is illustrative, and modifications thereof may occur to those skilled in the art. The invention is not limited to the embodiment disclosed herein, but is to be limited only as defined by the appended claims.
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A translaminar stitching module is disclosed for stitching complex airframe details comprised of composite materials. The stitching module is self-digitizing, microprocessor controlled, and has six degrees of motion which allow the module to stitch along straight, bowed, twisted and highly contoured paths. During the stitching operation positioning is controlled by a microprocessor by controlling movement along five of the module's six axes through the use of encoder feedback. Upon receipt of the encoded data a microprocessor interpolates between selected coordinate point inputs and inserts the required stitch pitch for proper movement along the stitching path.
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TECHNICAL FIELD
The present invention relates generally to endoscope devices and, more particularly, to a fiber optic periodontal endoscope instrument.
BACKGROUND ART
Presently the only way a dentist can see a tooth surface below the level of the gingiva is to anesthetize the patent and surgically expose the area. Normally the dentist does not choose to surgically expose a subgingival area. Instead, he tries to find calculus and foreign objects on tooth surfaces by feeling the surface with a sharp explorer instrument.
Periodontal probes for measuring the depths of pockets or recesses which form between the tooth and the gum and for use in endodontic techniques involving measurements of root canals are known. A periodontal endoscope called the Perioscope has been reported in the literature. This device utilizes a 1.2 mm diameter coherent fiber optic endoscope with a wide angle lens at its tip. Also attached to the tip is a 5 mm long guide plate which is used to retract the anesthetized gingiva of the patient being examined. The image in the Perioscope is viewed by the dentist by putting his eye to the lens at the other end of the Perioscope. The Perioscope allows visualization of both the root and the epithelial wall of the pocket at a 4× magnification. The device is described in the following journal article:
Matsumoto K., Nakano K., Kojima T.: Direct Observation of the Root Wall and Pocket Tissue, Quintessence Int. 19:483, 1988.
However, the foregoing Perioscope can be difficult to use due to an inability to adjust the position of the lens relative to the Perioscope body as well as the light beam emanating from the fiber optic probe tip. Another difficulty with the Perioscope is that the gingiva must be anesthetized and reflected before the root can be fully visualized.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to enable a dentist to see a tooth surface below the level of the gingiva without anesthetizing the patent and surgically exposing the area.
Another object of the invention is to enable the dentist to locate calculus and foreign objects on tooth surfaces without the use of sharp explorers.
Still another object of the present invention is to provide a fiber optic periodontal probe wherein the imaging lens and point of illumination emanating the probe are each easily and individually adjustable.
An additional object of the invention is to provide direct linear measurement of gaps in restoration margins and to find cracks in root surfaces.
Still another object is to provide a fiber optic probe having easily detachable fiber optic probe tips of varying cross-section to optimize the illuminated viewing area in relation to the size and topology of the surface over which the probe travels.
A fiber optic periodontal endoscope, in accordance with the present invention, comprises an assembly containing an image magnifying viewer and a light source. A handle containing a coherent fiber optic image conduit is connected to the assembly to transmit light from the light source to the surface of the tooth and to transmit the image of the tooth surface back to the assembly means. A tip containing a coherent fiber optic image conduit is connected to the handle for transmitting light and the image to and from the tooth surface.
The assembly may also include a mirror for reflecting the image from the coherent fiber optic image conduit in the handle up through a magnifier housing of the assembly. The magnifying viewer housing has an optical viewing axis which is at right angles to the optical axis of the image conduit in the handle.
The tip is preferably rotatably secured to the front end of the handle to permit rotation of the forwardmost end of the fiber optics in the tip about the longitudinal axis of the tip. The handle is also preferably rotatably secured to the assembly means to permit rotation of the magnifier about the longitudinal axis of the handle. In this manner, the positioning of the viewer is adjustable independent of the point of illumination of the tip.
The fiber optic bundle in the handle is preferably self-contained and therefore has opposite ends terminating at opposite ends of the handle and polished to an optical surface. Likewise, the fiber optics in the tip are preferably self contained therein with opposite ends terminating proximate opposite ends of the tip.
The rear end of the handle is received within a bore located in the front end of the assembly means. An annular boss of greater diameter than the rear end of the handle is seated against the front end of the assembly means and captured by a first threaded cap for rotatable mounting against the front end. The handle extends forwardly from the cap through a central opening in the cap end wall.
The front end of the handle is preferably bent at right angles to the handle longitudinal axis. The imager tip therefore extends at right angles to the handle longitudinal axis. The fiber optic bundle defining the forwardmost end of the imager tip is preferably bent through an additional 90° and optically finished to define a probe tip residing in a plane parallel to the longitudinal axis of the imager tip and perpendicular to the longitudinal axis of the handle.
The imager tip is formed with a collet having a tubular portion terminating in a rear annular boss rotatably mounted to the front end of the handle with a second threaded cap. The fiber optics in the imager tip extend through the collet with the rear end of the fiber optics being flush and mirror finished with respect to the rear end face of the annular boss. In this manner, the fiber optics in the handle and tip abut each other to permit reliable optical transmission of the image. If desired, an immersion oil may be disposed at the fiber optic interface between the handle and tip to minimize image degrading reflections.
Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein only the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a sectional view of a light and magnifying viewer assembly of the fiber optic periodontal probe of the present invention;
FIG. 2 is a sectional view of the handle of the probe;
FIG. 3 is an enlarged sectional view of the probe tip attached to the handle;
FIGS. 4 and 4A are bottom and side sectional views of one embodiment of a probe tip; and
FIGS. 5 and 5A are side and bottom sectional views of a second embodiment of a probe tip of the invention;
FIG. 6 is a side sectional view of a third embodiment of a probe tip;
FIG. 7 is a sectional view of a second embodiment of the light and magnifying viewer assembly depicted in FIG. 1.
DETAILED DESCRIPTION
A fiber optic periodontal endoscope 10, in accordance with the invention, is of three-part construction comprising a viewer and light assembly 12 (FIG. 1), a handle 14 (FIG. 2) attached to the assembly with a rotary joint 16, and a fiber optic tip 18 (FIGS. 3-6) attached to the front end of the handle with a rotary joint 20.
In FIG. 1, light is transmitted from a bulb 22 through a coherent fiber optic bundle 26 (e.g., 1.5 mm diameter) that makes a right angle bend at tip 25 (see FIG. 3) in the forward end of handle 14. The fiber optic bundle 26 is preferably optically mirror finished and terminates flush with opposite ends of handle 14. Light transmitted through fiber optic bundle 26 at the handle forward end 25 enters a second coherent fiber optic bundle 27 in probe tip 18. At the distal end 18a of the probe tip 18, the fiber optic bundle 27 makes another right angle bend so that the light travels out the side of the probe tip 18 rather than straight out the distal end. This allows illumination and visualization at the side of the tip 18a where it is most needed. The light then reflects off of the object being viewed creating an image which travels back along the fiber optic bundles 27,26. When the image reaches the magnifying viewer and light assembly, it is reflected by a front surface mirror upwardly through a lens holder 30 into, for example, a 23 mm focal length achromatic lens 32 providing approximately 4× magnification.
The viewer and light assembly 12, as depicted in FIG. 1, is formed from cylindrical rod stock having a rear cavity 34 open at the rear end thereof for receiving a light bulb 22 (e.g., 3 volt miniature flashlight bulb). Placed above this cavity is a front surface mirror 24 placed at a 45 degree angle from the long axis of the rod. The mirror is placed such that it keeps light from the light bulb from traveling directly up into the optics of the magnifier but still allows the image exiting the coherent image conduit in the handle to be viewed by the magnifying optics. The front end of the rod stock has a cylindrical cavity 38 which intersects the light bulb's cavity and the front surface of the mirror. Intersecting the intersection of these two cavities is a third cavity 36 which extends laterally from the front surface of the mirror opening to the side wall of the cylindrical stock. The rear end 26a of the fiber optic bundle 26 terminates flush with the rear end 14a of the handle 14 which is received within a longitudinally extending cylindrical passage 38 formed in a front end portion of the cylindrical stock extending forwardly of the beam splitter 24.
In FIG. 1, the forwardmost end of the stock is formed with a plurality of threads 40 cooperating with like threads 42 in the rotary joint 16. More specifically, the rotary joint 16 is in the form of a cylindrical cap 44 having a front end wall 46 with a central opening 47 through which the handle 14 extends and a rearwardly directed cylindrical cavity 48 of which the front end wall defines the bottom thereof. The cylindrical cavity inner side wall is formed with the threads 42 at its rearmost end while the bottom of the interior cylindrical side wall is of uniform diameter to receive an annular boss 50 of the handle (of greater diameter than the handle and corresponding to the diameter of the interior side wall). An O-ring 52 is captured between the boss 50 and front end wall 46 to give uniform resistance to rotations of the joint. A lock nut 43 keeps the cylindrical cap 44 from rotating when the joint is rotated.
In FIG. 1, extending laterally from the light assembly is magnifying viewer assembly 30 in the form of a cylindrical tube 54 having a central longitudinal axis L1 intersecting the reflection surface 24a of the mirror 24. The magnifier tube 54 contains lens 32 in its outer end which is adapted to receive the image reflected from the object being scanned.
Handle 14, as best depicted in FIG. 2, is an elongate member having a cylindrical surface 56 with annular boss 50 for rotatably securing the rear end of the handle to the assembly via rotary joint 16 in the manner described above. With reference to FIGS. 2 and 3, the front end of handle 14 is at right angles to the handle body and is formed with an exterior thread 58 for rotatably securing the imager tip 18 to the front end with rotary joint 20 in the manner described more fully below. The coherent fiber optic bundle 26 extends from a rear position flush with the rear end of the handle 14 through a central passageway formed in the handle and terminates flush with the front end 56a thereof. Both ends of the bundle 26 are orthogonal to the long axis of the bundle and polished to an optical finish. The rear end of the handle is beveled 28 at a 45 degree angle with the long axis of the handle to minimize light reflection from the rear end of the handle.
FIG. 3 is an illustration of an imager tip 18 with specific embodiments thereof depicted in FIGS. 4, 4A, 5, 5A, 5B, and 6. Common to each embodiment is a collet 60 in the form of a cylindrical sleeve (of stainless steel or plastic) having an annular boss 62 at the rear end thereof. A central longitudinal passageway 64 extends through the collet 60 and boss 62 to receive the fiber optic bundle 27 extending through the collet and terminating in a fiber optic tip 18a as depicted in FIGS. 4 and 5. The rotary joint 20 is defined by an internally threaded end cap 66 corresponding to the construction of cap 44 to rotatably secure the imager tip 18 to the front end 56a of the handle 14.
FIGS. 4, 4A, and 4B are illustrations of a rectangular probe tip which is essentially a coherent fiber optic bundle of rectangular cross-section (e.g., 1.0×0.5 mm) extending through the central longitudinal passageway of the collet of the imager tip 60 of like cross-section. The rear end 27a of this fiber optic bundle 27 is optically finished and flush with the base 65 of the collet 60 defined by the rear facing surface of the annular boss 62. The fiber optic bundle 27 may be coated with a thin plastic coating 68 which holds the glass fibers 69 together in case they are broken. The forwardmost end of the fiber optic bundle 27 makes a right angle bend at 70 and is cut off flush with the side of the bundle. The final 9 mm of the probe tip may be coated alternating black and white at 3 mm intervals for use by the dentist as a depth reference.
The following dimensional characteristics may be used in conjunction with the imager tip of FIG. 4:
Dimension A=20 mm
Dimension B=14 mm
Dimension C=6 mm
Dimension D=0.5 mm
Dimension E=1.0 mm
Dimension F=3.0 mm
Dimension G=0.130 in.
Dimension H=0.080 in.
Dimension I=0.040 in.
FIGS. 5 and 5A are illustrations of a second embodiment of an imager tip wherein the collet of FIG. 4 is used to contain a round fiber optic probe tip 67 defined by a coherent fiber optic bundle of cylindrical cross-section (FIG. 5A) extending through a central longitudinal passageway 64' of the collet of like cross-section and terminating at its forwardmost end in a right angle bend at the tip which is cut off flush with the side of the bundle to define the round tip 67. This fiber optic bundle may be placed inside a thin walled hypodermic needle tubing 75 (e.g., 22 gauge, thin wall and 0.7 mm outer diameter to allow a 0.5 mm fiber optic bundle to be placed inside). The feature of using needle tubing 75 makes this probe tip much more rugged and also allows better control of the glass fragments should the fiber optic glass shatter.
The following dimensional relationships apply with respect to the FIG. 5 probe tip:
Dimension AA=20 mm
Dimension BB=11 mm
Dimension CC=9 mm
Dimension DD=3.0 mm
Dimension EE=0.5 mm
FIG. 6 is an illustration of a third embodiment of an imager tip. In this tip, stainless steel tubing 75 (e.g., 5/64 inch, 0.012 inch wall) has an annular boss equivalent to the one in FIG. 4 brazed to the end of the tubing effectively making the entire tube a collet. A coherent fiber optic imaging bundle 27 fills the rear portion of the tube. A self-focusing rod lens (e.g., Nippon Sheet Glass SELFOC imaging lens) forms a butt joint with the end of the imaging bundle and is epoxied to the bundle with optical epoxy. The lens acts as a wide angle lens with a 5 mm focal length. This probe can be used to view the interior of extraction sockets or other areas that are commonly hidden from view in the oral environment.
FIG. 7 is an illustration of a second embodiment of the rotary joint shown in FIG. 1. In this embodiment the handle is retained by two ball plungers 84. The balls of which snap into a detent groove 85 placed on the shaft of the handle. This allows easier assembly and disassembly of the endoscope, simplifies manufacturing, and acts as a stress breaker if the endoscope is dropped.
The primary advantage of the fiber optic periodontal probe 10 of this invention is that it enables a dentist to visualize the surfaces of a crown, root and sulcus at a predetermined magnification (e.g., 4×) without the need for anesthesia or reflecting a flap. The ability to view the inner surface of the periodontal sulcus may prove helpful in diagnosis of incipient soft tissue pathology. Other possible uses would be to directly examine crown margins and to make sure crown margins are below existing restorations. The device may prove useful in visualizing vertical fractures of the crown and root. It may also be possible to directly view the interproximal surfaces of the teeth directly below their contact points and look for interproximal decay.
By placing a small bend in the currently designed end-looking probe tip of FIG. 6, a curved end-looking probe tip could be produced. This probe tip could prove valuable in periodontal surgeries to view areas of the root surface which are impossible to see otherwise, such as beneath the furcation. In another modification, the use of a smaller diameter rod lens would allow fabrication of a probe tip capable of being introduced into root canals. Various such modifications are believed obvious to one of ordinary skill from reviewing this disclosure.
The rotating joint 16 between the viewer and light assembly 12 and the handle 14, allows the active area of the probe tip 18a to be rotated in any direction about the longitudinal axis L of the handle to enable the operator to swivel the lens 32 around so that he can position the lens for ease of viewing. The lens 32 is focused so that the operator can see the image at a distance of 0-100 cm from the magnifying lens. Adding different lens combinations can increase magnification, as desired by the operator.
The front rotary joint 20 between the imager tip 18 and handle 14 allows the active area of the probe tip to be rotated in any direction about the longitudinal axis of the collet 60 so that the operator can visualize any surface of the tooth or sulcus.
Immersion oil 80 may be used to minimize image degrading reflections at each fiber optic interface.
The rectangular fiber optic tip 82 of FIG. 4 allows the operator to view a 1×0.5 mm area of the tooth or sulcus surface. The round probe tip of FIG. 5 allows the operator to view a 0.5 mm area on the tooth surface. Both of these views are a small area of the tooth surface and if placed in only one spot would probably provide very little information to the operator. However, the real information is gained as the operator moves the probe around the tooth's surface and watches the surface through the probe during such movement.
It will be readily apparent to one of ordinary skill in the art that the present invention fulfills all of the objects set forth above. After reading the foregoing specification, those skilled in the art will be able to effect various modifications, changes, substitutions of equivalents and various other aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only by the scope of the invention as set forth in the appended claims and equivalents thereof.
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A fiber optic periodontal endoscope includes a lens and light housing assly attached to a handle end tip containing fiber optic bundles transmitting light from the source to illuminate the probe tip. The returning image traveling back through the handle along the fiber optic bundle is reflected off a mirror toward the magnification lens housed in a portion of the assembly which is at right angles to the light housing portion. The probe has two rotating joints, one between the tip and handle and the other between the assembly and handle to enable rotation of the lens for ease of viewing and additional rotation of the probe tip to allow for illumination and visualization at the side of the tip.
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STATEMENT OF GOVERNMENTAL INTEREST
The Government has rights in this invention pursuant to Contract No. N00024-81-C-5301 awarded by the Department of the Navy.
BACKGROUND AND/OR ENVIRONMENT OF THE INVENTION 1. Field of the Invention
The present invention pertains generally to an apparatus and method of intercomputer communication, and more particularly to a low level message filter which provides content tag recognition and selection independent of the higher level processing occurring in an individual computing element. 2. Description of the Contemporary and/or Prior Art
As a result of the recent advances in solid-state circuit technology, distributed computer systems, using many smaller processors, is becoming a practical alternative to the highly centralized large-computer systems currently in use. Increased throughput, fault tolerance, inherent software modularity, and ease of system expansion are often mentioned as potential advantages of distributed over centralized architectures. However, most of the many possible distributed architectures are untried and, in general, each trades some advantages for others. Therefore, ease of system expansion, enabling one to accommodate many different computing elements on the same bus, is of particular interest.
Current distributed systems are costly to expand and upgrade and often require significant software module redesign and hardware interface redesign. The prior art does not teach a method of intercomputer communication which facilitates the integration of new systems with existing systems, and does not teach hardware message filtering responsive to the content of the data message.
Prior art devices, such as disclosed in U.S. Pat. No. 4,123,796 issued Oct. 31, 1978 to J. Y. Shih, utilize a transceiver connected to a data bus for communicating with a plurality of control devices. In the one-to-many communications system as taught by Shih, each module is given a unique address and the transceiver prefixes each data message by the address of the module, or modules, with which it wishes to communicate. The Shih reference does not teach the use of a content tag which allows each computer element to selectively receive data messages based on the relevancy of these date messages to the software modules processed by the computing element.
Similarly, U.S. Pat. No. 4,019,176 issued on Apr. 19, 1977 to Cour et al describes an intercomputer communication scheme in which all stations receive and select messages based on a "destination address code". The reference does not teach receiver selection based on the content of the data message.
The prior art does not teach the use of a low level message filter which processes content tags independent of the higher level processing occurring in an individual computing element.
SUMMARY OF THE INVENTION
The present inventor recognized that intercomputer communication for an extensible or a distributed computing system would best be accomplished by receiver selection of data messages based on the content of those messages. Similarly, the present inventor recognized that a low level message filter could process the content tags independent of the higher level processing occurring in each computing element.
As taught by the present invention, a "sending computing element" transmits a data message prefixed by an n-bit content tag. The content tag classifies the data message in terms of its content. The content tag is transmitted over the common broadcast bus to a set of independent computing elements. Each computing element is loaded with software processes, each of which has certain data requirements. A hardware message filter, associated with each computing element, is responsive to the content tags, and flags the computing element when a data message appears over the common broadcast bus which has relevance to its software. The message filter can be preset or dynamically programmed by the computing element as its data requirements charge.
An example might better explain the advantages of message broadcasting with receiver selection. A distributive computing system used in a grocery store chain might contain a series of independent computers, with each computer having one or more designated functions, i.e., a first computer calculates total sales tax, a second computer keeps track of can goods inventory, and a third computer keeps track of household inventory. A cash register or terminal would transmit data messages prefixed by a content tag. Each computing element would have a message filter which selects only data messages relevant to its unique function. If a household product was sold, for example, the first computer would like to know so that it could keep track of total sales tax, and a third computer would like to know so it could keep track of household inventory. The cash register or terminal need not know what computing system requires the data, as with the prior art devices.
In order to accomplish "receiver selection" in an efficient manner, the present invention discloses a low level message filter which operates independent of the higher level processing occurring in the computing element. The content tag is used by the message filter to address a memory unit. Each memory location addressed by a content tag is pre-loaded with a "1", if the content tag is relevant to the particular computing element, or "0" if the content tag corresponds to a data message which is irrelevant to software routines processed by the particular computing element. (It is within the contemplation of this invention to identify a relevant content tag by storing a value other than "1" in the particular memory location; the choice of "1" is arbitrary.)
The message filter can consist of a preset memory unit or a dynamically programmable memory unit. The preset version basically comprises a ROM connected to the common broadcast bus and addressed by the content tag. An enable control line enables the memory unit when a content tag appears over the common broadcast bus. If a memory location addressed by the content tag contains a "1" the computing element is alerted that a relevant data message will appear on the broadcast bus during the current message transfer cycle and provisions are made by a bus interface unit to transfer the data directly into the computer's memory.
A dynamically programmable message filter is also envisioned by the present invention, and generally comprises: a read/write memory; and an arbiter means and a multiplexer means which jointly cooperate to operably multiplex the n-bit address line between the common broadcast bus and the particular computing element. The computing element can address each memory location and program that location with "1" or a "0" to designate relevant content tags. When a content tag appearing over the common bus addresses a particular memory location set with a "1", a flag alerts the computing element to receive relevant data; if, however, the addressed memory location stores a "0" the data is not retrieved.
The invented dynamically programmable message filter uniquely allows software extensibility. Each computing element is loaded with software which includes one or more broadcast element modules and an executive module. Each broadcast element module is an independent software module which has specific data message requirements and which can be loaded in any host computing element capable of executing the computer program. The software module alerts the executive module of its data requirements which in turn programs the message filter to identify certain corresponding content tags. In this manner, a particular software module need not know the identity of its current host computing element, or the identity of computers hosting other software modules in the system. The invented system architecture will permit any program to be performed by any equally capable computer.
The invented method and apparatus can be used with either a parallel or a serial common broadcast bus. Similarly, other modifications are contemplated including a memory location storing m-bits for each of the possible 2 n messages allowing further classification or prioritizing of the data messages.
A first object of the present invention is to provide a method and apparatus for intercomputer communication based on message broadcast with receiver selection.
A second object of the present invention is a use of a content tag which allows receiving computing elements to select data messages based on the content of those data messages.
A third object of the present invention is the use of a low level message filter which provides content tag recognition and selection independent of the higher level processing occurring in the individual computing element.
A fourth object of the present invention is the use of a ROM memory unit, preset to select particular content codes.
A fifth object of the present invention is the use of a dynamically programmable memory unit, which is programmable by the computing element to select different content codes to satisfy changing software requirements.
A sixth object of the present invention is the use of a dynamically programmable message filter, which allows an extensible modular software architecture.
These objects, as well as other objects and advantages of the present invention will become readily apparent after reading the ensuing description of several non-limiting illustrative embodiments and viewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a distributive computing system using the invented intercomputing scheme;
FIG. 2 is a block diagrammatic view of a preset message filter using a ROM memory unit;
FIG. 3 is timing diagram for the preset message filter;
FIG. 4 is a block diagram of a dynamically programmable message filter;
FIG. 5 is timing diagram illustrating the operation of the common acknowledgement control line; and,
FIG. 6 is a block diagram of a dynamically programmable message filter used in combination with a serial broadcast bus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the invented distributed computer system in block diagrammatic form. Each computing element 10 can transmit and receive information over common broadcast bus 12. For purposes of illustration, computing element 14 is acting as a "sending computer" and is broadcasting a message along the broadcast bus 12. The "sending computer" gains access to the broadcast bus using one of the existing arbitration schemes. The message is prefaced with a content tag which identifies the subject content of the message. Each computing element contains a message filter which identifies content tags and accepts only those data messages associated with content tags relevant to software modules resident within that computing element. The message filter is a low level data filter which provides content tag recognition and selection independent of the higher level processing occurring in the host computer. Such a hardware message filter processes content tags more efficiently than higher lever processing. The message filter can be preset to select only certain content tags or can be dynamically programmed by the host computing element 10 to select certain content tags. The "sending computer" 14 need not know what, if any, computing elements will be receiving the message. Conventional systems required the "sending computer" to know and designate each receiving computer.
FIG. 2 is block diagram of the message filter according to the present invention which is preset to respond to certain content tags. The message filter 16 connects to the broadcast bus 12, which in this embodiment is a parallel bus, and to a DATA/CONTENT control line 18. The message filter 16 generally contains a memory unit 20 which can be a read only memory (ROM) comprising a single or a plurality of memory chips. The DATA/CONTENT control line 18 is actuated by the "sending computer" 14 when the broadcast bus 12 is loaded with a content tag, which in turn enables memory unit 20. (If, memory unit 20 is a single ROM chip, the DATA/CONTENT control line could connect to the chip enable line). When memory unit 20 is enabled, the common parallel data bus connects directly to the n-bit address line 22 of memory unit 20. After the memory unit 20 is enabled, the content tag appears over the parallel common data bus 12 and addresses a particular location in memory unit 20. The memory unit 20 has a "1" or "0" stored in each memory location which indicates the relevance of that content tag to the host computing element. Data read from memory unit 20 appears along the Received Message line 24. If the content tag addresses a memory location storing a "0", the Message Receive line is not asserted; if, however, the content tag identifies a memory location storing "1", the Receive Message line 24 will be asserted. When the Receive Message 24 is asserted, the bus interface unit of the host computing element 10 will then prepare to receive the data message that will be subsequently transmitted over broadcast bus 12.
FIG. 3 is, by way of example, a timing diagram illustrating the operation of the message filter. The DATA/CONTENT control line goes low when a content tag is on the bus and enables the memory unit. When the memory unit identifies a relevant content tag, the Receive Message flag line goes high. After receiving the Receive Memory flag, the computing element prepares to receive the data.
FIG. 4 is a block diagrammatic view of a dynamically programmable message filter as taught by the present invention. The dynamic message filter generally comprises: an arbiter 26 connected to control bus 27 for arbitrating access to the message filter memory unit 30; a multiplexer 28 controlled by arbiter 26 and connected to the broadcast bus 12 and the host computing element 10 for allowing either the host computing element 10 to read or write onto the memory unit 30, or allowing the parallel broadcast bus 12 access to the n-bit address line of the message unit 30; and, a programmable read/write memory unit with each memory address dynamically programmable.
Arbiter 26 is a digital logic arrangement which receives as input the DATA/CONTENT control line 18 and an Access Request 32 from host computing element 10. The Access Request flag 32 is generated by a Message Filter Address Decoder 34 which operably connects to the host computing element 10 via address bus 36. The arbiter 26 has two output lines which operably connect to multiplexer 28. When line 38 is asserted multiplexer 28 allows the host computing element 10 access to memory unit 30; alternatively, when control line 40 is asserted multiplexer 28 enables the broadcast bus to connect to the n-bit address line associated with memory unit 30. The arbiter 26 also asserts a Content Tag Acknowledgement flag over an open common collector acknowledgement line 42. The Content Tag Acknowledgement flag 42 is asserted by arbiter 26 after the message filter associated with that particular host computing element has reviewed the content tag currently on the common data bus 12. The "sending computer" waits for acknowledgement from each receiving computer before the data message is transmitted. The Content Tag Acknowledgement flag 42 is asserted by each computing element whether or not it desires to receive the particular data message.
FIG. 5 illustrates the operation of the Content Tag Acknowledgement control line. The DATA/CONTENT control line 18 goes low when a content tag appears on the common data bus 12. Each computing element asserts a positive acknowledgement signal when its corresponding message filter has processed the content tag. When all the acknowledged signals are high, the common acknowledgement line 44 goes high. When the common open collector acknowledgement line 44 goes high, the "sending computer causes the DATA/CONTENT line to go high and transmits the data message over the common data bus 12.
Referring to FIG. 4, multiplexer 28 receives as inputs an n-bit wide content tag 46 appearing on broadcast bus 12; a read/write (R/W) control signal 48 from computing element 10; a n-bit address line 50 from computing element 10 for accessing memory locations in memory unit 30; and, a data bus 52 associated with computing element 10 for reading data from or storing data in memory unit 30. Multiplexer 28 is controlled by control lines 38 and 40 from arbiter 26, which directs the multiplexer to either allow the R/W control line 48, data bus 52 and address bus 50 assess to memory unit 30; or alternatively, allow the n-bit wide content tag 46 access to the memory unit's n-bit address line 56. Multiplexer 28 provides as output: R/W 54 which allows the host computing element 10 to read out or write data into the memory unit 30; a n-bit address line 56 for accessing a particular memory location in the memory unit 30; a data bus 58 which allows the host computing element 10 to record data into or read data from a particular memory location; and, an INT flag 60 which is asserted when a content tag address a memory location containing a "1". The INT flag 60 causes the bus interface unit of the computing element 10 to transfer data directly into the computer's memory and to commence processing message data which will subsequently appear on the common bus 12.
The memory unit 30 is a 2 n ×1 programmable read/write memory. It is dynamically programmed by the host computing element 10 so that a memory location addressed by a particular content tag can be programmed to a "1" if the data is relevant, and a "0" if the date is not relevant. Data stored in the memory location is sent to the multiplexer 28 via line 56. A "1" asserted along line 56 causes multiplexer 28 to assert an INT flag 60 which instructs the host computer 10 to commence processing message data which will subsequently appear over common bus 12.
Although the embodiment shown in FIG. 4 contains a 2 n ×1 memory unit, it is within the contemplation of this invention to use a 2 n ×m message filter. The m-bits stored in each memory location will include the bit discussed above plus additional bits which provide further filtering based on priorities, message classification and/or and access privileges. The additional stored bits can be processed by computing element 10 or by additional hardwire filtering as taught by this invention.
In operation, the host computing element can dynamically program the message filter to respond to selected content tags as required by software modules resident in that computing element. To accomplish this the host computing element 10 (through an executive software module) first addresses the message filter along address bus 36. In response to this address, Message Filter Address Detector 34 actuates an Access Request flag 32, thereby directing arbiter 26 and multiplexer 28 to provide the host computing element 10 with access to memory unit 30. arbiter 26 may delay the host computing element's request if a content tag is also available over data bus 12. Once the host computing element 10 has access to the memory unit, data line 52, address bus 50, and R/W control line 48 are used in a conventional manner to read data from or write data into a particular memory location.
After the filter is dynamically programmed to respond to selected content tags, the memory filter proceeds to alert the when selected data messages appear on the common bus 12. In operation, the arbiter 26, in accordance with its arbitration schedule, will assert the bus control flag 40, when the DATA/CONTENT line goes low. In response to the flag 40, multiplexer 48 operably connects the common bus 12 to the n-bit address line 56 associated with memory unit 30. The data ("1" or "0") stored in the memory location which is selected by the control tag address, will appear as an output along line 58. If the host computing element 10 desired to receive the data message associated with a particular content tag a "1" would be stored in the memory location addressed by that content tag. When the memory location is addressed by that content tag, INT flag 60 will become asserted, notifying the host computing element 10 to commence processing the message data which will appear over broadcast bus 12 during the current data cycle.
FIG. 6 is a block diagrammatic representation of a dynamic memory filter used in combination with a serial broadcast data bus. In this embodiment an n-bit serial to parallel converter 64 receives as inputs: a start content tag control line 66; and, serial data transmitted over serial bus 62. The n-bit serial to parallel converter 64 provides an n-bit wide content tag address as an output which is operably connected to multiplier 28. Multiplexer 28, arbiter 26, Message Filter Decoder 34 and memory unit 30 operate similar to that previously described in this specification. In operation, the Start Content Tag 66 actuates the n-bit serial to parallel converter 64 when the serial bits representing a content tag data is transmitted along the serial data bus 62. The n-bit serial to parallel converter 64 thus converts the serial bits received into a parallel format. It will be noted that either a preset message filter or a programmable message filter can be used in conjunction with a serial bus.
It will be understood that various changes in the details, arrangement of parts, and operable conditions which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principles and scope of the present invention.
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An apparatus and method of intercomputer communications based on message broadcast with receiver selection is taught. A distributed computer system is described in which each computing element includes a hardware message filter which provides content tag recognition and selection. The overall system architecture allows software modularity and both hardware and software extensibility. The message filter can be preset or dynamically programmed, and can be operated in conjunction with a serial or parallel broadcast bus.
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FIELD OF THE INVENTION
[0001] The present invention relates to a waveguide structure; more particularly relates to diminishing a scattering of optical power, increasing an alignment tolerance for a production, lessening a polarization sensitivity, and improving a yield of a cleaving process.
DESCRIPTION OF THE RELATED ARTS
[0002] A prior art is revealed in a U.S. Pat. No. 6,483,863, “A symmetric waveguide electro-absorption-modulated laser”, which is an adjustable laser device with more than two stacked layers of asymmetric optical waveguides. An optical waveguide layer of the laser device is a growth region to enhance a first optical mode; and, the other optical waveguide layer connected with the previous optical waveguide layer is a modulator having a second optical mode with an effective refractive index different from that of the first optical mode. A light is transmitted from the previous optical waveguide layer through a cone at a side.
[0003] Please refer to FIG. 8 , general waveguide structures used in gradual-coupling side-illuminating photo detectors may be divided into two categories. One category is an asymmetric twin waveguide (ATG) having two layers. The bottom layer in the waveguide structure of the ATG is a layer of an optical fiber waveguide 19 for collecting optical power. The top layer is a layer of an optical coupling waveguide 20 for shifting the position of the optical power. In order to obtain the same responsivities for the two optical modes, not only a special design is done to the refractive index of the epitaxy layer; but also a geometric cone-shaped structure is used for defining to increase light absorbing are a and to effectively absorb optical power with a small area of an absorbing layer. However, a waveguide structure having two cone-shaped layer is hard to be fabricated because it is difficult to align the two layers of optical waveguides; and, a great scattering loss to the optical power occurs during its transmission in the cone-shaped structure. Please refer to FIG. 9 , which is a view of a refractive index curve for various epitaxy layer thicknesses, including an epitaxy layer thickness for an optical fiber waveguide 21 and that for an optical coupling waveguide 22 . Please refer to FIG. 10 , which is a view of distributions of optical power simulated by using a beam propagation method (BPM). Regarding the distribution of total optical power 23 , twenty percent of power loses at the first 500 μm in the front although with a good exchanging rate between the energy distribution of the optical fiber waveguide 24 and the energy distribution of the optical coupling waveguide 25 under a prerequisite of two precisely aligned optical waveguides; and, an energy distribution of an absorbing layer 26 is included. The length of the optical fiber waveguide 27 is 100 μm; the length of the optical coupling waveguide 28 is 400 μm; and, the waveguide length for the absorbing layer 29 is 50 μm.
[0004] However, another category of a waveguide structure of a short planar multimode waveguide (SPMG) is revealed. Please refer to FIG. 11 , which is a sectional view of a second prior art of SPMG, which comprises a substrate 30 , an undoped optical waveguide layer 31 , a first N-doped optical matching layer 32 , a second N-doped optical matching layer 33 , an absorbing layer 34 and a P-doped layer 35 . An optical fiber waveguide and an optical coupling waveguide are combined with an epitaxy structure; and, through a design of a very short distance for the oscillation cycle of optical power, the scattering of the optical power is reduced and the difficulties for a production is diminished. However, because the shape of the optical waveguide is not defined through etching, several adjustable factors are omitted in a design and so difficulties are increased on considering both of the responsivity and the polarization sensitivity. Thereby, the precision of the cleaving during its process strongly affects its responsivity. Please refer to FIG. 12 and FIG. 13 , which are views of the distributions of optical power under a TE mode and a TM mode, comprising curves of total energy distributions 36 a , 36 b and curves of energy distributions of optical fiber waveguides 37 a , 37 b , optical coupling waveguides 38 a , 38 b and waveguides for absorbing layers 39 a , 39 b , where lengths of the fiber waveguide and the coupling waveguide 40 are both 20 μm and waveguide lengths for absorbing layers 41 are 20 μm too.
[0005] Although the scattering of optical power is diminished and the difficulties for a production are reduced by using the above prior arts, good exchange rates, low polarization sensitivity and improved yield for cleaving process are all in lack. Hence, the prior arts do not fulfill users' requests on actual use.
SUMMARY OF THE INVENTION
[0006] The main purpose of the present i n v e n t i o n is to improve a y i e I d of a cleaving process, to lessen difficulties for a production, to diminish scattering of optical power on shifting, and to obtain a high optical responsivity and a low polarization sensitivity.
[0007] To achieve the above purpose, the present invention is a waveguide structure having a ladder configuration, comprising a first optical waveguide layer, a second optical waveguide layer and a third optical waveguide layer, where the first optical waveguide layer is a layer of an optical fiber waveguide to collect optical power; the second optical waveguide layer is a layer of a coupling waveguide located away from a cleaving surface between the first optical waveguide layer and the third optical waveguide layer for transferring the position of the optical power into the third optical waveguide layer with the same width of the second optical aveguide layer as that of the first optical waveguide layer to obtain an easy production; and the third optical waveguide layer is an active region having a characteristic of absorbing optical power. Accordingly, a novel waveguide structure having a ladder configuration is obtained.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0008] The present invention will be better understood from the following detailed descriptions of the preferred embodiments according to the present invention, taken in conjunction with the accompanying drawings, in which
[0009] FIG. 1A is a sectional view showing a first preferred embodiment according to the present invention;
[0010] FIG. 1B is a sectional view showing a second preferred embodiment;
[0011] FIG. 2 is a sectional view showing an application of the first preferred embodiment as a photo detector having a distributed Bragg reflector;
[0012] FIG. 3 is a view showing curves of optical power distributions under a TE mode simulated by using a BPM method;
[0013] FIG. 4 is a view showing the curves under a TM mode;
[0014] FIG. 5 is a view showing distributional curves of total optical power at various cleaving positions under different polarization modes;
[0015] FIG. 6 is a view showing the curves with various incident wavelengths;
[0016] FIG. 7 is a top view showing an application as a photo detector;
[0017] FIG. 8 is a perspective view of a first prior art of ATG;
[0018] FIG. 9 is a view of a refractive index curve for various epitaxy layer thicknesses;
[0019] FIG. 10 is a view of distributions of optical power simulated by using the BPM method;
[0020] FIG. 11 is a sectional view of a second prior art of SPMG;
[0021] FIG. 12 is a view of the distributions of optical power under a TE mode; and
[0022] FIG. 13 is a view of the distributions under a TM mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The following descriptions of the preferred embodiments are provided to understand the features and the structures of the present invention.
[0024] Please refer to FIG. 1A and FIG. 1B , which are sectional views showing a first preferred embodiment and a second preferred embodiment according to the present invention. As shown in the figures, the present invention is a waveguide structure having a ladder configuration, comprising a substrate 1 , a first optical waveguide layer 2 , a second optical waveguide layer 3 and a third optical waveguide layer 4 , where the first optical waveguide layer 2 , the second optical waveguide layer 3 and the third optical waveguide layer 4 are stacked on the substrate 1 forming a ladder configuration; the first optical waveguide layer 2 is covered on the substrate 1 ; the second optical waveguide layer 3 is covered on the first optical waveguide layer 2 ; and the third optical waveguide layer 4 is covered on the second optical waveguide layer 3 . The substrate 1 is a layer of a doped or semi-insulated semiconductor, made of GaAs, InP, GaN, AlN, Si or GaSb. The first optical waveguide layer 2 , the second optical waveguide layer 3 and the third optical waveguide layer 4 are each a layer of a compound or a compound alloy, where the compound is GaAs, InP or GaN; and the compound alloy is AlGaN, InGaN, InGaAs, InGaAsP, InAlAs, InAlGaAs, GaAs or AlGaAs. Or, the first optical waveguide layer 2 , the second optical waveguide layer 3 and the third optical waveguide layer 4 are each a layer of a column IV element or an alloy of a column IV element, where the column IV element is Si; and the alloy of a column IV element is SiGe.
[0025] The first optical waveguide layer 2 is a layer of an optical fiber waveguide for collecting optical power, shaped into a square with a length longer than 160 micrometer (μm) and not longer than a length between 200 μm and 300 μm to provide a high cleaving tolerance. The width of the first optical waveguide layer 2 is around several micrometers for collecting most of the optical power. The first optical waveguide layer 2 is obtained by using a material having a lower refractive index 201 inter-inserted with layers of a material having a higher refractive index 202 . The layers of the material having the higher refractive index 202 can grows thicker and thicker from bottom to top; or, the first optical waveguide layer 2 a can be a single layer of a material having a slightly higher refractive index than that of the substrate 1 (as shown in FIG. 1B ). With the width of the first optical waveguide layer 2 , 2 a , most of the optical power is collected.
[0026] The second optical waveguide layer 3 is a layer of a coupling waveguide to transfer the position of the optical power collected by the first optical waveguide layer 2 into the third optical waveguide layer 4 . The second optical waveguide layer 3 is deposed between the first optical waveguide layer 2 and the third optical waveguide layer 4 and is located away from the cleaving facet 101 to improve the yield of the cleaving process. The second optical waveguide layer 3 is shaped into a square with a length between 20 μm and 60 μm and a width as wide as that of the first optical waveguide layer 2 for an easy fabrication. The second optical waveguide layer 3 can be a single layer or multi-layers of a material having a higher refractive index. For example, the substrate 1 can be made of InP and the first optical waveguide layer 2 can be made of InGaAsP, where a refractive index is obtained by adjusting the mole fraction of phosphorus. Then, the thickness and the refractive index of the second optical waveguide layer 3 is determined to obtain a better efficiency of shifting.
[0027] The third optical waveguide layer 4 is an active region having a light-absorbing material; or, can be replaced with a device of a photo detector or a light modulator having a structure of P-doped—undoped—N-doped (P-I-N), where the light-absorbing material is made of a P-doped or undoped material Please refer to FIG. 2 , which is a sectional view showing an application of the first preferred embodiment as a photo detector having a distributed Bragg reflector. As shown in the figure, multi-layers of optical reflection films or distributed Bragg reflectors 5 fabricated through a lithography can be grown behind the photo detector. After an absorption of optical power, remaining optical power is reflected by the distributed Bragg reflector 5 to improve the product of the efficiency and the bandwidth. Thus, a novel waveguide structure having a ladder configuration is obtained.
[0028] Please refer to FIG. 3 and FIG. 4 which are views showing curves of optical power distributions under a transverse electricwave (TE) mode and under a transverse magneticwave (TM) mode simulated by using a beam propagation method (BPM). As shown in the figures, views showing the distributions of optical power under a TE mode and a TM mode simulated by using a BPM method are obtained. Distribution curves shown in the figures comprise total energy distribution curves 6 a , 6 b and energy distribution curves for optical fiber waveguides 7 a , 7 b , coupling waveguides 8 a , 8 b and waveguides in active regions 9 a , 9 b . The length of a first optical waveguide layer 10 according to the present invention is 260 μm; a second 11 , 40 μm; and, a third 12 , 20 μm. With such a structure, distributions of optical power under various modes are simulated; and, almost the same absorbing efficiencies are found. Hence, it is known that such a structure is not sensitive to polarization. Furthermore, a high responsivity and a low polarization sensitivity is obtained by precisely adjusting the length and the structure of the coupling waveguide of the second optical waveguide layer 3 with no regard to the cleaving position.
[0029] Please refer to FIG. 5 , which is a view showing distributional curves of total optical power at various cleaving positions under various modes (TE, TM). As shown in the figure, curves of distributions of total optical power at various cleaving positions under various modes simulated by using the BPM method are obtained. Distributional curves in the figure show total energy distributions under a TE mode 13 a and a TM mode 14 a . Accordingly, the present invention has a structure with similar cleaving positions and similar related responsivities under various modes.
[0030] Please refer to FIG. 6 , which is a view showing the curves with various incident wavelengths. As shown in the figure, views showing the distributions of optical power with various incident wavelengths under various modes simulated by using the BPM method are obtained. Distribution curves in the figure show total energy distributions under a TE mode 13 b and a TM mode 14 b . As is shown in the figure, the structure of the present invention has small differences over responsivities for various incident wavelengths under various modes with regard to the changes in the wavelengths; and, so, the shifting efficiency of optical power is improved for being applied to a coarse wave division multiplexing (CWDM) system.
[0031] Please refer to FIG. 7 , which is a top view showing an application to a photo detector. As shown in the figure, the present invention is applied to a photo detector or a light modulator with a structure of P-doped 15 —undoped—N-doped 16 . The coupling waveguide of the second optical waveguide layer has an optical square mask 17 to increase an alignment tolerance for a production. The length of the optical fiber waveguide of the first optical waveguide layer is longer to provide; higher cleaving tolerance so that the optical power is steadily transferred at the cleaving position 18 with no loss owing to scattering. The waveguide structure of the present invention can be constructed with a photo detector of a uni-traveling carrier photo detector (UTCPD) or an avalanche photo detector (APD) to obtain a side-illuminating photo detector.
[0032] To sum up, the present invention is a waveguide structure having a ladder configuration, where a scattering of optical power is lowered; an alignment tolerance for a production is increased; a sensitivity polarization is lessened; and a yield for a cleaving process is improved.
[0033] The preferred embodiments herein disclosed are not intended to unnecessarily limit the scope of the invention. Therefore, simple modifications or variations belonging to the equivalent of the scope of the claims and the instructions disclosed herein for a patent are all within the scope of the present invention.
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A waveguide structure is formed in the present invention. With the structure, a yield of a cleaving process is improved. A high responsivity and a low sensitivity can be achieved. And an error tolerance for a production is also increased. The present invention can be applied to optoelectronic elements, such as an optical diode and a light modulator.
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BACKGROUND OF THE INVENTION
This invention relates to an apparatus for spreading and feeding laundry flat work pieces before feeding them to subsequent processing equipment.
U.S. Pat. No. 4,106,227 assigned to the present assignee discloses a spreader feeder apparatus for spreading laundry flatwork pieces before feeding them to subsequent processing equipment. Separate pairs of flatwork clamps are normally located respectively at the left end, middle and right end of the apparatus. The left end and right end clamps are movable straight across the entry side of the apparatus to the middle before being spread apart. The paired clamps operate to spread their respective flatwork pieces in the order in which their respective start switches are operated manually. Interference among the paired clamps or between clamps of each pair is prevented. No intermediate flatwork transfer operation is required between the insertion of a flatwork piece into a pair of clamps and the spreading of that flatwork piece.
SUMMARY OF THE INVENTION
The apparatus is for spreading laundry flatwork pieces, such as bed sheets, before feeding them to subsequent processing equipment, such as an ironer and a folder. The flatwork pieces are spread apart by pairs of clamps, there normally being one pair of clamps at the left end, another pair of clamps at the right end, and a third pair of clamps at the center of the apparatus. The spread-out flatwork pieces are blown onto a conveyor for conveying them to the subsequent processing apparatus. Trailing edge sensors are positioned at different levels below the clamps to sense the upward passage of the bottom edge of the laundry flat piece deposited on the conveyor, and a selector switch enables one of the sensors and disables the other, depending upon the speed at which the conveyor is being operated. Proximity switches sense the positions of the clamps. There is an overlying conveyor cooperating with the main conveyor for sandwiching the laundry flat piece as it is moved into the apparatus for stretching purposes. The main conveyor can be moved to an extended position beyond the clamps to facilitate hand feeding of small laundry flat pieces without engagement by the clamps. Spreader belts spread the laundry flat piece laterally, and the spreader belts have outwardly projecting bristles for engaging the laundry flat piece very effectively. A safety switch is associated with each pair of spreader belts to detect the presence between them of a foreign object, and the spreader belts are stopped in response to the actuation of either safety switch. Air discharge pipes are provided with nozzles for discharging vertically narrow, horizontally thin-shaped laterally diverging streams of air which merge with each other to form a continuous blanket of air flowing above the conveyor.
Accordingly, it is a general object of the invention to increase the efficiency and convenience of operation of a spreader feeder apparatus.
Another object of the invention is to provide improved safety features in a spreader feeder apparatus.
A further object of the invention is to provide a spreader feeder apparatus capable of operating at different speeds.
A further object of the invention is to provide a spreader feeder apparatus with an extendable conveyor.
A further object of the invention is to incorporate safety switches with the spreading belts of a spreader feeder apparatus for disabling the belts when a foreign object such as hand is caught between the belts.
Still another object of the invention is to discharge air in a spreader feeder apparatus in a horizontal plane acting substantially like a knife blade.
A further object of the invention is to brush a laundry flatwork piece in a spreader feeder apparatus for improved spreading action.
Another object of the invention is to sandwich a laundry flatwork piece as it moves into the apparatus.
Other objects of this invention will appear from the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front elevational view of a spreader feeder apparatus in accordance with a preferred embodiment of the invention;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a fragmentary view of the front of the apparatus;
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 4;
FIG. 6 is a fragmentary view taken along line 6--6 of FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 1;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 4;
FIG. 9 is a sectional view taken along line 9--9 of FIG. 1;
FIG. 10 is a sectional view taken along line 10--10 of FIG. 9;
FIG. 11 is a view similar to FIG. 9 showing a portion of the spreader belts in a changed position;
FIG. 12 is a sectional view taken along line 12--12 of FIG. 9;
FIG. 13 is a detailed view of a pin included in FIG. 12;
FIG. 14 is a fragmentary view of a conveyor arrangement showing the conveyor in a retracted position;
FIG. 15 is a fragmentary view showing a laundry flatwork piece being blown down onto the conveyor;
FIG. 16 is a view of an air discharge pipe included in the apparatus;
FIG. 17 is a somewhat schematic view of the apparatus illustrating changed positions of the conveyor;
FIG. 18 is a cross-sectional view taken along line 18--18 of FIG. 17;
FIG. 19 is a view similar to FIG. 14 showing the conveyor in an extended position;
FIG. 20 is a schematic diagram of a control circuit for the apparatus;
FIG. 21 is a schematic diagram of another portion of the control circuit;
FIG. 22 is a schematic diagram of still another portion of the control circuit;
FIG. 23 is a cross-sectional view taken along line 23--23 of FIG. 18;
FIG. 24 shows an air discharge nozzle included in the apparatus;
FIG. 25 is a circuit diagram of an operating circuit for the apparatus;
FIG. 26 is a schematic diagram of a pneumatic system; and
FIG. 27 is a circuit diagram of a control circuit for the pneumatic system.
Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
DETAILED DESCRIPTION
Referring first to FIG. 1, the present apparatus has a framework with laterally spaced, wheel-mounted, upstanding, sheet metal end cabinets 30 and 31 and a horizontally elongated top carriage 32 extending between the end cabinets at the top and slidably adjustable between the normal operating position, shown in full lines in FIG. 8, and a retracted position, shown in phantom in FIG. 8, for a purpose explained hereinafter.
CONVEYOR
A wide, flexible endless belt conveyor 33 is located below the top carriage 32 and extends for almost the complete lateral distance between the upstanding end cabinets 30 and 31. This conveyor has a plurality of laterally spaced, relatively narrow, flexible endless belts 33a with upper runs or courses of travel which extend into the apparatus (which for convenience of description will be referred to as the forward direction).
Referring to FIG. 2, at the entry side of the apparatus the conveyor belts 33a extend up across a lower front roller 330 and up across and over an upper front roller 331, passing forward (i.e., into the machine) from roller 331 to an intermediate upper idler roller 332, and forward from the latter to a rear roller 333, passing down across the back of the latter and then back toward the entry side of the machine to an intermediate idler roller 334, and down across the latter to a lowermost roller 335, passing up across the front of the lowermost roller 335 to another intermediate roller 336, and passing up across the top of roller 336 to the roller 330.
The rollers 331, 332, 333, 334 and 336 have stationary axes of rotation. The lower front roller 330 is displaceable from the normal position shown in FIG. 2, where it is almost directly beneath the upper front roller 331, to the extended position shown in FIG. 17, where it projects outward from the machine at its entry side. The lowermost roller 335 is displaceable from the normal, lowered position shown in FIG. 1 to the raised position shown in FIG. 17.
The upper front roller 331 is driven from an electric motor 337 (FIG. 4) through a gear reduction 338. The motor 337 is located at the right side of the machine, viewed from its entry side as shown in FIG. 4. Rollers 332 and 353 are also driven. The other rollers 330, 333, 334, 335 and 336 for the conveyor belts 33a are idler rollers. The motor drive to the upper front roller 331 and rollers 332 and 353 is in a direction to move the conveyor belts 33a from right to left in FIG. 2 across the top of the roller 331 over to the intermediate upper roller 332. Thus, the upper run of the conveyor is into the machine (i.e., "forward" away from the entry side of the machine), and the lower return run of the conveyor is "rearward" from the interior of the machine to its entry side.
Referring to FIG. 18, at each end the lower front roller 330 is rotatably mounted in a respective carrier 340 which is displaceable longitudinally by a respective pneumatic cylinder-and-piston unit 341. A rack 342 (FIG. 17) extends from each roller carrier 340 at the opposite end from where it supports the roller 330. This rack has downwardly facing teeth which mesh with a small rotatable first pinion gear 343. A fixed rack 344 has upwardly facing teeth which engage the pinion 343 from below. A similar second pinion 345 is engaged between the respective racks 342 and 344 a short distance forward (i.e., into the machine) from the first pinion 343. The upper and lower racks 342 and 344 at each end of roller 330 extend parallel to each other. As best seen in FIG. 18, both pinions 343 and 345 of each pair are rotatably supported by a plate 346 which is connected by a cross pin assembly 346' to the outer end of the piston of the respective cylinder-and-piston unit 341.
Referring to FIG. 23, the cross pin assembly 346' includes a bolt 700 received in a sleeve bearing or bushing 701 carried by a yoke 702 on the outer end of the piston rod 341a (FIG. 14) of the cylinder-and-piston unit 341. The screw-threaded inner end of bolt 700 is attached to a cylindrical rod 703, which is movable along an inclined slot 704 in the inside wall 705 of a housing 706 for the cylinder-and-piston unit 341. This housing 706 is fixedly mounted on the corresponding end cabinet 30 or 31. The inner end of the slide rod 703 is rigidly connected to the aforementioned plate 346.
As shown in FIG. 18, the plate 346 is located at the inner side of the lower rack 344 and the upper rack 342. Plate 346 rotatably supports the pinions 343 and 345 near its opposite ends. FIG. 23 shows the pivotal support for the pinion 343 in the form of a bolt 707 having a screw-threaded stem threadedly received in the plate 346 and a smooth cylindrical shank segment outside the plate on which the pinion 343 is rotatable. Bolt 707 has an enlarged head on its outer end which is received in a complementary counterbore 343a formed in the outer end face of pinion 343.
The other pinion 345 has an identical pivotal support on plate 346.
With this arrangement, the plate 346, the pinions 343 and 345, and the cross pin assembly 346' move in unison with the piston rod 341a of the cylinder-and-piston unit 341.
A pair of upper and lower guide rails 708 and 709 (FIG. 23) are bolted to the inside wall 705 of housing 706. The lower rack 344 is affixed to the inside of the lower guide rail 709 by the same bolts which mount this guide rail on the housing wall 705. The guide rails 708 and 709 are located above and below the slot 704 in the housing wall 705 and they extend at the same inclination downward toward the entry side of the machine.
With this arrangement, the lower rack 344 is fixedly mounted on the housing 706, and it is inclined downward toward the entry side of the machine.
The roller carrier 340 comprises top and bottom plates 710 and 711 to which an inner plate 712 is attached by bolts 713 to provide a unitary channel. The upper rack 342 is attached by bolts 714 to the bottom of the top plate 710. The top plate 710 has a flat bottom face which slidably engages the flat top face of the upper guide rail 708. The flat bottom face of the lower rack 344 and the flat bottom face of the lower guide rail 709 are slidably engaged by the top face of the bottom plate 711 of the roller carrier 340.
With this arrangement, the roller carrier 340 and the upper rack 342 are slidable as a unit along the fixed guide rails 708 and 709.
The lower front roller 330 of the conveyor is rotatably mounted on a horizontal shaft 715 by a ball bearing 716 at each end. The shaft 715 extends beyond the roller into a central opening 717 in the end wall 712 of the roller carrier 340. This end wall presents a cylindrical projection 718 at its inner end which extends concentrically around the opening 717. Inside this projection the end wall 712 presents a flat end face 719. A pair of cylindrical spacers 720 and 721 are engaged between this end face and the outside of the ball bearing 716 for roller 330.
With this arrangement, the sliding movement of the roller carrier 340 along the fixed guide rails 708 and 709 is imparted to the roller 330 without impairing the freedom of the roller to rotate freely. Roller 330 is moved at a differential rate of 2:1 as compared to the movement of the piston.
As shown in FIG. 14, when the pistons of the respective cylinder-and-piston units 341 are retracted, the lower rear roller 330 is in its normal retracted position. As shown in FIG. 19, when the pistons are extended, roller 330 is in its extended position, displaced downward toward the entry side of the machine from its normal retracted position.
The lower roller 335 for the conveyor belt 33a is rotatably mounted on the front ends of respective arms 348 (FIGS. 2 and 3). The back ends of these arms are horizontally pivoted at 349. A pair of tension springs 350 and 351 act on these arms to pull them down to the horizontal position shown in FIGS. 2 and 3. However, when the lower front roller 330 is moved out to its extended position by the cylinder-and-piston units 341 (FIG. 17), the conveyor belts 33a pull the lower roller 335 up. The downward pull of springs 350 and 351 maintains the conveyor belts 33a under the desired degree of tension in both positions of rollers 330 and 335.
At the entry side of the machine a pivoted cover plate 470 (FIG. 14) normally is held up in front of rollers 330 and 331 by a magnetic catch 471. This plate 470 is manually moved down out of the way (FIG. 19) when the roller 330 is moved to its extended position.
The conveyor also has sets of upper, flexible, endless conveyor belts 352 (FIG. 2) which overlie the lower conveyor belts 33a where the latter pass over the roller 332. The upper conveyor belts 352 extend around a front idler roller 353 and a back idler roller 354, which are respectively located in front of and behind the roller 332.
The vertical position of roller 332 is such that it flexes the lower run of the upper conveyor belts 352 upward slightly to maintain an appropriate tension on these belts. The purpose of the upper conveyor belts 352 is to hold the laundry flatwork down on the lower conveyor belts 33a near roller 332, and to exert a stretching action on the flatwork.
The back roller 335 for the lower conveyor belts 33a and the back roller 354 for the upper conveyor belts 352 are rotatably supported at their opposite ends by respective plates 355 (FIGS. 2,3,17 and 18). These plates 355 are pivotally connected to the upper ends of respective posts 356 which, as shown in FIG. 2, are inclined downward from these plates toward the entry side of the machine. The lower ends of the posts 356 are pivotally supported from the framework of the machine. The length of the posts 356 is telescopically adjustable to provide the desired belt tension in the conveyor.
SPREADERS
At the entry side of the machine (FIG. 1) two pairs of confronting, laterally directed, flexible endless belts 41-42 and 43-44 are located a short distance below the conveyor belts 33a. The paired belts 41-42 are at the left side of the longitudinal centerline of the conveyor 33, and the paired belts 43-44 are at the right side of this centerline. The left-hand belts 41-42 present contiguous runs which move from the center laterally outward to the left for spreading from the center to the left the part of a sheet which passes up between them. The right-hand belts 43-44 present contiguous runs which move from the center laterally outward to the right for spreading from the center to the right another part of the same sheet passing up between them. Therefore, the paired belts 41-42 and 43-44 will be referred to as spreader belts.
The respective rear spreader belts 42 and 44 are longer than the respective spreader belts 41 and 43 with which they are paired, and they extend laterally inward past the latter toward the the longitudinal centerline of the apparatus. This provides a gap between the front belts 41 and 43 midway across the apparatus at its entry side where a sheet may hang down directly behind the rear belts 42 and 44. This facilitates the passage of the sheet up between the confronting pairs of spreader belts 41-42 and 43-44, with the belts 41-42 spreading part of the sheet to the left as it passes up between them and with the belts 43-44 spreading another part of the sheet to the right as it passes up between them.
At the right side of the machine in FIG. 1, the rear belt 44 is driven by a vertical drive roller 45 (FIG. 2) at its laterally outboard (right) end. This drive roller is on the upper end of a rotatable vertical shaft 46 which extends up from a pulley 47 driven by a belt 48 from an idler pulley 49. The idler pulley is driven from an electric motor 50 by a belt 51.
The shorter front belt 43 at this side of the machine is driven by a vertical drive roller 52 (FIG. 2) at its laterally outboard (right) end. This drive roller is on the upper end of a vertical shaft 53 which carries a gear 54 driven by a gear 55 on shaft 46. Shaft 53 is rotatably mounted on the framework of the machine.
With this arrangement, the respective drive rollers 45 and 52 for belts 44 and 43 are rotated in opposite directions by the motor 50 and they pull the confronting, contiguous runs of these belts laterally outboard (i.e., from left to right in FIG. 1).
The other pair of spreader belts 41, 42 are driven in the same manner, with the confronting, contiguous runs of these belts being pulled from right to left laterally outward in FIG. 1. The drive arrangement for belts 41, 42 is a mirror image of the one for belts 43,44 and therefore need not be described in detail. In FIG. 4, the drive roller and other parts associated with belt 42 are given the same reference numerals as those associated with belt 44, but with a "prime" suffix added.
As shown in FIG. 4, the laterally inward end of spreader belt 44 extends around a rotatably mounted idler roller 56. Likewise, the laterally inward end of spreader belt 42 extends around a rotatably mounted idler roller 56'. Both of these idler rollers are supported from the framework of the machine.
A pivotally articulated three-piece linkage is located inside the endless loop formed by spreader belt 43. Referring to FIG. 9, this linkage comprises a fixedly mounted member 57, which is located toward belt 44, a pivotally adjustable member 58, which is located away from belt 44, and a linkage piece 62 acting between members 57 and 58. The linkage members 57 and 58 are pivotally connected at 59 a short distance laterally inward from the drive roller 52 for belt 43. Each of the linkage members 57 and 58 is generally channel-shaped in cross-section and the pivotally adjustable member 58 fits snugly but slidably outside the fixed member 57.
At its laterally inward end the fixed linkage member 57 carries an idler roller 60 (FIG. 9), which is located in close proximity to belt 44. Belt 43 extends around this idler roller 60 at the beginning of its laterally outward run of course of movement in contiguous, confronting relationship to belt 44.
The third linkage piece 62 has upper and lower walls 62a and 62b (FIG. 10) which respectively fit closely below and above the upper and lower walls of the fixed linkage member 57. At one end of the third linkage piece 62, aligned vertical pivot pins 61 (FIG. 10) connect its upper and lower walls to the corresponding walls of linkage member 57. At its opposite end, the linkage piece 62 carries a roller 63 around which the spreader belt 43 extends. The linkage member 62 has a bridge segment 62c (FIG. 9) which extends between and interconnects its upper and lower walls. This bridge segment is located just inside the spreader belt 43 where the latter passes from roller 63 to roller 60.
Aligned arcuate slots 64 are formed in the upper and lower walls 62a and 62b of linkage piece 62, as best seen in FIG. 9. A cross pin 65 carried by the pivotally adjustable linkage member 58 is snugly but slidably received in these slots 64 to couple the third linkage piece 62 to the pivoted linkage member 58.
A pneumatic cylinder-and-piston unit 66 acts between the fixed linkage member 57 and the third linkage piece 62 for moving the spreader belt between its normal position, shown in full lines in FIG. 9 and in phantom in FIG. 11, to a retracted position, shown in full lines in FIG. 11. The cylinder of this unit is pivotally mounted at 67 on a bracket 68 attached to the inside of linkage member 57. The piston of this unit has a square extension 69 on its outer end which is rigidly fastened to a channel-shaped yoke 70. This yoke carries a cross pin 71 whose opposite ends are received in complementary openings in the upper wall 62a and the lower wall 62b of the third linkage piece.
With this arrangement, when the cylinder-and-piston unit 66 is actuated to extend the piston from the normal, retracted position shown in FIGS. 9 and 10, the outward movement of the piston is imparted through the yoke 70 and cross pin 71 to the third linkage piece 62, causing the latter to pivot about pins 61 clockwise in FIG. 9 (with respect to the fixed linkage member 57). Such pivotal movement of linkage piece 62 is imparted through the slot-and-pin coupling 64-65 to the pivoted linkage member 58, causing the latter to pivot about pin 59 clockwise with respect to linkage member 57 from the phantom-line position in FIG. 11 to the full line position in that Figure.
An identical arrangement is provided at the other front spreader belt 41 for retracting it at the same time that spreader belt 43 is retracted.
The purpose of retracting the spreader belts 41 and 43 to the full line position of FIG. 11 is to get them out of the way of the machine operators when small laundry pieces are being fed into the machine. Such small pieces do not require the lateral spreading action of the spreader belts at the entry side of the machine. The motor drive to these spreader belts is disabled at this time, as described in detail hereinafter. Also, when the spreader belts are retracted and disabled, the conveyor 33 will be in its extended position at the entry side of the machine, as shown in FIGS. 17 and 19.
At each pair of the spreader belts 41-42 and 43-44 a safety switch is provided to stop the belts if one of the machine operators gets her hand caught between the belts. FIGS. 9, 12 and 13 show the safety switch arrangement for belts 43-44. The safety switch arrangement for belts 41-42 is the same.
Referring to FIG. 9, a snap-acting switch 500 is mounted inside the rear spreader belt 44. The actuator 501 of this switch engages the back of a flat plate 502, which extends across an opening 503 formed in an elongated plate 504 extending directly behind the run of belt 44 which is next to the front spreader belt 43 of this pair. The laterally inward edge of the opening 503 is located inward past the front spreader belt 43 in the latter's normal operating position, as shown in FIG. 9. The laterally outward edge of the opening 503 is located outward past the roller 60 where the spreader belts 43 and 44 first come into confronting, contiguous relationship to one another. A pair of spring biased pins 505 and 506 extend behind plate 502 at its opposite ends. These pins normally hold plate 502 against the back of the longer plate 504.
If the operator's hand or some other foreign object gets caught between the confronting runs of the spreader belts 43, 44 or is closely approaching entry between these belts, the foreign object will bend the plate 502 in and operate the safety switch 500, which will turn off the motor driving the rear belt 44.
Each spreader belt 41,42, 43 and 44 presents a plurality of closely spaced, outwardly protruding bristles across its entire extent for more effectively gripping the laundry flatwork.
BLOWDOWN
Three blowpipes B-1, B-2 and B-3 (FIG. 1) extend horizontally above the level of the conveyor belts 33a at the entry side of the machine. The left and right blowpipes B-1 and B-2 extend transversely across the conveyor for most of its width respectively to the left and right of the longitudinal centerline of the machine. The middle blowpipe B-3 extends transversely across a narrow region at the center of the conveyor 33. Referring to FIG. 16, the left blowpipe B-1 comprises an elongated horizontal tube 360 having an air inlet connection 361 midway along its length and having its opposite ends closed. The tube 360 on one side carries a plurality of discharge nozzles 362 at evenly spaced intervals along its length. Each nozzle has a horizontally elongated, vertically narrow discharge opening 363 (FIG. 24), so that air is discharged from the nozzle in a fan-like pattern which has a narrow dimension vertically and a much wider, diverging flow transverse to the conveyor 33. The fan-like discharged from adjacent nozzles 362 merge into each other to provide a continuous forwardly moving blanket of air across the entire transverse extent of the conveyor 33 served by that blowpipe.
The right blowpipe B-2 is of the same construction as the blowpipe B-1.
If desired, the nozzles 362 may be set into the corresponding blowpipe tube 360 at acute angles so that the central axis of each nozzle's spray pattern extends forward and laterally outward at an acute angle.
The middle blowpipe B-3 has a short horizontal tube carrying a small number of spray nozzles which are set to spray forward and laterally outward on each side, so that the combined action of the three blowpipes B-1, B-2 and B-3 is an uninterrupted blanket of forwardly moving air which completely covers the conveyor 33 from side to side.
This blanket of air moves at a slight angle upward with respect to the path of the conveyor belts 33a from the upper front roller 331 to the intermediate roller 332 (FIG. 2). This forwardly moving blanket of air holds the laundry flatwork piece down on the conveyor belts 33a until it passes beneath the upper conveyor belts 352, from which point the upper conveyor belts 352 hold it down on the lower conveyor belts until it approaches the point (at the rear roller 333) where it moves off the lower conveyor belts 33a.
A pair of vertical straps 364 suspend the left blowpipe B-1 in the horizontal position shown in FIG. 2. This is also true of the right blowpipe B-2. The short middle blowpipe B-3 is suspended by a vertical strap 365. The upper ends of these straps are attached to the top carriage 32 of the machine. Thus, the blowpipes move in unison with the top carriage 32 when it is displaced, as described hereinafter.
Flexible hoses 366 connect the blowpipes B-1, B-2 and B-3 to a suitable source of pressurized air through normally-closed solenoid valves.
TOP CARRIAGE
The top carriage 32 is mounted on two rollers 392 (FIGS. 4 and 8) at each side of the machine. These rollers roll along fixed horizontal tracks 393 at the top of the respective end cabinets 30 and 31 of the machine. At each side a pneumatic cylinder-and-piston unit 394 (FIG. 8) moves the top carriage between a normal position (shown in full lines in FIG. 8) and a retracted position (shown in phantom in FIG. 8). In its normal position, the top carriage closes a limit switch 389, for a purpose explained hereinafter. In its retracted position, the top carriage closes a limit switch 389'.
The pair of pneumatic cylinder-and-piston units 394 for positioning the top carriage 32, the pair of pneumatic cylinder-and-piston units 341 for positioning the lower front roller 330 of conveyor 33, and the pair of pneumatic cylinder-and-piston units 66 for positioning the spreader belts 41 and 43 are operated in synchronism such that:
(a) when large laundry workpieces are to be fed into the machine, the spreader belts 41 and 43 are in their operative positions (as shown in FIG. 9), the conveyor 33 is in its retracted position (as shown in full lines in FIG. 8), and the top carriage 32 is positioned toward the entry side of the machine (as shown in full lines in FIG. 8); and
(b) when short laundry workpieces are to be fed into the machine, the spreader belts 41 and 43 are retracted to their inoperative positions (as shown in full lines in FIG. 11), the conveyor 33 is in its extended position (as shown in phantom in FIG. 8), and the top carriage 32 is retracted (as shown in phantom in FIG. 8).
SHEET SPREADING AND DEPOSITING ON CONVEYOR
The top carriage 32 carries three pairs of sheet clamps, each pair served by an individual machine operator whose job is to insert the adjacent corners on the upper end of a sheet or other large laundry workpiece into his or her pair of clamps, after which these clamps are spread apart laterally from the middle of the apparatus to the left and right, respectively. The three pairs of clamps are operated one at a time and they act on different sheets. Normally, the three pairs of clamps are positioned at the middle, left end and right end of the apparatus. The middle clamps are designated M-1 and M-2 in FIG. 1, the left end clamps are designated L-1 and L-2, and the right end clamps are designated R-1 and R-2. The clamps do not operate when short workpieces are being fed into the machine.
Assuming that the operator at the middle of the machine is ready first, followed by the operator at the left, and later by the operator at the right, the sheet spreading and depositing operations take place as follows:
(1) After the corners of one sheet are inserted in the clamps M-1 and M-2 of the middle pair, clamp M-1 is moved horizontally to the left and clamp M-2 is moved horizontally to the right, carrying the respective adjacent corners of this sheet away from each other to spread the top edge of the sheet. The trailing part of the sheet hanging down from these clamps is engaged between the spreader belts 41 and 42 (to the left) and between the spreader belts 43 and 44 (to the right), and the direction of movement of these spreader belts is such that this trailing part of the sheet is spread to the left and to the right on opposite sides of its centerline between its clamped upper corners.
The clamps M-1 and M-2 release the respective corners of this sheet after these clamps stop at their outermost positions to the left and right, respectively. The blowpipes B-1, B-2 and B-3 then discharge air to force the just-released, spread-open leading end of the sheet down onto the forwardly-advancing upper run of conveyor 33. The timing of the release of the sheet by the clamps and the discharge of air by the blowpipes is under the control of a photoelectric sensor 78 (FIG. 2) at the longitudinal center of the machine. As both clamps move laterally outward, the top edge of the sheet moves past sensor 78, which senses the rising middle part of the sheet's top edge. Adjustment of the heighth of 78 and its reflector controls the tension of the sheet. An adjustable time delay is provided between this sensing and the stopping of the laterally outward movement of the clamps. This allows for adjusting the tension on the sheet. The clamps open to release the sheet after they reach their outermost positions, provided the spacing between successive sheets is sufficient. After another adjustable time delay following the opening of the clamps, the blowpipes B-1, B-2 and B-3 are supplied with pressurized air for an adjustable time interval to blow the just-released sheet onto the conveyor 33.
This conveyor 33 pulls the trailing part of the sheet up between the paired spreader belts 41-42 and 43-44, and these paired belts continue to spread the sheet laterally outward in each direction as it is drawn up between them.
Two trailing edge sensors 98 and 99 (FIG. 1) are located respectively below the left-hand spreader belts 41, 42 and the right-hand spreader belts 43, 44. Each of these sensors comprises a photoelectric cell which senses light reflected from an adjacent reflector 98a and 99a. The position of these elements laterally of the machine is shown in FIG. 7, from which it will be apparent that a sheet being spread apart by the paired spreader belts 41, 42 and 43, 44 will hang down over the photocells 98 and 99 until the trailing edge of this sheet moves up past them.
The photocells 98 and 99 are at different levels, with photocell 98 being lower. Both are adjustable vertically but photocell 99 will always be higher. Since they are at different levels, the trailing edge of a sheet will move up past photocell 98 before it moves up past photocell 99.
When the conveyor 33 in the machine is operated at slow speed, both photocells 98 and 99 will be connected in the control circuit of the machine in such a way that the circuit will respond to the energization of the last one (the higher photocell 99) to be uncovered by the upward movement of the trailing edge of the sheet past it. When the conveyor 33 is operated at high speed, the upper photocell 99 is disabled and the control circuit will respond only to the energization of the lower photocell 98 when the trailing edge of the sheet moves past it. This is described in more detail in the following description of the FIG. 20 control circuit.
(2) The corners of another sheet are inserted in the clamps L-1 and L-2 at the left end of the machine by an operator there who then pushes a start or grading button. This may be done any time the clamps are at this feed station. When the middle clamps M-1 and M-2 start returning to the middle station, the left clamps L-1 and L-2 are actuated to move in unison to the right, carrying their sheet across the spreader belt 41 on that side until they reach the centered position where they stop. Upon the movement of the trailing edge of the preceding sheet up past the sensor 98 or 99 which is then effective, or the end of a minimum pause interval, whichever occurs later, the clamp L-1 now is moved horizontally to the left and clamp L-2 is moved horizontally to the right.
The same operation now takes place on this sheet as has been described in detail for the preceding sheet acted on by the middle clamps M-1 and M-2.
(3) The corners of a third sheet S-R are inserted in the clamps R-1 and R-2 at the right end of the apparatus by the operator there. When the left clamp L-2 starts returning to the left station, the right clamps R-1 and R-2 are moved in unison to the left to the centered position, carrying their sheet across the spreader belt 43 on that side. After pausing at the middle for a minimum pause interval or after a time delay following the uncovering of the effective trailing edge sensor 98 or 99 by the trailing edge of the immediately preceding sheet, whichever is longer, clamp R-1 is moved to the left and clamp R-2 is moved to the right. These clamps spread apart the top corners of this sheet and pass the trailing part of the sheet between the paired spreader belts 41-42 and 43-44.
The same operation now takes place on this sheet as has been described in detail for the sheet acted on by the middle clamps M-1 and M-2.
It is to be understood that the apparatus follows a "demand" sequence of operation. That is, the order in which the respective sets of clamps are operated depends upon the order in which the machine operators signal their readiness after inserting their respective sheets in the corresponding paired clamps.
Each sheet clamp of each pair preferably is constructed as disclosed in detail in U.S. Pat. No. 4,106,277. Each clamp is operated by a respective air cylinder 87 (FIG. 15) mounted in the top carriage 32. The clamp is closed when air pressure is applied to the top of the air cylinder and is released from the bottom; it is opened when pressure is supplied to the bottom of the cylinder and released from the top (not explained in previous patent). Therefore, it will be apparent that a sheet whose top edge is held by any pair of clamps L-1 and L-2, M-1 and M-2, or R-1 and R-2 is released by those clamps when pressurized air is supplied to the lower part of the respective air cylinders 87 for those clamps.
FIG. 4 shows the middle clamp M-1 as being slightly mounted on a pair of upper and lower, cantilevered, horizontal guide rods 100-1 and 101-1, which are mounted at the left side of the top carriage 32 and terminate just short of the centerline of the machine. These guide rods are rigidly interconnected by a vertical connecting piece extending between them. The middle clamp M-1 has an upper roller 82 (FIG. 15), which is in rolling engagement with the top of the upper guide rod 100-1, and a lower roller 83 in rolling engagement with the bottom of the lower guide rod 101-1.
The other middle clamp M-2 is slidably mounted on similar upper and lower cantilevered horizontal guide rods 100-2 and 101-1, which are mounted at the right side of the top carriage 32 and terminate just short of the machine's centerline. As shown in FIG. 2, clamp M-2 has an upper roller 82-2 in rolling engagement with the top of the upper guide rod 100-2 and a lower roller 83-2 in rolling engagement with the bottom of the lower guide rod 101-2.
The mounting of the rods 100-1, 101-1 for clamp M-1 and the mountings of the rods 100-2, 101-2 for clamp M-2 have enough play in them to permit the free ends of these rods to be displaced as much as 3 inches toward the entry side of the machine and away from the conveyor 33, midway across the machine at its entry side. An air cylinder-and-piston unit is coupled to the adjacent free inner ends of these paired rods for effecting such displacement.
The clamps L-1 and L-2 which normally are at the left end of the apparatus are similarly mounted on a single pair of horizontal guide rods 103 and 104 (FIG. 15) which extend completely across the entry side and are spaced forward (i.e., in the direction into the apparatus away from its entry side) from the respective paired guide rods for the middle clamps M-1 and M-2. These guide rods 103 and 104 are interconnected by a rigid vertical piece 105.
The right end clamps R-1 and R-2 are slidable on the same horizontal guide rods 103 and 104 as clamps L-1 and L-2.
The two middle clamps M-1 and M-2 are coupled separately to respective flexible endless cables to be displaced from their normal position close together midway across the apparatus at its entry side to their extended positions at the left and right ends respectively, of the apparatus.
As shown in FIG. 2, clamp M-2 is carried by an attachment piece 106 having a vertical leg which is fastened to this clamp next to its air cylinder 87. This attachment piece extends up from the clamp and has its upper end attached to a horizontal cable 111. As shown schematically in FIG. 4, the cable 111 is an endless flexible cable which extends from a pulley 112 at the left end of the apparatus to a pulley 113 at its right end. The connection 110 between the attachment piece 106 for the clamp M-2 and the cable 111 is made on the lower horizontal run of this cable.
The other middle clamp M-1 has a similar connection to a similar cable 115, which extends around a pulley 116 at the left side of the machine and around a pulley 117 at the right. As shown in FIG. 5, the pulleys 116, 117 and cable 115 are offset in front of the pulleys 112, 113 and cable 111 to avoid interference between them.
As shown in FIG. 5, the left end pulley 116 for cable 115 is mounted on the output shaft of a reversible clutch-brake unit 119 of known design, having a brake which is electrically-applied and spring-released and a clutch which is electrically-engaged and spring-released for driving an output shaft in one direction or the other. The clutch-brake unit has an input shaft carrying a pulley driven by a flexible endless chain 122, whose opposite end is driven by an idler pulley 123.
The idler pulley 123 is driven by a flexible endless belt 129 whose opposite end extends around a drive pulley mounted on a horizontal drive shaft 131 extending transversely across the interior of the top carriage 32 of the apparatus framework and rotatably supported by bearings 132 and 133 at opposite ends.
These bearings are supported by the top carriage 32 of apparatus framework. Drive shaft 131 is driven by an electric motor 135 through a belt and pulleys. As long as motor 135 is on, the drive shaft 131 is driven continuously. Normally the clutch-brake unit 119 for cable 111 is energized so that the brake is applied and the clutch is disengaged.
Referring to FIG. 5, the pulley 112 at the left end of the cable 111 for the clamp M-2 is driven through a similar clutch-brake unit 124 located directly to the right of the aforementioned clutch-brake unit 119. The clutch-brake unit 124 has an input shaft carrying a pulley which is driven through a flexible endless chain 127 from a pulley 128 on the shaft 131.
The outer left end clamp L-1 is coupled to a flexible endless cable 145 (FIG. 4) which is spaced below and behind the cables 111 and 115 for the middle clamps M-1 and M-2. Clamp L-1 is attached to the lower horizontal run of cable 145. Cable 145 extends around a pulley 151 at its left end and around an idler pulley 152 at its right end.
The inner left end clamp L-2 is coupled to a flexible endless cable 146 (FIG. 5), which is located behind and below cable 145. Clamp L-2 is attached to the upper horizontal run of cable 146. Cable 146 extends around a pulley 157 at its left end and around an idler pulley 158 at its right end.
The drive pulley 151 for cable 145 is driven through a clutch-brake unit 153 (of the type already described) from the drive shaft 131 through a chain 154.
Similarly, the drive pulley 157 for cable 146 is driven through a clutch-brake unit 158 from the drive shaft 131 through a chain 159.
The inner right end clamp R-1 is coupled to a flexible endless cable 166 (FIG. 4). Clamp R-1 is attached to the upper horizontal run of cable 166. Cable 166 extends around a drive pulley 174 at its left end and around an idler pulley 176 at its right end. Pulley 174 is driven through a clutch-brake unit 180 (FIG. 5) from the drive shaft 131 through a chain 181.
The outer right end clamp R-2 is coupled to a flexible endless cable 165 (FIG. 4). Clamp R-2 is attached to the lower horizontal run of cable 165. Cable 165 extends around a drive pulley 172 at its left end and around an idler pulley 171 at its right end. Pulley 172 is driven through a clutch-brake unit from the drive shaft 131 through a chain 182. This clutch-brake unit is below the clutch-brake unit 158 for pulley 157 and is hidden by it in FIG. 5.
In the operation of the apparatus, when the middle clamps M-1 and M-2 are at the middle of the machine and the operator there wants to insert the corners of a flatwork piece that is to be spread, the adjacent free ends of the rods 100-1, 101-1, 100-2 and 101-2 are displaced toward the operator about 3 inches by actuating the corresponding cylinder-and-piston unit. This moves the middle clamps away from any preceding flatwork piece already in the machine. This helps particularly when the flatwork pieces are wet and liable to tangle easily. After the flatwork piece is in the middle clamps M-1 and M-2, the free ends of their guide rods 100-1, 101-1, 100-2 and 101-2 are retracted (away from the operator and toward the conveyor 33) before they are spread apart. Now the middle clamps may be moved simultaneously from the centered position where they are close together midway across the apparatus, over to the spread apart positions in which clamp M-1 is at the left end and clamp M-2 is at the right end of the apparatus, and then they are moved simultaneously back to the centered position. To move these clamps apart, the cable 115 is driven clockwise in FIG. 4 through its clutch-brake unit 119 and the cable 111 is driven counterclockwise through its clutch-brake unit 124. To move these clamps together, the direction of movement of their respective cables is reversed.
In the sequence of operation of the left end clamps L-1 and L-2, these clamps are moved simultaneously from their normal position close together at the left end of the apparatus over to the middle of the apparatus (still close together). This is done by driving the cable 145 counterclockwise in FIG. 4 through its clutch-brake unit 153 and driving the lower cable 146 clockwise through its clutch-brake unit. Thereafter, these clamps are spread apart, by driving the upper cable 145 clockwise to move clamp L-1 back to its starting position at the left end of the apparatus and driving the lower cable 145 clockwise to move clamp L-2 to the right end of the apparatus. Finally, after these clamps have released their sheet, the upper cable 145 remains stationary while the lower cable 146 is driven counterclockwise to move clamp L-2 to the left end of the apparatus, close to clamp L-1.
In the operating sequence of the right end clamps R-1 and R-2, these clamps are moved simultaneously from their normal position close to each other at the right end of the apparatus over to the middle of the apparatus (still close to each other). This is done by driving the upper cable 165 clockwise in FIG. 4 through its clutch-brake unit and driving the lower cable 166 counterclockwise through its clutch-brake unit 180. Thereafter, these clamps are spread apart by driving cable 165 counterclockwise and cable 166 counterclockwise until the clamps are at a position where the sheet is spread. The clamps are stopped here. The clamps both return to the feed station after the sheet is released.
In accordance with one feature of the present invention, each air cylinder for each of the clamps M-1 and M-2, L-1 and L-2, and R-1 and R-2 receives air through a Siamese (or double) helically-wound extensible hose mounted on a corresponding trolley wire which extends horizontally from left to right across the inside of the top carriage.
Referring to FIGS. 5 and 6, the middle clamp M-1 has a horizontally extending fitting 450 on the back (FIG. 5) which is connected to the laterally outward end of a Siamese (or double) helically-wound flexible air hose 451 for supplying air to the air cylinder on this clamp. As shown in FIG. 6, this end of the helical hose is suspended by a roller 452 from a horizontal transverse wire 453 above. The laterally inward end of the helical air hose 451 is attached to the fixidly supported end of rigid air tubes 454, 454a FIG. 5 which extends horizontally laterally outward to a source of pressurized air mounted inside the top carriage 32 at its left end.
The other middle clamp M-2 has a similar air supply arrangement which is a mirror image of the one just described for clamp M-1. Corresponding elements of the air supply arrangement for clamp M-2 are given the same reference numerals as those for clamp M-1, but with a "prime" suffix added.
With this arrangement, when the middle clamps M-1 and M-2 are spread apart, the respective coiled air hoses unwind, and are extended in length, as shown in phantom in FIG. 6.
The left-hand clamp L-1 has a fitting 455 connected to the laterally inward end of a Siamese (or double) helically-wound, flexible, horizontally extending air hose 456. The laterally outward end of this hose is attached to a fixedly positioned, rigid air line 457 at the left side of the top carriage 32. A roller (not shown) at the laterally inward end of the helical hose 456 suspends it from a horizontal trolley wire (not shown) above.
The other left-hand clamp L-1 has a similar slidably supported Siamese (or double) helically-wound air hose connected to it in the same manner as for clamp L-2. This air supply arrangement for clamp L-1 is hidden below other parts of the apparatus in FIG. 5.
The right-hand clamp R-1 is connected to the laterally inward end of a Siamese (or double) helically-wound, flexible, horizontally extending air hose 458 and 458a. The laterally outward end of these hoses are attached to fixedly positioned, rigid air lines 459 and 459a at the right side of the top carriage. A roller (not shown) suspends the inward end of the hose 458 from a horizontal trolley wire (not shown) above.
The other right-hand clamp R-2 is connected to the laterally inward end of a Siamese (or double) helically-wound, flexible, horizontally extending air hose 458 and 458b. The opposite end of this hose is attached to fixedly positioned rigid air lines (which are obscured in FIG. 5 by other parts of the apparatus) at the right side of the top carriage 32.
With this arrangement, the separate air supply lines to the clamp release cylinders on the individual clamps are kept as compact as possible and free from interference with any of the other parts of the apparatus within the top carriage 32 where they are located.
CONTROL CIRCUIT FOR ELECTRIC MOTORS
FIG. 25 illustrates schematically in simplified form the control circuit for the conveyor motor 337, the spreader belt motor 50, and the clamp positioning motor 135.
This control circuit includes a first relay coil 370 which operates a set of contacts 370a for controlling the energization of the conveyor motor 337 and a set of contacts 370b for controlling the energization of relay coil 371. The energization of the spreader belt motor 50 and the clamp positioning motor 135 is controlled by relay coil 371 which operates two sets of relay contacts 371a and 371b.
The conveyor motor 337 has a thermal overload 337a which operates a set of contacts 337b. The spreader belt motor 50 has a thermal overload 50a which operates a set of contacts 50b. The clamp positioning motor 135 has a thermal overload 135a which operates a set of contacts 135b. The respective thermal overload contacts 337b, 50b and 135b are closed normally (i.e., as long as the corresponding motors 337, 50 and 135 are not overloaded).
The relay coil 370 is in series with six switches and a resistor 372 across an 18 volt D.C. power supply. These six switches include a manual emergency switch 373 at the left-hand operator station at the entry side of the machine, a manual emergency switch 374 at the middle operator station, a manual emergency switch 375 at the right-hand operator station, a manual stop switch 376, a safety switch 500' associated with the spreader belts 41,42 at the left side of the machine, and the safety switch 500 associated with the spreader belts 43, 44 at the right side of the machine, as already described in detail. Normally, these six switches are all closed while the machine is in operation, and therefore relay coil 370 is energized and its two sets of contacts 370a and 370b are closed.
The conveyor motor 337 is under the control of an SCR motor controller 380 of known design. This motor controller has input terminals 381 connected to one phase of a 230 volt, 3-phase power supply 382 and output terminals 383 connected to the conveyor motor. The motor controller includes a start circuit having a 48 volt terminal 384, which is connected through the normally-closed thermal cutout contacts 337b and the normally-open relay contacts 370a to a terminal 385 of the motor controller which leads to a holding circuit therein. A first set of normally-open contacts 386 of a manually operated start switch is connected between the relay contacts 370a and an input terminal 387 of the motor controller 380 which is connected to a starting coil.
In the normal operation of the machine, relay coil 370 will be energized and its contacts 370a will be closed, the start switch contacts 386 will be open, and the thermal cutout contacts 337b for the conveyor motor will be closed. Under these circumstances, motor 337 will be energized if start switch 386 is closed momentarily.
If relay coil 370 is de-energized (by opening any one of the switches 373-376, 500' and 500 in series with it or a power failure, the relay contacts 370a will open, causing the conveyor motor 337 to be de-energized. After relay coil 370 is again energized, the start switch 386 must be closed in order to restart the conveyor motor 337. Therefore, even if the de-energization of the relay coil 370 is only momentary, the machine operator must close the start switch 386 manually in order to restart the conveyor 33.
The start switch has a second set of normally-open contacts 386' which are connected in series with the second set of relay contacts 370b operated by relay coil 370. The relay contacts 370b and the start switch contacts 386' are connected between one terminal of a 230 volt power supply 388 and one side of the relay coil 371. The opposite side of this relay coil is connected to the opposite terminal of this power supply through the normally-closed thermal overload contacts 50b of the spreader belt motor 50 and the normally-closed thermal overload contacts 153b of the clamp positioning motor 135 and a limit switch 389. Switch 389 is closed when the conveyor 33 is retracted and top carriage 32 moved back into position for automatic feeding of laundry work pieces by the spreader belts 41, 42 and 43, 44 and is open when the conveyor 33 is extended and the carriage is moved forward for hand feeding of short work pieces.
When energized, relay coil 371 closes its set of normally-open contacts 371a, which are in parallel with the start switch contacts 386'. The relay contacts 371a provide a holding circuit for keeping relay coil 371 energized after the start switch contacts 386' reopen.
The normally-open relay contacts 371b operated by relay coil 371 are connected in series with the spreader belt motor 50 and with the clamp positioning motor 135 across the power supply 392 through switch 390 and fuses 391.
In the normal operation of the machine, switches 373-376, 500' and 500 are all closed and relay coil 370 is energized. Consequently, the conveyor motor 337 is energized through the now-closed relay contacts 370a.
If switch 389 is closed (i.e., if the conveyor 33 is retracted in automatic feed position), the relay coil 371 will be energized through the now-closed relay contacts 370b when the start switch contacts 386' are closed. Consequently, the relay contacts 371b will be closed, completing an energization circuit for the spreader belt motor 50 and the clamp positioning motor 135 and the spreader belts 41, 42, 43 and 44 will operate, as described, as will the clamps operated by motor 135.
However, if switch 389 is open (i.e., if the conveyor 33 is extended) both the spreader motor 50 and the clamp positioning motor 135 will be de-energized.
CONTROL CIRCUIT FOR CLAMPS AT THE LEFT END
FIG. 20 shows schematically the electrical circuit for controlling the spreading and release of the flatwork which is inserted into the left station clamps L-1 and L-2. The circuit for the flatwork inserted in the right station clamps R-1 and R-2 is the same. The circuit for the flatwork inserted in the middle clamps M-1 and M-2 is simpler and is shown in FIG. 21.
For convenience of description, the circuit elements and signals pertaining to clamps L-1 and L-2 will be referred to as being in the "left channel" and the circuit elements and signals pertaining to clamps R-1 and R-2 will be referred to as being in the "right channel", and the circuit elements and signals pertaining to clamps M-1 and M-2 will be referred to as being in the "middle channel".
Referring to FIG. 20, an AND gate 200 at the left side of this Figure is under the control of:
(1) a normally-open L-2 limit switch 201, which is closed when the inner clamp L-2 of the left pair is in its starting position to the left, as shown in FIG. 1;
(2) a normally-open L-1 limit switch 202, which is closed when the outer clamp L-1 of this pair is in its starting position, as shown in FIG. 1; and
(3) a start switch 203 located at the left end of the machine for actuation by the operator there. The start switch 203 has three push buttons: "regular"; "tear"; and "stain". The latter two are for use by the operator when she detects a tear or a stain in the flatwork, in which case that flatwork will go through the present apparatus the same as a "regular" piece of flatwork having no such defect but will be rejected automatically later by equipment at the output side of the present apparatus.
When a start switch at 203 is closed Start/Return flip-flop 296 is set and if the limit switches 201 and 202 for both clamps are both closed, the AND gate 200 will set a Forward/Stop flip-flop 204 which sends an output signal via an inverter 205 to one input of an AND gate 206. Assuming that a start switch has not been closed already at either the middle channel or the right channel, the other two inputs to AND gate 206 will be high or "1", and the AND gate 206 will send an output signal via line 207 to one input terminal of an AND gate 208. Under the circumstances assumed, the other two inputs to gate 208 will be high.
The AND gate 208 now produces an output signal on a feedback line 209 which is connected to one input terminal of each of two OR gates 210 and 211. The outputs of these OR gates are, respectively, the second and third inputs to the AND gate 206, and the signal on line 209 will cause these OR gates to maintain these second and third inputs to the AND gate 206 high irrespective of the logic level of the other input signals to these OR gates. Therefore, the feedback signal on line 209 latches the AND gate 206 in the condition to which it was actuated initially by the left channel start signal on line 205.
The OR gate 210 has a second input at M-A which changes level in response to a center channel "A" signal. Similarly, the OR gate 211 has a second input at R-A which changes level in response to a right channel "A" signal. However, once the AND gate 206 has been latched, as described, neither a center channel "A" signal nor a right channel "A" signal can now interfere with or interrupt the left channel operation which was initiated by operating a left channel start button at 203, as described.
The left channel start signal at the output side of the AND gate 208 goes through an AND gate 212 and an inverter 213 to a line L-B.
The AND gate 208 in the left channel control circuit has two additional input lines M-B and R-B which come from the respective control circuits for the middle and right channels and which correspond to the output line L-B in the left channel circuit of FIG. 21.
ESTABLISHING PRIORITY OF OPERATION AMONG THE LEFT, RIGHT AND MIDDLE CHANNELS
If the left channel start switch was operated first, then the left channel "B" signal appearing at line L-B will inhibit the AND gate 208 in the right channel control circuit and will inhibit the AND gate 208 in the middle channel control circuit. Therefore, neither the right channel start signal nor the middle channel start signal can now get through to the output of its AND gate 208.
However, if the left channel start switch was operated second, for example, after the right channel start switch, then its AND gate 208 would be inhibited by the right channel signal at its R-B input and the signal on its input line 207 would be high and its output would be absent. These two signals are applied to the respective input terminals of an exclusive NOR gate 214 and the signal at the output of 214 will be low. After a time delay in the time delay circuit 215 this low will be applied as the left channel "A" signal on line L-A.
Line L-A is connected to an input of one of the two OR gates 210 and 211 in the right channel control circuit and the middle channel control circuit. The left channel "A" signal will not affect the previously "latched" right channel control circuit (under the conditions assumed) but it will disable the AND gate 206 in the middle channel control circuit. Thus, the second start signal (in the left channel) will now produce an "A" output signal which prevents the third start signal (in this instance, the middle channel "start" signal) from getting past the AND gate 206 in the middle channel control circuit just as the first "start" signal (in this instance, the right channel "start" signal) has produced a "B" signal which is preventing the second "start" signal (for the left channel) from passing through the AND gate 208 in the left channel control circuit.
With this arrangement, then, the first start switch that is operated (whether for the left channel, the right channel, or the middle channel) disables the operation of the second channel to have its start signal pass through gate 208, and the second similarly disables the third. Therefore, even if two or all three of the operators attempt to start their respective channels at about the same time, the first one started will finish most of its operation before the second begins, and the second before the third.
MOVING THE LEFT CHANNEL CLAMPS L-2 AND L-1 FROM THE LEFT END TO THE MIDDLE OF THE APPARATUS
The AND gate 212 has a first input connected to the output of AND gate 208 and a second input via line 219 from a "forward/reverse" flip-flop 220 which will provide a "1" on line 219 if the L-2 limit switch 201 has been operated properly. Normally this will be true, and the AND gate 212 will be enabled by the respective signals on its two inputs. The output signal from the inverter 213 is applied via line 221 to one input of a NOR gate 222 which has its output connected to the "L-2R" block 224. This block represents the control circuit for the clutch-brake unit 158 (FIG. 4) for the cable 146 which positions the inner left clamp L-2. When the correct signal is established at point 223 by the NOR gate 222, the inner left clamp L-2 begins to move to the right from its normal position near the left end of the apparatus over to a position at the middle of the apparatus.
The signal level at point 223 also depends on two other inputs to the NOR gate 222.
One of these inputs is connected via lines 225 and 226 to a flip-flop 227, which at this time establishes a low at this input.
The third input to the NOR gate 222 is connected via line 228 to a flip-flop 252, which establishes a low at this input until the "stretch" sensor 78 has been operated by the sheet or other piece of flatwork.
Therefore, with the inner left clamp L-2 at its normal position (to the left) and the left channel "start" signal having come through to the NOR gate 222, the latter will establish a high at point 223 to begin driving cable 146 clockwise in FIG. 4 to move the left inner clamp L-2 to the right, toward the middle of the apparatus.
The left outer clamp L-1 begins moving to the right at the same time as the left inner clamp L-2. This is done by actuating the clutch-brake unit 153 (FIG. 5) to drive cable 145 counterclockwise in FIG. 4. This is designated schematically by the "L-1 R" block 230 at the middle left in FIG. 20.
As shown in FIG. 20, such actuation of the "L-1 R" block 230 requires an output signal of the proper level from an AND gate 231. One input of this AND gate is connected via lines 232 and 233 to the output of the NOR gate 222. A second input of this AND gate is connected via line 242 and an inverter to a flip-flop 234, which is connected through a time delay circuit 235 to the L-1 limit switch 202, which is closed while the left outer clamp L-1 is in its normal position at the left end of the apparatus. Such closing of the outer limit switch 202 sets the flip-flop 234 to establish a high at the corresponding input of the AND gate 231. Then, when the correct level signal appears at point 223 for starting the left inner clamp L-2 to move in, this same signal enables the AND gate 231 to actuate the "L-1 R" block 230 for causing the left outer clamp L-1 to begin moving to the right, toward the middle of the apparatus, in unison with the left inner clamp L-2.
CLAMPS PAUSE AT THE MIDDLE OF THE APPARATUS
The signal that causes clamp L-1 to move toward the center of the machine also supplies one input to an AND gate 600. The second input to this gate is supplied when the middle limit switch 601 is actuated by the clamp L-2 reaching the center of the machine. Switch 601 is a proximity limit switch that senses a vane carried on the L-2 clamp carriage.
When both inputs are present to AND gate 600, an output appears at 602 which is applied to a time delay circuit 236. The time delay provided by 236 is adjustable to provide a fine adjustment (1 or 2 inches) of where the clamps stop at the center of the machine.
After time delay provided by 236 has expired, the signal is passed on to an OR gate 237 which sets the flip-flop 227.
When this happens, the NOR gate 222 is disabled via lines 226 and 225 and the actuating signal at point 223 for the "L-2 R" drive 224 disappears. Consequently, the inner left clamp L-2 stops moving to the right. Note that this "stop" signal at point 223 is applied to one input of a NOR gate 238, causing the latter to actuate the brake 239 in the clutch-brake unit for the drive cable 146 for the left inner clamp L-2, so that this cable is braked to a stop now. (The other input to the NOR gate 238 is the same as the input at 223 at this time.)
The disabling of NOR gate 222 also removes one enabling input to the AND gate 231 ahead of the "L-1 R" drive 230.
Also, when the flip-flop 227 is set it applies a signal via line 240 to an OR gate 241 for resetting the flip-flop 234, which now removes the other enabling input for the AND gate 231 on line 242. The purpose of flip-flop 234 is to control the direction of movement of clamp L-1.
The "L-1 R" drive 230 is disabled, de-clutching the counterclockwise drive for the cable 145 in FIG. 4, which had been moving the left outer clamp L-1 to the right. At the same time the brake actuating signal at the output of NOR gate 400 is applied to the brake 401 in the clutch-brake unit 153 for cable 145, so that it is braked to a stop simultaneously with the drive cable 146 for the left inner clamp L-2.
The setting of flip-flop 227 (by the OR gate 237, as described) also applies a signal via lines 226 and 243, through an OR gate 244, through line 604 to AND gate 603. The other input to AND gate 603 is high (1) since the output of AND gate 212 is high at this time. Therefore, the output of AND gate 603 is high and is passed by line 245 to one input of a NOR gate 246. The output of this NOR gate is connected to the "L-1 L" block 247 (FIG. 20) which controls the energization of the clutch-brake unit 153 for the cable 145. However, this input signal to the NOR gate 246 disables it from operating the "L-1 L" block 247 at this time. Therefore, the outer left clamp L-1 now pauses at its position near the middle of the apparatus.
The inner left clamp L-2 also is under the control of flip-flop 227 via lines 226 and 225 and NOR gate 222. The "L-2 R" block 224 at the upper right will be disabled, and the clamp L-2 will stop, in response to the setting of flip-flop 227 and it will remain disabled until flip-flop 227 is reset.
Therefore, the outer left clamp L-1 will stop at a location just to the left of the centerline of the machine and the inner left clamp L-2 will stop at a location just to the right of this centerline.
The duration of the clamps' "pause at the middle" is determined jointly by:
(1) an adjustable time delay circuit 248 which begins to time out in response to the setting of flip-flop 227; and
(2) the actuation of the trailing edge sensor 98 or 99 (whichever is effective at this time) by the immediately preceding sheet (which has already been released by its clamps and blown onto conveyor 33).
The output of time delay circuit 248 is connected to one input of an AND gate 649, whose output is connected to a reset terminal of flip-flop 227. AND gate 649 has a second input via line 678 from the output side of a time delay circuit 605 connected to the output of the AND gate 276. This adjustable time delay provided by the time delay circuit 605 has the same effect as moving up or moving down the trailing edge sensor 98 or 99 whichever is effective at this time.
A switch 606 connected to one input of the AND gate 276 determines whether the lower trailing edge sensor 98 or the upper trailing edge sensor 99 is effective.
In the lower position of switch 606, it is connected to a line which is continuously at a high (logic 1) potential. In this setting of the switch, whenever the trailing edge of the laundry piece moves up past the lower photocell 98, the latter will produce a logic 1 signal to the other input of AND gate 276, causing its output to go high. This lower position of switch 606 is used for higher speed operation of the conveyor 33.
In the upper position of switch 606, the AND gate 276 receives its first logic 1 input signal from the lower photocell 98 when the trailing edge of the laundry piece moves up past it. The AND gate 276 receives its second logic 1 input signal from the upper photocell 99 when the trailing edge of the laundry piece moves up past it. When this happens, the output of the AND gate 276 goes high. This upper position of switch 606 is used for lower speed operation of the conveyor 33.
The time delay circuit 248 may be set to time out after 0.1 or 0.2 second, typically, and this determines the minimum duration of the clamps' pause at the middle. For example, if there is no preceding piece of flatwork in the machine or if it is a short piece, the pause at the middle will be determined by the time delay circuit 248. Usually, however, there will be a preceding flatwork piece being pulled forward by the conveyor 33, but with its trailing edge not yet past the trailing edge sensor 98 or 99 which is effective at that time. In that case, the AND gate 649 will not be enabled until substantially immediately after the trailing edge of the preceding flatwork piece moves up past the trailing edge sensor 98 or 99 whichever is effective.
MOVEMENT OF CLAMP L-1 FROM THE MIDDLE TO THE LEFT
MOVEMENT OF CLAMP L-2 FROM THE MIDDLE TO THE RIGHT
When the flip-flop 227 is reset, its output signal via lines 226 and 243, the OR gate 224, line 604, and gate 603, and line 245 enables the NOR gate 246. A second input to this NOR gate is connected to the output line 242 from flip-flop 234 through an inverter. Flip-flop 234 was reset when flip-flop 227 was previously set but is unaffected by the resetting of flip-flop 227. A third input to the NOR gate 246 is from the L-1 limit switch 202, and this input now is low. All input signals to the NOR gate 246 are low, thus enabling it, and its output now actuates the "L-1 L" block 247 so that the cable 145 is now driven clockwise in FIG. 4 to move the outer left clamp L-1 from near the middle of the apparatus back over to the left.
The resetting of the flip-flop 227 after the time delay also enables the NOR gate 222 again via lines 226 and 225, so that the "L-2 R" block 224 is actuated again and the "L-2 Brake" block 239 is disabled. Consequently, the clockwise drive to the cable 146 for the inner left clamp L-2 in FIG 5 is re-established and this clamp again begins moving to the right (from near the middle of the apparatus toward its right end).
STOPPING THE OUTWARD MOVEMENT OF CLAMPs L-1 and L-2
When the top edge of the flatwork held by the two outwardly-moving clamps L-1 and L-2 moves up past the "stretch" sensor 78, this sensor (at the lower left corner of FIG. 20) enables an adjustable time delay circuit 430. When the delay is completed, the signal is passed on to AND gate 251, the output of which triggers a flip-flop 252.
A time delay circuit 251 TD also controls AND gate 251 to prevent the flip-flop 252 from being triggered by the movement of clamps L-1 and L-2 past this sensor. Beginning when the clamps start moving apart until the time delay in circuit 251 TD has been completed, the "stretch" sensor is inoperative in effect because the AND gate 251 is disabled. The triggering of flip-flop 252 causes NOR gate 222 to be disabled via line 228. This action of NOR gate 222 disables the "L-2 R" block 224 and enables the "L-2 Brake" block 239. Therefore, the movement of the inner left clamp L-2 to the right is stopped.
Also, this disabling signal on line 228 is applied via line 263 through the OR gate 244, line 604, AND gate 603, and NOR gate 246, disabling the latter so as to disable the "L-1 L" block 247 and enable brake block 401. Therefore, the movement of the outer left clamp L-1 to the left also is stopped.
FLATWORK RELEASED BY CLAMPS L-1 AND L-2 AND BLOWN ONTO CONVEYOR 33
The output of flip-flop 252 is connected through the "Pause Before Release" time delay circuit 408 to one input terminal of an AND gate 409. The other input terminal of AND gate 409 is connected to the output of a "sheet overlap" time delay circuit 277 associated with a flip-flop 420 at the output side of AND gate 276. Flip-flop 420 is set in response to the actuation of the effective trailing edge sensor 98 or 99, as described, and circuit 277 begins to time out. Assuming that the spacing between the leading (top) edge of the present sheet and the trailing (bottom) edge of the immediately preceding sheet is sufficient, so that time delay circuit 277 has timed out, the AND gate 409 will be enabled when flip-flop 252 has been triggered in response to "stretch" sensor 78 and after the time delay provided by 408 has elapsed.
The output of AND gate 409 is connected to an OR gate 410 (at the lower right in FIG. 20), which is enabled in response to the enabling of AND gate 409. The output of OR gate 410 is connected via line 255 to flip-flop 253, so that flip-flop 253 is operated in response to the enabling of OR gate 410. When this happens, flip-flop 253 actuates the clamps L-1 and L-2 to release the sheet. (This is done through the air cylinder 87 for each clamp, as already explained.) The clamp-release circuitry is designated schematically by the block 256 in FIG. 20. A time delay circuit 257 associated with the flip-flop 253 restores it after a suitable time interval so as to restore the clamps to their normal condition following their release of the sheet.
The time interval between the operation of the stretch sensor 78 and stopping of the clamp carriages depends upon the adjustment of the time delay circuit 430. The adjustablility of this time interval enables the tension on the sheet between the clamps at the time of its release to be adjusted. This adjustment is made whenever possible by adjusting the beam of 78 higher or lower on the reflector because addition of time delay by 430 causes narrow flatwork not to be stretched as tightly as wide pieces.
The AND gate 409 also controls the actuation of the blow-pipes B-1, B-2 and B-3 for blowing onto the conveyor 33 the flat-work piece which has just been released by the left clamps L-1 and L-2. The output of AND gate 409 is connected through an adjustable time delay circuit 258 to trigger a flip-flop 411 which operates the block 259 which designates schematically in FIG. 20 the blowpipes B-1, B-2 and B-3 and their electropneumatic controls.
The duration of the air blasts from these blowpipes is determined by an adjustable time delay circuit 260, which is connected between the output of flip-flop 411 and its reset input, which causes the flip-flop to reset after a time delay in time delay circuit 260, thus turning off the blowpipes.
The output of AND gate 409 is also connected to flip-flop 611 and will trigger it, provided line 233Q (the data input to flip-flop 611) is high. Since this is true from the time that the clamps begin their movement until they start back to the station after blow down of the sheet, the flip-flop 611 will be triggered each time a sheet is fed from the left station and successfully blown down onto the conveyor.
An electro-mechanical counter is represented by block 612 in FIG. 20. This is operated each time a pulse output comes from flip-flop 611. The length of the pulse depends on the time delay provided by a time delay circuit 613 through which the output signal resets 611.
The output of time delay circuit 258 is connected to an adjustable "Pause After Release" time delay circuit 264 whose output is connected via line 413 to flip-flop 252 to reset the latter after circuit 264 times out.
Resetting flip-flop 252 sets flip-flop 607 through line 608 and supplies a signal to AND gate 422. The other input to AND gate 422 is supplied from flip-flop 607, which resets itself after a 0.1 second time delay provided by a time delay circuit 609. Thus, the output of AND gate 422 will be a 0.1 second pulse whenever flip-flop 252 is reset. This pulse output from AND gate 422 resets flip-flop 420. This inhibits the blowpipes from operating until the trailing edge passes the trailing edge sensor 98 or 99 which is effective at this time and the "sheet overlap" time delay 277 times out.
RETURN OF CLAMP L-2 FROM RIGHT END TO LEFT END OF APPARATUS
After the time delay circuits 258 and 264 time out, the OR gate 267 is enabled via line 266 to apply a signal through a "reverse" line 268 which extends to one input of an OR gate 269. This signal through the OR gate 269 reverses the "forward/reverse" flip-flop 220, thereby making its output on line 219 low and the output from the AND gate 212 low. This logic level change at the output of AND gate 212 produces the signal at line 221 for disabling the NOR gate 222.
The reversal of the flip-flop 220 also produces an output signal on line 219 which is applied to a NOR gate 271 to actuate the "L-2 L" block 272. This block represents schematically the reversing clutch for cable 146 (FIG. 5) which now drives this cable counterclockwise in FIG. 5 to move the left inner clamp L-2 from the right end of the apparatus toward the left. The signal at the output of the NOR gate 271 at this time causes the NOR gate 238 to release the L-2 brake 239 which had been applied to hold the cable 146 stationary.
For the NOR gate 271 to be enabled by the signal on line 219, as described, its two other inputs must be "low" also. One of these is the signal on line 270, which is low unless clamp L-2 is back at its starting position. The remaining input on line 273 has the proper level if either of the following two conditions is met:
(1) the outer left clamp L-1 is back in its starting position at the left end of the apparatus, holding the limit switch 202 closed and thereby providing the proper signal polarity on the input line 274 to a NOR gate 275 whose output is connected to line 273; or
(2) the "L-1 L" block 247 is energized, which means that the outer left clamp L-1 is moving to the left.
ENABLING NEXT CHANNEL TO OPERATE
The clamps for the next channel cannot move until the inner left clamp L-2 begins its return from the right end of the apparatus over to its starting position at the left end. This happens, as described, in response to a "reverse" signal on line 268.
This "reverse" signal passes through the OR gate 269 and is applied via line 290 to one input of an AND gate 291. A second input to this AND gate is from the output of AND gate 212 through a time delay circuit 431. With both inputs to the AND gate 291 now high, this AND gate delivers a reset signal via OR gate 292 to reset the flip-flop 204. This disables the AND gate 206 which, in turn, disables the AND gate 208 in the channel priority circuitry in the left channel control circuit of FIG. 20. Therefore, the signal L-B at the outlet side of the inverter 213 in the left channel control circuit goes high and no longer inhibits the operation of the next channel in order. The second channel to have its start button pushed would have a low on equivalent "A" line. As this second channel started its "A" signal would go high, allowing the third channel to have its start button pushed to have its signal move up to its line 207.
Consequently, if, for example, the next channel to operate is the right channel, its clamps R-1 and R-2 can now begin moving from their starting positions at the right end of the machine over to the middle of the machine because the inner left clamp L-2 will be out of their way, moving to the left.
If the next channel is the middle channel, then there is no initial movement of its clamps M-1 and M-2 to the middle of the apparatus because that is their starting position, so they immediately begin to move apart when the trailing edge photocell 98 or 99 (whichever is effective) sees the trailing edge of the previous sheet and time delay 605 has expired.
TRAILING EDGE DETECTED
As already explained, the operation of the left channel all this time has inhibited whichever of the other two channels (right or middle) is next in the order of operation, as determined by the order in which the respective start switches for the different channels were closed.
The AND gate 276 is controlled by one of the trailing edge sensors 98 or 99, as described, and its output is connected via an inverter and line 278 to one input of the AND gate 249. The second input to this gate is from the inverted output of flip-flop 252. This output occurs after the "pause after release" has occurred, that is, when the flip-flop is reset.
At the time that the piece of flatwork is blown onto the conveyor and the clamps start to return to their station and the sheet is covering the "trailing edge" sensors 98 and 99, both inputs to gate 249 are high (1) so that the output of this gate is low. This signal will go high when the "trailing edge" sensor 98 or 99 whichever is effective at this time is uncovered, resulting in a signal that switches from 0 to 1 at the output of gate 249. This signal will be discussed later in connection with the "Quality Control Circuit".
As already explained, the flip-flop 227 is part of the "pause at the middle" circuitry for the left channel which performs this control function for the clamps L-1 and L-2 after they have moved together from the left over to the middle of the apparatus.
FIG. 20 shows a second time delay circuit R 236 connected to the input of flip-flop 227 through the OR gate 237. R 236 is part of the right channel control circuit (which is identical to the left channel control circuit) and it has its input connected via AND gate R 600 to a line R 231a in the right channel circuit which is the counterpart of AND gate 600 and line 231a in the left channel circuit.
If the right channel is in operation before the left channel flatwork has moved up past the effective trailing edge sensor 98 or 99 (which is possible because the right channel clamps R-1 and R-2 can begin moving to the left from their starting position at the right end toward the middle of the apparatus), there will be an enabling signal on line R 231a in the right channel control circuit. After the clamps have reached center, as sensed by centering limit switch 601, the signal is high (1) on both inputs of gate R 600.
This starts the time delay circuit R 236, which times out after an inch or two of clamp movement which is adjusted so the clamps are centered on the center of the machine.
The output signal from R 236 now operates the flip-flop 227 the same as it was operated by the output signal from the corresponding left channel time delay circuit 236. After the "pause at the middle" interval determined by the time delay circuit 248, the latter delivers an enabling signal to one input of an AND gate 649. A second enabling signal at the other input of this AND gate appears on line 678 in response to effective trailing edge sensor 98 or 99 being uncovered by the previous piece of flatwork being fed.
Therefore, with the right channel clamps R-1 and R-2 at the middle of the apparatus, the flip-flop 227 will be reset through the AND gate 649 in response to the movement of the left channel flatwork up past the effective trailing edge sensor. This operation of the flip-flop 227 produces a signal on line 226 and the branch line R 225 in the right channel control circuit which is the counterpart of line 225 in the left channel control circuit of FIG. 20. In response to this signal on line R 225, the right channel clamps R-1 and R-2 will move out to the left and right from their pause position at the middle of the apparatus so as to spread the leading edge of the right channel flatwork. The foregoing description assumed that the right channel was next to operate after the left channel.
However, if the middle channel is next to operate after the left channel, then the flip-flop 227 will not be operated by the right channel time delay circuit R 236 as just described. Instead, the signal from the effective trailing edge sensor will be applied via line 294 to the middle channel control circuit (FIG. 21). The two middle channel clamps M-1 and M-2 start at the middle of the apparatus, and after this signal appears on line 294, indicating that the trailing edge of the left channel flatwork has moved up past the effective trailing edge sensor, these middle clamps can be spread apart, as explained hereinafter with reference to FIG. 21.
MISFEED
If a piece of flatwork was not inserted in the left channel clamps L-1 and L-2, or has dropped out of either or both of these clamps, of if the diagonally opposite corners are fastened in the clamps, then the "stretch" sensor 78 will not be actuated as the clamps move out from the middle of the apparatus to the left and right, respectively. Therefore, this sensor cannot trigger the stopping of the outer left clamp L-1 and the reversal of the inner left clamp L-2, as previously described.
This control function will be achieved through a left channel misfeed time delay circuit 280 (at the lower middle of FIG. 20), whose output 281 is connected to one input of an OR gate 282. The output 283 of this OR gate is connected through a time delay circuit 432, which provides a 0.01 second time delay, to one input of the previously mentioned OR gate 267. As already explained, the output of OR gate 267 is connected via line 268 and OR gate 269 to the "forward/reverse" flip-flop 220 for reversing the direction of the inner left clamp L-2.
Also, the output of OR gate 282 is connected via lines 283 and 433 to one input of OR gate 410, so that the clamps will release the sheet immediately upon the enabling of OR gate 282 (and slightly before the clamp movements are reversed.)
The input of the left channel misfeed time delay circuit 280 is connected via lines 285 and 286 to the output of an AND gate 287. One input 288 of the AND gate 287 is connected via lines 232 and 288 to the output 223 of the NOR gate 222. The other input 289 of the AND gate 287 is connected to the output of the NOR gate 246.
With this arrangement, the AND gate 287 is enabled while the other left clamp L-1 is moving out to the left and the inner left clamp L-2 is moving out to the right. This starts the time delay circuit 280, and after a time interval long enough for the two clamps to have moved substantially all the way out, this delay circuit produces an output signal at 281 which goes through OR gate 282, time delay circuit 432 and OR gate 267 to line 268 for reversing the flip-flop 220. This reversal of flip-flop 220
(1) disables the NOR gate 222 (as described in the section headed "Return of Clamp L-2 from Right End to Left End of Apparatus") to disable the L-2R drive 224 and actuate the L-2 brake 239, thereby preventing the inner left clamp L-2 from continuing to move out to the right, and
(2) enables the NOR gate 271 to actuate the "L-2 L" block 272, for reversing the drive to the inner left clamp L-2 so as to bring it back to the left end of the apparatus.
Slightly later, the outer left clamp L-1 in moving to the left will have closed its limit switch 202, thereby disabling the NOR gate 246 and stopping the "L-1 L" drive 247 so that the outer left clamp L-1 will stop moving out to the left.
When the leftward-moving inner left clamp L-2 closes its limit switch 201, this disables the OR gate 271 and de-energizes the "L-2 L" drive 272 for cable 146 in FIG. 5. At the same time, the NOR gate 238 is enabled for operating the brake 239 for this cable.
Consequently, both clamps L-1 and L-2 are now stopped at their starting positions at the left end of the apparatus.
The right channel control circuit has a time delay circuit 280R in FIG. 20, with its input from a line 286R extending from the output of an AND gate corresponding to AND gate 287, and its output on line 281R going to a second input of OR gate 282.
CLAMP RETURN
The operator may bring back her clamps after she has operated one of her start buttons. Assuming that she decides to do this after the clamps L-1 and L-2 for this flatwork have been displaced from their starting positions at the left end of the apparatus, when she momentarily closes the "return" switch 295 in FIG. 20, this resets the "start/return" flip-flop 296.
This flip-flop, via lines 297 and 298, enables OR gate 269, which resets flip-flop 220. Through the NOR gate 271 the flip-flop 220 now actuates the "L-2 L" block 272 to bring the inner left clamp L-2 back to the left.
Flip-flop 296 also resets flip-flop 234, via lines 297 and 299 and OR gate 241, to actuate the "L-1 L" block 247 to bring the outer left clamp L-1 back to the left.
The operation of the "return" switch 295 also cancels out any quality control designations (i.e., "Tear" or "Stain") which the operator may have included by the signal on line 403 to the quality control section (FIG. 22).
The operation of a "clamp" button causes the clamps to release the sheet which had been inserted by the operator. This is effected through circuitry which does not appear in FIG. 20.
Also, the machine is provided with a "stop" switch which causes all three pairs of clamps to release their respective sheets and all three return "buttons" to be effectively operated.
MIDDLE CHANNEL CONTROL CIRCUIT
FIG. 21 shows schematically the control circuit for the middle clamps M-1 and M-2. Elements in this Figure which correspond to those in the end channel control circuit of FIG. 20 are given the same reference numerals, and the detailed description of these elements and their functions will not be repeated.
FIG. 21 is substantially simpler than FIG. 20 because the clamps M-1 and M-2 have less complicated movements. They are both stationary at the middle, or moving apart, or stationary near the opposite ends of the apparatus, or moving toward each other. They do not move in the same direction at any time. As a consequence, the control circuitry for these middle station clamps is substantially simpler than the control circuitry for either pair of end channel clamps.
With both middle clamps M-1 and M-2 at their middle positions, the limit switches 201 and 202 in FIG. 21 will be closed, thereby enabling an AND gate 445 which triggers a flip-flop 220 to provide an enabling signal via an inverter 220' and line 219 leading to one input of an AND gate 212.
When the operator now presses one of the three push buttons for the start switch at 203, the AND gate 200 will be enabled and will set the "forward/stop" flip-flop 204. This flip-flop will enable the AND gate 206 via an inverter 204', provided there is no inhibit signal at the L-A input to OR gate 210 or at the R-A input to OR gate 211. The output from AND gate 206 will enable the next AND gate 208, provided there is no inhibit signal on the latter's L-B input or R-B input. The AND gate 208 now provides a second enabling input to the AND gate 212, so that AND gate 212 now is enabled (provided both middle clamps are properly positioned at the middle channel loading station).
The output from the AND gate 212 supplies one enabling input to an AND gate 310 through an adjustable time delay circuit 440, which preferably provides a time delay of about 1.0 second.
The output from the AND gate 212 also is applied through an inverter 213 to a line designated M-B, which provides the M-B inhibit input to the AND gate 208 in each of the left and right channel circuits.
The output from AND gate 212 also is applied through an OR gate 441 to a block 442, which represents schematically the mechanism for returning the middle clamps forward toward the conveyor 33 at the entry side of the apparatus, so that the middle clamps are not rearwardly offset from the end clamps as much as they were when the operator was inserting the laundry piece into the middle clamps.
The output from the time delay circuit 440 at the output side of AND gate 212 is applied via line 301 to one input of an AND gate 291, but at this time the signal on line 290 disables the AND gate 291.
The AND gate 310 has a second input from flip-flop 252 (FIG. 20) via lines 608 and 451. As already explained, flip-flop 252 produces this signal after the stretch sensor 78 senses that the top edge of the flatwork stretched out.
A third input to the AND gate 310 is from OR gate 311. One of its inputs is line 294. As already explained in the section headed "Trailing Edge Detector", a signal of the proper level appears on line 294 following the passage of the trailing edge of the preceding piece of flatwork up past the effective trailing edge sensor 98 or 99. Consequently, the AND gate 310 will be enabled at a time when the flatwork will not interfere with, or be interfered with by, the preceding flatwork.
When the AND gate 310 is enabled it energizes the block 224 designated "out right and left" in FIG. 21. This represents the forward clutches for both cables 111 and 115 in FIG. 5, so that both clamps M-1 and M-2 now move laterally outward, to the left and right, respectively. The time delay circuit 440 has delayed this spreading of the middle clamps long enough for these clamps and their support rails to have moved rearward to their operating positions.
A feedback line 312 from the output of AND gate 310 to a second input of the OR gate 311 maintains the latter enabled even after the trailing edge input signals to its first input 294 is no longer present.
The enabling of AND gate 310 also applies a signal via line 286M to one input of an OR gate 313 in the control circuitry in the center of FIG. 20. This OR gate has a second input via line 286 from the AND gate 287 of the left channel control circuit and a third input via line 286R from the same AND gate in the right channel control circuit. Accordingly, the OR gate 313 will be enabled whenever any pair of clamps L-1 and L-2, M-1 and M-2, or R-1 and R-2, are moving apart.
The output signal from the OR gate 313 is applied via line 314 through the time delay circuit 251 TD to the AND gate 251. As already explained, the AND gate 251 is enabled in response to the actuation of "stretch" sensor 78 when the flatwork is spread apart by the outwardly moving clamps after the time delay in circuit 251 TD has timed out.
As already explained, the actuation of the "stretch" sensor causes the outwardly-moving clamps to be operated to release the flatwork and actuates the blowpipes to blow the released flatwork onto the conveyor 33. When the middle channel is in operation, these control functions are effected by the circuit elements shown in FIG. 21 and described under the previous heading "Flatwork Released by Clamps . . . and Blown onto Conveyor 33".
The same is true for "Stopping the Outward Movement of Clamps". The outwardly-moving clamps M-1 and M-2 are stopped automatically by disabling block 224 in FIG. 21 and enabling blocks 239 and 401 via NOR gates 238 and 400, respectively, to apply the brakes for the M-1 and M-2 cables 115 and 111 in FIG. 5.
When the flatwork has been blown onto the conveyor there is a short adjustable pause in time delay 264 before line 268M goes high. The signal path is line 266, OR gate 267, line 268M (FIG. 20), line 268 (FIG. 21), OR gate 269, line 290, and flip-flop 220 (resetting it). Flip-flop 220 actuates the "in left" block 272 and the "in right" block 230 through NOR gates 271 and 246 in the same manner as described in detail for the left channel. The "in left" block 272 and the "in right" block 230 in FIG. 21 represent schematically the reverse clutches for the cables 111 and 115 in FIG. 5. Consequently, the direction of these cables is reversed and both clamps M-1 and M-2 are moved back toward the middle of the apparatus.
In FIG. 20, a "misfeed" time delay circuit 280M is connected to the input line 286M from the center channel circuit (FIG. 21) through an inverter 315. The output of this time delay circuit 280M is connected to a second input of the OR gate 282 for the purpose of automatically reversing the outwardly-moving middle clamps M-1 and M-2 in the event of a misfeed of the middle channel sheet. The enabling of the OR gate 282 will produce a signal on line 268M in FIGS. 20 and 21 for reversing the flip-flop 220 to reverse the drive to cables 111 and 115.
As already explained, the middle clamps and their support rails 100-1 and 100-2 are retracted to the operating (reverse) position in response to the closing of start switch 203 for the middle channel.
If either middle clamp is not at its loading position along the respective support rail 100-1 or 100-2, then the pneumatic retraction device 442 for these support rails will be actuated through OR gate 441 from line 443 at the output side of an inverter 444. The input side of the inverter is connected to the output of an AND gate 445 having its respective inputs connected to the limit switches 201 and 202 for the middle clamps. Accordingly, the middle clamps will not be displaced toward the operator for convenience in loading them unless they are at the correct positions along their respective support rails.
Also, the middle clamps cannot begin to spread apart if either of them is not properly positioned at the middle channel loading station (holding the corresponding limit switch 201 or 202 closed) because in that event the AND gate 200 would not be enabled.
QUALITY CONTROL CIRCUIT
FIG. 22 shows a portion of the quality control circuit in the present system. As already mentioned, if the operator notices a tear or a stain in the sheet or other piece of flatwork, she may operate the correspondingly labeled pushbutton in the start switch 203 at her station. This will permit the defective flatwork to go through the present apparatus the same as a perfect piece of flatwork, but be rejected later, such as in a folder at the outlet side of the present apparatus.
FIG. 22 shows the quality control circuitry pertaining to a "tear" defect in the left channel flatwork.
The block 203T represents schematically the "tear" contacts of the operator's start switch. When closed, these switch contacts set a flip-flop 320, and the output of this flip-flop is the data input of a flip-flop 321.
The signal on 322 will now set the flip-flop 321 to produce an output signal on a line 325 leading to one input of an OR gate 326. This OR gate has two other inputs, on lines 325M and 325R, which are the lines in the middle channel and right channel quality control circuitry corresponding to line 325 in the left channel quality control circuitry.
Thus, the OR gate 326 will be anabled by a "tear" input signal for the left, middle or right channel, followed by the counter operating.
The output of flip-flop 321 is applied via OR gate 328 and line 327 to reset the flip-flop 320, so that the latter becomes ready to receive another quality control input signal.
Flip-flop 321 is maintained in its set condition until the trailing edge of this piece of flatwork is detected by the "trailing edge" sensor. When the trailing edge is detected, a signal appears on line 293 which sets flip-flop 404, provided a "tear" signal is present at 325, 325M or 325R. Line 407 connects the output of flip-flop 404 to the "tear" output 405 feeding the external quality control equipment. This signal also is passed through time delay 406 and after a 0.1 second resets flip-flop 404.
The operation of the "stain" channel is identical to that of the "tear channel."
Thus, for a "tear" or "stain" signal to be delivered to the apparatus which can reject the defective flatwork, the following conditions must have occurred:
(1) the operator has closed the "tear" or "stain" start switch contacts at 203;
(2) the clamps have moved out;
(3) the "stretch" sensor 78 has been actuated; and
(4) the "trailing edge" sensor has been operated.
FIG. 26 shows a schematic diagram of the pneumatic system of the part of the apparatus that controls clamp control. Accumulator tank 1001 is a high pressure air storage reservoir which receives high pressure air through a high pressure regulator 1002. There are six solenoid valves 1003-1008. At the right side of FIG. 26, there are three pairs of actuating cylinders 1010-1015. From the high pressure reservoir 1001, high pressure air is reduced by a low pressure regulator 1016 which supplies low pressure air to a supply line 1017 which is read by a meter 1018. High pressure is applied over three lines 1019, 1020 and 1021.
Low pressure lines 1022, 1023 and 1024 lead to valves 1008, 1006 and 1004 respectively. In the de-energized condition of the solenoid valves shown in the drawings, low pressure air is fed through the valves to lines 1025, 1026 and 1027. These lines feed air through valves 1007, 1005 and 1003 via lines 1028, 1029 and 1030 to the lower side of the pneumatic cylinders 1010-1015. With low pressure on the cylinders, the clamps of the apparatus are in a low pressure clamping condition where they grip the article only reasonably lightly so that it is relatively easy to insert and remove articles.
When valves 1008, 1006 and 1004 are energized by the circuit of FIG. 27 as will be explained, these valves shift to the right as viewed in the drawings until the passageways 1031, 1032 and 1033 line up with orifices 1034, 1035 and 1036. In this condition, high pressure air is supplied from lines 1019, 1020 and 1021 through the valves to the cylinders 1010-1015. The low pressure air is off. The cylinders then cause the clamps to exert more force on the article for holding it more tightly, and this condition occurs when the clamps are away from their home station such as when the article is being spread. Thus, a heavy or wet article will not tend to be pulled from the clamps.
FIG. 27 shows the electrical schematic diagram for operating the pneumatic circuit just described. Terminals 1111 and 1112 receive 12 volts direct current, with terminal 1111 being positive and terminal 1112 being negative. Terminal 1113 receives a signal from the left inboard proximity switch, terminal 1114 receives a signal from the both center proximity switches, and terminal 1115 receives a signal from the right inboard proximity switch. These signals are inverted from the proximity switch signals previously discussed coming respectively from block 201, the output of AND gate 445 and block R201. Terminal 1116 is a ground terminal, and terminal 1117 at the lower right receives 18 volts D.C. Terminals 1118 and 1119 receive 230 volts of alternating current.
The transformer 1120 and the diodes 1121 and 1122 rectify the alternating current from terminals 1118 and 1119. The signals from terminals 1113, 1114 and 1115 are amplified by the amplifiers 1122, 1123 and 1124. These signals are applied by transistors 1125, 1126 and 1127 to the coils of solenoid valves 1008, 1006 and 1004. Thus, when the clamps leave the left, right and center inboard stations, the valves 1008, 1006 and 1004 are energized to apply high pressure to the clamps in accordance with the previous description.
Switches 1128, 1129 and 1130 are operator controlled, and when they are closed, they energize the coils of valves 1007, 1005 and 1003. These valves cause the clamps to open and close, and the energized condition opens the clamps. For example, when valve 1003 is energized, passage 1150 connects line 1025 to line 1151. This applies pressure to the upper side of the cylinders 1010 and 1011 causing the clamps to open. Lines 1152 and 1153 do the same thing for the other clamps. Normally the clamps are opened automatically as previously described by outputs to blocks 256, 256M and 256R.
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An apparatus for spreading laundry flatwork pieces, such as bed sheets, before feeding them to subsequent processing equipment, such as an ironer and a folder. The flatwork pieces are spread apart by pairs of clamps, there normally being one pair of clamps at the left end, another pair of clamps at the right end, and a third pair of clamps at the center of the apparatus. The spread-out flatwork pieces are blown onto a conveyor for conveying them to the subsequent processing apparatus. Trailing edge sensors are positioned at different levels below the clamps to sense the upward passage of the bottom edge of the laundry flat piece deposited on the conveyor, and a selector switch enables one of the sensors and disables the other, depending upon the speed at which the conveyor is being operated. Proximity switches sense the positions of the clamps. There is an overlying conveyor cooperating with the main conveyor for sandwiching the laundry flat piece as it is moved into the apparatus for stretching purposes. The main conveyor can be moved to an extended position beyond the clamps to facilitate hand feeding of small laundry flat pieces without engagement by the clamps.
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BACKGROUND AND SUMMARY
[0001] The present invention pertains to a manually operated, engine driven vibratory concrete screed and, more particularly, to an improved vibration isolation and control system for such a screed.
[0002] Vibratory screeds are used to smooth the surface of freshly poured concrete and eliminate air pockets within the concrete mass. One type of manually operated screed is driven by a small gasoline engine (e.g. 1 to 2.5 horsepower) that turns an eccentric exciter mechanism to impart a high speed vibratory force to a screed blade attached to the exciter mechanism. For example, an engine operating in the range of 5,000-7,500 rpm will generate in a centrifugal force in the range of about 245 lbs. to 550 lbs. This type of vibratory screed includes an operating handle connected through a frame piece to the vibratory exciter and engine. The machine is pulled over the surface of the concrete and a small amount of fresh concrete will build-up behind the blade to ensure that the surface is uniform and depressions are not created. The blade may be up to 24 feet in length and, although vibration of the blade helps make the concrete flow, the operator must still pull the machine. When the build-up of concrete behind the blade is uneven, there is a tendency for one end of the blade to lift and create an uneven surface. The operator must tilt the operating handle downwardly on one side to generate a force sufficient to counteract the upward movement of the blade. This requires the operator to exert a large amount of force on the handle. Also, the screed blade may have to be turned horizontally over the surface of the concrete, as when moving around a curve or a corner, requiring the operator to exert a large amount of force on the handle in a generally horizontal plane.
[0003] It is also necessary to isolate the transmission of vibration from the exciter and blade to the operator. Specifically, the frame that carries the operator handle is isolated from its connection to the blade or to the exciter mechanism with rubber or other elastomer vibration isolators. It is desirable to use as soft a vibration isolator as possible to provide maximum vibration isolation for the operator. However, because of the high loads that the operator must impose on the blade for the reasons discussed above, harder vibration isolators are required in order to provide an adequately stiff connection between the operator handle and the blade to transmit the required control force. Soft vibration isolators, e.g. those having a durometer of about 30 provide excellent vibration isolation for the operator, but are too soft to permit adequate force to be transmitted from the handle, through the isolators, to the blade. Soft isolators also amplify the distance through which the operator must move the operating handle to adequately control the blade. The operator handle may be as much as 3.5 feet from the vibration isolators such that a very small amount of movement at the isolator connection is magnified into a large amount of movement where the operator grasps the operating handle.
SUMMARY OF THE INVENTION
[0004] In accordance with the present invention, a vibration isolation system for a vibratory screed which includes a blade, a vibratory exciter mechanism driven by an engine and attached to the blade, and an operating handle frame connected to the exciter mechanism, comprises a bifurcated frame member having a pair of arms positioned to straddle the exciter mechanism for attachment on laterally opposite sides thereof; an elastomeric vibration isolator captured between each arm and a surface of the exciter mechanism, the isolator being confined to limit vertical compressive movement and to permit substantially greater horizontal shear movement; and a retainer attached to each of the arms or to the exciter, the retainer adapted to engage the isolator to limit the amplitude of horizontal shear movement. Preferably, each arm of the frame member includes an upper attachment surface, and the opposite sides of the exciter mechanism have mounting surfaces that are disposed generally parallel to the upper attachment surfaces, and the isolators are confined between the attachment surfaces and the mounting surfaces.
[0005] In a presently preferred construction, the isolators include rigid upper and lower end plates that have threaded connectors attached thereto, and the attachment surfaces and the mounting surfaces are adapted to receive threaded fasteners for attachment to the threaded connectors. Each of the upper attachment surfaces is formed integrally with a retainer. In the preferred embodiment, each of the retainers comprises a downwardly opening cup having an upper base surface that forms the attachment surface and a downwardly divergent side wall that is positioned to engage the isolator to limit the amplitude of horizontal movement. Each of the isolators preferably comprises a cylindrical body, and the retainer cup has a frustoconical shape that is coaxial with the cylindrical axis of the isolator in a no-horizontal-load rest position, the cup wall positioned to engage the isolator under a horizontal shear load to provide the amplitude limit. The elastomeric isolator is preferably made of a natural rubber material having a durometer of about 30.
[0006] The apparatus also includes an elastomeric support isolator that is attached at one end to the frame member between the frame arms and at an opposite end to the surface of the exciter mechanism. The exciter mechanism includes an exciter housing that is positioned between the arms of the frame member and has an upwardly extending exciter drive shaft. The engine is positioned directly above the exciter housing and includes a downwardly extending output shaft connected to the exciter drive shaft, and an engine output shaft housing connected to the exciter housing with a flexible connection. The flexible connection includes an elastomer housing and a plurality of elastomer shock absorbers surrounding the elastomer coupling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a vibratory concrete screed incorporating the subject invention.
[0008] FIG. 2 is an exploded perspective view of a portion of the apparatus shown in FIG. 1 .
[0009] FIG. 3 is a side elevation showing the mounting of the elastomeric vibration isolator of the present invention.
[0010] FIG. 4 is a vertical section taken on line 4 - 4 of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] A vibratory concrete screed 10 includes a long blade 11 which may be made, for example, from an aluminum or magnesium extrusion. The blade may have a length of up to about 24 feet. The blade 11 is clamped to the underside of an exciter mechanism 12 which includes an eccentric device driven by an engine 13 to impart a horizontal vibratory motion to the blade 11 . A supporting frame 14 is attached to the exciter mechanism 12 and includes an operator handle 15 . The screed 10 is operated over the surface of freshly poured concrete by the operator pulling the blade from the operator handle 15 . The vibration isolation system of the present invention is intended to overcome the problems in prior art devices, discussed briefly above, while providing necessary isolation of vibratory force to the operator. These problems include control of the tendency of the blade to move upwardly when the build-up of concrete behind the blade is uneven, and the need to pull one end of the blade in a circular arc around the opposite end as for movement around a curve. Both of these operations require a large amount of force to be exerted by the operator and, if the vibration isolation device between the operator handle and the exciter is too soft, control becomes difficult. On the other hand, if the vibration isolating device is too hard, then the vibratory forces transmitted to the operator become too great.
[0012] The blade 11 is demountably attached to the bottom of the exciter mechanism 12 such that the working face 16 of the blade faces the operator grasping the handles 15 , whereby the screed is pulled over the surface of the freshly poured concrete. As best seen in FIGS. 1 and 3 , the upper edge of the working face 16 of the blade 11 is provided with a horizontal mounting rib 17 that is received in a groove 18 in a casting that comprises a lower exciter housing 20 . The front of the blade 11 also includes an upper horizontal mounting rib 21 over which a pair of mounting clips 22 are attached to the housing 20 with machine screws 23 to clamp the blade 11 to the exciter housing 20 .
[0013] Referring also to FIG. 2 , the engine 13 is mounted vertically above and directly to the exciter housing 20 and includes a direct driving connection between the engine drive shaft (not shown) and an eccentric exciter mechanism mounted within the housing 20 via a flexible elastomer coupling 24 . The flexible coupling 24 is enclosed in an engine output shaft housing 25 attached to the engine and overlying the exciter housing, the engine output shaft housing also enclosing three elastomer shock absorbers 26 equally spaced around the flexible coupling 24 . The shock absorbers 26 interconnect the engine output shaft housing 25 and the exciter housing 20 . Each of the shock absorbers 26 is attached at its lower end to a coupling surface 27 on the exciter housing 20 and at its upper end to the engine output shaft housing 25 with machine screws 28 . As shown in FIG. 1 , in the assembled position, the interface between the exciter housing 20 and the clutch housing 25 is sealed with an annular seal 30 . The direct driving connection between the engine 13 and the exciter mechanism 12 eliminates the need for a gear box or transmission and also helps isolate the transmission of vibrations from the engine to the operator handle.
[0014] The main supporting frame 14 includes a bifurcated lower frame member 31 defining a pair of mounting arms 32 . Each of the arms 32 terminates in a downwardly opening cup 33 which encloses an elastomeric vibration isolator 34 and provides means for attaching the isolator to the arm 32 . The lower ends of the vibration isolators 34 are attached to a mounting surface 35 on the exciter housing 20 on opposite sides of the exciter mechanism. Referring also to FIG. 4 , the vibration isolators 34 are of a conventional construction, but are mounted and restrained in a unique manner that isolates the transmission of vibration to the operator yet provides the operator with the ability to control blade movement when the operator is required to exert additional force to the operator handle 15 . Each vibration isolator 34 includes a cylindrical body of an elastomer material, preferably natural rubber, with a relatively soft formulation, preferably about 30 durometer. The flat opposite ends of the elastomer body 36 are molded or otherwise attached to rigid metal end plates 37 to which nuts 38 or other suitable internally threaded connectors are welded. Each of the vibration isolators 34 is connected to the mounting surface 35 on the exciter housing 20 with a machine screw 40 extending upwardly through the underside of the mounting surface and into threaded engagement with a nut 38 . Each of the cups 33 includes an interior upper attachment surface 41 which engages the upper end plate 37 of the isolator 34 when the latter is inserted into the cup. Connection between the isolator 34 and the frame arm 32 is completed with an upper machine screw 42 extending through the attachment surface 41 and into threaded engagement with the nut 38 at the upper end of the isolator. With this isolator mounting arrangement, the isolators 34 are confined to significantly limit vertical compressive movement, but are capable of undergoing substantially greater horizontal shear movement because of the substantially unconfined elastomer body 36 combined with the low durometer and high flexibility of the elastomer material. The downwardly opening cups 33 within which the isolators 34 are confined, each has a generally frustoconical downwardly divergent wall 43 . In the no-load at rest position, there is no contact between the cylindrical elastomer body 36 and the wall 43 of the cup. In this mode, which is the predominant operating position over most conditions of use, the low durometer elastomer bodies 36 are very effective in isolating the transmission of vibration back through the arms 32 and frame member 31 to the operator handle 15 . However, when the operator must exert substantial force on the operator handle, as discussed above, movement of the operator handle and frame relative to the exciter housing 20 and blade 11 will result in horizontal deflection of the elastomer bodies 36 until a portion of the inside surface of the frustoconical walls 43 come into contact with the elastomer bodies. This contact provides, temporarily, a more rigid connection between the operator handle 15 and the blade 11 , thereby permitting the operator to exercise direct and more positive control. The cups could also be formed integrally with and as a part of the exciter housing 20 , such that the cups would be upwardly opening. Furthermore, the cups could have a cylindrical or other shape and the elastomer isolator body have a frustoconical or other shape. The important feature is shear movement of the isolators be permitted, but confined to certain maximum limits.
[0015] To provide additional support and a more stable connection between the exciter housing 20 and the supporting frame 14 , an elastomeric support isolator 44 is attached between the frame member 31 and a rear support surface 45 on the exciter housing 20 . The support isolator 44 may be of a construction identical to the vibration isolators 34 . The upper end of the support isolator 44 is attached to an intermediate frame portion 46 , between the arms 32 , with a threaded stud (not shown) attached to the intermediate frame portion and threaded into the upper end of the support isolator 44 . Similarly, the lower end of the support isolator 44 is connected to the rear support surface 45 with a machine screw (not shown) extending upwardly through the surface 45 and into threaded engagement with the isolator 44 . However, the support isolator 44 need not be and is preferably not confined in a cup, as are the vibration isolators 34 . The support isolator assists in transmitting vertical downward movement imposed by the operator on the operator handle to the blade.
[0016] It should be noted that the flexible elastomer coupling 24 and the elastomer shock absorbers 26 that comprise the flexible connection between the exciter housing and the clutch housing 25 may be identical to the vibration isolators 34 and the support isolator 44 , except that the flexible coupling 24 and shock absorbers 26 are smaller in size. The durometer of these shock absorbers, however, may be somewhat higher for example, about 50.
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A vibratory concrete screed includes a vibration isolation system that minimizes the transmission of vibrations to the operator under normal operating conditions, but becomes more rigid during screed control forces applied to the blade through the isolation system when the operator applies greater forces to the operator handle. The system includes low durometer elastomer vibration isolators isolating the operator handle from the vibration exciter and screed blade in a manner that limits vertical compressive movement of the isolators, yet permits substantially greater horizontal shear movement to effectively isolate the operator from vibration. The isolator mounting arrangement also includes retainers that engage the isolator to limit the amplitude of horizontal shear movement when the operator applies a greater control force to the operator handle.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This non-provisional patent application claims the benefit of an earlier-filed provisional application. The first provisional application was assigned Ser. No. 62/347,120. It listed the same inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
MICROFICHE APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0004] This invention relates to the field of tensile strength members such as multi-stranded synthetic cables. More specifically, the invention comprises devices and methods for creating a synthetic tensile member having a fixed and stable length.
2. Description of the Related Art
[0005] The term “tensile member” encompasses a very broad range of known devices, including steel rods, helically wrapped wire ropes/cables, fiber ropes/cables, wound slings, rope slings grommets, etc. These devices have for many years been made using steel. For a fixed installation—such as a bridge stay—a relatively rigid rod may be used. For a more mobile or dynamic installations—such as the rigging on the boom of a crane—helically wrapped wire rope may be used. Steel tensile members have been mass produced for over one hundred years and the properties of these tensile members are very well understood. For example, it is well understood how to manufacture a steel tensile member to a precise level of performance and a precise overall length.
[0006] Such wire ropes may need to be “set” or “bedded” when they are first assembled. This process involves applying tension to tighten the interwoven nature of the strands within the rope. An initial “stretch” will occur, after which a wire rope remains in the “set” state. Significantly, the amount of set needed is predictable. It is therefore possible to create a wire rope that is “short” by a calculated amount so that when the wire rope is set it will lengthen by a known amount and wind up being the proper length.
[0007] A termination must generally be added to a tensile member in order to transmit a load into or out of the tensile member. A terminations is most commonly affixed to the end of a tensile member, though it can be affixed to an intermediate point as well. In this context, the term “termination” means a structure that is affixed to the tensile member (or otherwise caused to become present on the tensile member) to transmit a load to or from the tensile member. The term encompasses solid anchors, soft splices, and round grommet or sling structures. The term also includes terminations that may be incorporated on a subcomponent of a larger tensile member, such as a sub-rope or strand.
[0008] As stated previously, wire rope is an example of a steel tensile member. A hook or loading eye is often added to wire rope. The hook or loading eye in this context is a termination. Such prior art terminations on large wire ropes commonly include a socket. A length of the wire rope is placed within the socket and “upset” into an enlarged diameter. The upset portion is then potted into the socket using molten lead or—more recently—a strong epoxy. Once the potted portion solidifies, the end of the wire rope is locked into the socket and the termination is thereby permanently affixed.
[0009] In recent years materials much stronger than steel have become available for use in the construction of cables and other tensile strength members. Many different materials are used for the filaments in a synthetic cable. These include DYNEEMA, SPECTRA, TECHNORA, TWARON, KEVLAR, VECTRAN, PBO, carbon fiber, nano-tubes, and glass fiber (among many others). In general the individual filaments have a thickness that is less than that of human hair. The filaments are very strong in tension, but they are not very rigid. They also tend to have low surface friction. These facts make such synthetic filaments difficult to handle during the process of adding a termination and difficult to organize. The present invention is particularly applicable to terminated tensile members made of such high-strength synthetic filaments, for reasons which will be explained in the descriptive text to follow. While the invention could in theory be applied to older cable technologies—such as wire rope—it likely would offer little advantage for that application. Thus, the invention is not really applicable to wire rope and other similar cables made of very stiff elements.
[0010] In this disclosure the term “synthetic tensile member” should be understood to encompass a tensile member made primarily of synthetic filaments. However, it should be understood that other traditional constituents (such as metallic strands) may be present in these “synthetic” cables as well. Synthetic tensile member is also intended to apply to subcomponents of larger assemblies or tensile members, such as the sub-rope or strand of a large, rope/cable. Additionally, the terms “rope” and “cable” will be used interchangeably—as they are both common industry terms that apply to nearly all structural materials.
[0011] The present invention is applicable to many different types of tensile members (not just cables). However, because cables are a very common application and because the inventive principles will be the same across the differing types of tensile members, cables are used in the descriptive embodiments. Some terminology used in the construction of cables will therefore benefit the reader's understanding, though it is important to know that the terminology varies within the industry and even varies within descriptive materials produced by the same manufacturer. For purposes of this patent application, the smallest individual component of a cable is known as a “filament.” A filament is often created by an extrusion process (though others are used). Many filaments are grouped together to create a strand. The filaments are braided and/or twisted together using a variety of known techniques in order to create a cohesive strand. There may also be sub-groups of filaments within each strand. As the overall cable size gets larger, more and more layers of filament organization will typically be added. The strands are typically braided and/or twisted together to form a cable. In other examples the strands may be purely parallel and encased in individual surrounding jackets. In still other examples the strands may be arranged in a “cable lay” pattern that is well known in the fabrication of wire ropes.
[0012] The inventive principles to be disclosed may be applied to an individual strand. They may also be applied to an entire cable made up of many strands. Thus, the invention may be applied to a completed tensile member and it may be applied to a component of an overall tensile member before the component is installed into the final assembly.
[0013] FIGS. 1-4 provide some background materials to aid the reader's understanding. FIG. 1 depicts a very simple cable 10 that is made of three helically wrapped strands 12 . Each strand 12 contains many, many individual filaments. FIG. 2 shows the cable of FIG. 1 with a termination 36 attached. Anchor 18 in this example is a radially symmetric component with an expanding central passage 19 . A length of the cable is placed in this expanding internal passage and splayed apart. Potting compound is introduced into the passage in a liquid state. The potting compound is any substance which transitions from a liquid to a solid over time (such as an epoxy). The potting compound hardens to form potted region 20 . Once the potted region is formed, anchor 18 is locked to the end of cable 10 and a termination 36 is thereby created.
[0014] In other examples the cable will be locked to the anchor without the use of a potting compound. Those skilled in the art will know that frictional devices (such as a “spike-and-cone” system) can be used to lock the anchor to the cable). In still other examples the anchor will be formed as a splice in which an end of the cable is formed into a loop and woven back into itself.
[0015] FIG. 3 provides an example with a more complex organization. Cable assembly 30 includes three individual cables 10 within an encompassing jacket 28 . An anchor 18 is affixed to the end of each cable 10 . Collector 22 includes three receivers 26 —each of which is configured to receive an anchor 18 . The anchors are connected to collector 22 and a load transferring feature 24 (shown using hidden lines) transfers tension from collector 22 to an external component.
[0016] FIG. 4 shows another example using three parallel cables 10 . Each cable 10 includes a termination 36 . The three terminations 36 are connected to loading block 32 using a pin joint. This example illustrates the need for uniformity and predictability of the length of the three cables. If one of the cables is slightly shorter, it will carry a disproportionate higher share of the overall load.
[0017] Producing synthetic tensile members with a consistent and predictable overall length is presently a serious industry challenge. The problems result from one or more of the following factors:
[0018] 1. The mechanical properties of synthetic filaments vary from batch to batch. While this is true of more traditional materials, the variance is synthetic materials is much greater;
[0019] 2. Most strands or cables must be created by braiding together thousands to millions of individual synthetic filaments. Two braiding or interweaving machines may appear to produce a similar result but in fact the properties will vary;
[0020] 3. There are many steps in fabricating a completed cable assembly using synthetic filaments. Each step introduces additional variations and these variations tend to accumulate;
[0021] 4. Synthetic filaments must generally be elastically bent and interwoven during the manufacturing process. These filaments have a low coefficient of friction, and since they are not stiff they are designed to move and “bed” during use. This bedding or setting process changes both the mechanical properties of a cable as a whole (such as the modulus of elasticity) and the overall length;
[0022] 5. Synthetic filaments are temperature sensitive. This fact affects stillness and length in the normal working range; and
[0023] 6. The addition of a termination to a cable end introduces a considerable slip variable (“setting” or “bedding”) when the cable assembly is first loaded. This variable increases the overall cable length, but the amount of increase has proved to be unpredictable. This is especially the case with friction or grip based termination methods, such as a splice (which is the most common method of synthetic cable termination).
[0024] All these issues tend to grow more significant as a cable assembly increases in length, strength, and complexity. It is difficult to predict the behavior of larger tensile members due to the accumulation of manufacturing tolerances for all the subcomponents. Further, it may be some time before the length becomes stable as the length of some cable assemblies may continue to grow under tension as the interworking elements stabilize. If such a tension member is combined in parallel with other tension members, an uneven distribution of the overall load results.
[0025] For these reasons, it is not presently common to use synthetic cables where a precise length or stability is important. Exemplary applications include large crane boom stays, bridge stays, and multi-point lifting slings or multi-cable bridle assemblies. Because of the enormous loads involved, it is common to use a parallel assembly of four or more cables in these applications.
[0026] There are length-adjusting mechanisms known in the prior art. One example is a large turnbuckle. It is rarely practical to include such a large and heavy item. Further, a turnbuckle does not remedy the concerns of length or load stability unless it is periodically readjusted (A turnbuckle must be initially tensioned and then periodically re-tensioned as the cable “sets”). A suitable turnbuckle will also require a substantial torque to adjust, and it is often difficult to apply such a large amount of torque in the field. One may imagine a turnbuckle on a dragline crane that is 50 meters in the air. Adjusting such a turnbuckle would not be easy. Further, an improper adjustment may permanently damage the boom if not properly matched with adjustments to the other cables.
[0027] The present invention seeks to remedy both the problem of length consistency and the problem of length stability. The invention solves these problems across all types of synthetic filament-based tensile members and termination methods—without the need for a field adjustment device.
BRIEF SUMMARY OF THE PRESENT INVENTION
[0028] The present invention comprises a method for producing a synthetic filament tensile member having a precisely known and stable length. The invention also comprises equipment configured to carry out the method. A tensile member is prepared by attaching terminations to an assembly of synthetic filaments. The tensile member is then attached to a loading apparatus that subjects the tensile member to a pre-defined loading process. The tensile member is thereby conditioned to a stable length. The length is then measured and a length adjusting component is added to the tensile member (or a suitable modification is made to the tensile member) to create a precise length that is configured for the tensile member's particular application.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0029] FIG. 1 is a perspective view, showing a prior art cable made of three wrapped strands.
[0030] FIG. 2 is a sectional elevation view, showing one way in which a termination can be attached to a cable.
[0031] FIG. 3 is a perspective view, showing a cable termination in which multiple anchors are attached to a collector.
[0032] FIG. 4 is a perspective view, showing a parallel cable assembly.
[0033] FIG. 5 is an elevation view, showing a tensioning rig employed in the present invention.
[0034] FIG. 6 is a perspective view, showing the addition of an extension link.
[0035] FIG. 7 is a perspective view, showing the use of an extended tang.
[0036] FIG. 8 is an elevation view, showing a splice-based termination.
[0037] FIG. 9 is a sectional view, showing the nature of the thimble used in the splice-based termination of FIG. 8 .
[0038] FIG. 10 is a perspective view, showing a thimble block.
[0039] FIG. 11 is an elevation and perspective view, showing a termination having a threaded shaft and an extension bushing.
[0040] FIG. 12 is an elevation view, showing the placement of the extension bushing on the threaded shaft.
[0041] FIG. 13 is a perspective view, showing the use of a plug in a loading eye.
[0042] FIG. 14 is a perspective view, showing the addition of an extension link to a spliced termination.
[0043] FIG. 15 is a perspective view, showing the use of a compressive bushing.
[0044] FIG. 16 is an elevation view, showing the use of a correction block.
[0045] FIG. 17 is an elevation view, showing the use of an extension link in the middle of a cable assembly.
[0046] FIG. 18 is a plot showing applied tension over time.
REFERENCE NUMERALS IN THE DRAWINGS
[0047] 10 cable
[0048] 12 strand
[0049] 18 anchor
[0050] 19 passage
[0051] 20 potted region
[0052] 22 collector
[0053] 24 load transferring feature
[0054] 26 receiver
[0055] 28 jacket
[0056] 30 cable assembly
[0057] 32 loading block
[0058] 34 parallel assembly
[0059] 36 termination
[0060] 38 loading fixture
[0061] 40 static fixture
[0062] 42 extension link
[0063] 44 first cross bore
[0064] 45 first attachment reference
[0065] 46 second cross bore
[0066] 47 second attachment reference
[0067] 48 tang
[0068] 50 pin
[0069] 52 first clevis
[0070] 54 second clevis
[0071] 56 extended tang
[0072] 58 reference axis
[0073] 60 cross bore
[0074] 62 thimble
[0075] 64 strands
[0076] 66 jacket
[0077] 68 thimble block
[0078] 70 threaded shaft
[0079] 72 extension bushing
[0080] 74 mating surface
[0081] 76 bearing surface
[0082] 78 through bore
[0083] 80 fusion
[0084] 82 eye
[0085] 84 cross bore
[0086] 86 plug
[0087] 88 offset cross bore
[0088] 90 spliced eye
[0089] 92 bushing half
[0090] 94 correction block
[0091] 96 overhang
DETAILED DESCRIPTION OF THE INVENTION
[0092] A cable made according to the present invention will generally have a first termination on its first end and a second termination on its second end. The first termination will have a first attachment reference—such as the center axis of a first cross bore through the first termination. The second termination will likewise have a second attachment reference—such as the center axis of a second cross bore through the second termination.
[0093] Returning to FIG. 4 , those skilled in the art will know that the parallel assembly of three cables will typically have a loading block 32 or analogous anchoring component on each end. The example shown uses a large transverse pin joint to connect the terminations 36 to the loading block 32 . For this particular installation, there is a known distance between the pin joint axis on the loading block 32 shown and the pin joint axis on the loading block on the opposite end of the cables. The cables must match this known distance in order to be correctly installed. In other words, the distance between the first and second attachment references on the cables must be equal to the known distance.
[0094] FIG. 5 shows a synthetic cable assembly created by adding a termination 36 to each end of cable 10 . The first termination is connected to static fixture 40 . First attachment reference 45 on the first termination is the center line of a pin joint used to attach the first termination to the static fixture (Note that the first attachment reference could be at some other point along the assembly and need not coincide with the attachment point).
[0095] The second termination is attached to loading fixture 38 . A predetermined tension profile is then applied through loading fixture 38 . Second attachment reference 47 on the second termination is the center line of a pin joint used to attach the second termination to loading fixture 38 (Note that the second attachment reference could be at some other point along the assembly and need not coincide with the attachment point).
[0096] This tension profile may assume many forms, but it is preferable to include a pull test to a higher load than is anticipated in the end-use application. Where practical, it is also preferable to include multiple pulls to better condition the cable.
[0097] FIG. 18 depicts an exemplary tension profile. The “design load” represents the maximum tension the cable assembly is expected to see in its upcoming installation. In this example, two ramped “pulls” are made to a level exceeding the design load by 20%. A third pull is established with a sinusoidal component applied over an extended period. With some fiber types, it is also beneficial to hold a load for a defined period so that the fibers will permanently elongate and better distribute the load.
[0098] The tension profile is configured to fully “bed” (“set”) both the terminations and the lay of the cable itself. The length of the overall assembly will tend to extend for some period and then stabilize. Once the length has stabilized, the distance between the first attachment reference on the first termination and the second attachment reference on the second termination is determined. Two carefully pre-cut and terminated cable assemblies may have lengths that are very nearly the same. However, the length variation will tend to grow with the bedding process.
[0099] This step may be accomplished in many ways. As one example, if the first and second attachment references are simple cross bores through tangs on the terminations, then closely fitted dowels can be placed in these cross bores. The assembly can then be placed under a suitable tension level and the distance between the dowels can be measured.
[0100] In many instances it will be desirable to design the cable and terminations so that the bedded cable assembly winds up being a bit short. A length-adjustment component may then be added to bring the overall assembly of the now-stabilized cable to the proper length. There are many ways to provide such a length-adjustment component. The following embodiments illustrate some of these ways.
[0101] FIG. 6 shows a second termination 36 on the second end of cable 10 . The termination includes tang 48 . A cross bore through the tang is used to attach the termination. The central axis of this cross bore is the second attachment reference used to determine the overall length of the cable assembly.
[0102] Extension link 42 is provided to increase the effective length of the cable assembly. The extension link includes first clevis 52 and second clevis 54 . The extension link also includes first cross bore 44 and second cross bore 46 . First cross bore 44 is aligned with the cross bore in tang 48 and pin 50 is inserted to connect the extension link to the second termination. Second cross bore 46 is offset a distance “D” from first cross bore 44 . In this example the second cross bore 46 becomes a third attachment reference. If one then measures the distance from the first attachment reference (on the opposite end of the cable) and the new third attachment reference created by the presence of second cross bore 46 , the overall length of the cable will be increased.
[0103] To improve accuracy, it is preferable to take the length measurements while the cable assembly is under a fixed reference load. The reference load is preferably as close as possible to the load anticipated for the end-use application.
[0104] The process as applied in this exemplary embodiment may then be summarized as follows:
[0105] 1. A known distance is the target value needed for the cable's desired installation at the anticipated reference load;
[0106] 2. The cable is created with an overall length that is marginally too short for the known distance and defined reference load;
[0107] 3. The cable undergoes the setting process depicted in FIG. 5 ;
[0108] 4. The distance between the first and second attachment references is accurately determined;
[0109] 5. An offset distance between the second attachment reference and a desired third attachment reference is calculated; and
[0110] 6. An extension link 42 of suitable length is manufactured (or possibly pulled from inventory) and attached to the second termination, where the extension link provides the additional distance needed for the cable to have the correct overall length.
[0111] Using exemplary numbers, the known distance for a particular installation is 30.260 meters. Once manufactured and set (as depicted in FIG. 5 ), the distance between the first and second attachment references is carefully measured to be 29.900 meters. An extension link is manufactured where the distance “D” between the first and second cross bores 44 , 46 is 0.360 meters. This extension link is then installed as shown in FIG. 6 . The cable assembly thus made now has the exact length desired (30.260 meters). And, the length is stable as the cable assembly has already been properly set. In this way countless assemblies can be created to exacting specification with a length that is stable and predictable over time.
[0112] FIG. 7 provides another embodiment in which the second termination 36 is provided with an extended tang 56 . Loading cross bore 59 is provided so that the cable assembly can be attached to loading fixture 38 (as depicted in FIG. 5 ). Once the loading process has been used to set the cable and its terminations, a second cross bore 60 is created in extended tang 56 . In this example, both loading cross bore 59 and cross bore 60 are located with respect to reference axis 58 . The cable is again manufactured a bit short. Cross bore 60 is offset by a distance (D 2 −D 1 ). Cross bore 60 then becomes the desired third attachment reference and provides the correct overall length for the cable.
[0113] FIG. 8 shows a second termination 36 made using a splice. A splice involves passing a length of cable around a thimble 62 and then weaving it back on itself. Such a termination can be very strong. However, because the interweaving is a highly-skilled manual process, it introduces considerable uncertainty regarding the final length of the cable following the setting process depicted in FIG. 5 . While generally improved, similar process variation challenges are also involved in round slings, grommets, reeved cable block tension members, or wound slings. These types of looped tensile members will commonly include a thimble of some sort for support of high loads.
[0114] FIG. 9 depicts a cross section through thimble 62 . The reader will note how the thimble in this example includes a concave channel configured to receive the cable strands 64 (and jacket 66 in this ease). The inward facing surface of thimble 62 is planar. In many cases thimble 62 may simply be a pulley or sheave configuration with a central cross bore.
[0115] FIG. 10 depicts thimble block 68 , which is configured to slide laterally into the thimble. When the thimble block is installed within the middle portion of the thimble, loading cross bore 59 allows the cable assembly to be set as shown in FIG. 5 . Once a stable length is achieved a distance between the first and second attachment references is determined. An additional length required for the cable is determined. Cross bore 60 is then created in the thimble block. The additional length needed will be equal to (D 2 −D 1 ) in the depletion of FIG. 10 . Cross bore 60 then becomes the desired third attachment reference.
[0116] Up to this point the second and third attachment references have been the centerlines of cross bores. This will not always be the case, as there are many different components used to attach terminations to external components. FIGS. 11 and 12 illustrate a different approach.
[0117] The second termination 36 in this example includes a long threaded shaft 70 . The cable assembly is attached to an external object by passing threaded shaft 70 through a hole in a thick steel plate and then threading a nut onto the exposed end of the threaded shaft. The nut is then tightened. Bearing surface 76 on termination 36 provides the desired second attachment reference.
[0118] In this example—once the cable assembly is set as shown in FIG. 5 —the cable assembly's length is again too short. Extension bushing 72 is provided to address this problem. Extension bushing 72 has mating surface 74 and bearing surface 76 on its opposite end. It also includes through bore 78 . Through bore 78 is slipped over threaded shaft 70 and mating surface 74 on extension bushing 72 is mated to bearing surface 76 on termination 26 .
[0119] The mated assembly is shown in FIG. 12 . Bearing surface 76 has thereby been extended by the distance “D” to form the desired third attachment reference. The two mating surfaces may be joined by adhesives, welding, or some other suitable method to create fusion 80 . The termination and the extension bushing thereafter behave as one integrated part. Where possible, it is desirable for the length adjustment part to be permanent. The purpose of the fusion is simply to provide this permanence.
[0120] FIG. 13 shows a second termination incorporating eye 82 and an enlarged cross bore 84 . Plug 86 is configured to slide laterally into cross bore 84 . Offset cross bore 88 provides the desired third attachment reference. It is offset from the center of plug 86 an appropriate amount to produce the desired overall length for the cable assembly.
[0121] FIG. 14 shows an embodiment where an extension link 42 is added to a spliced type of termination. A length of cable is wrapped around a thimble and woven back into itself to create spliced eye 90 . The extension link is connected to this spliced eye by passing a lateral pin through the extension link and the spliced eye.
[0122] In the prior examples a cable that was marginally too short was extended by the addition of a length-adjustment component. In other instances the cable will be made marginally too long and the length-adjustment component will need to shorten its effective length. FIG. 15 shows a second termination 36 that includes a planar posterior bearing surface where the cable exits the anchor. In this example two bushing halves 92 have been clamped around the cable up against this posterior bearing surface. The two bushing halves create bearing surface 76 —effectively reducing the length of the cable. Bearing surface 76 then becomes the desired third attachment reference. The reader should note that this type of corrective bushing can be added to each of the individual anchors as shown in the example of FIG. 3 in order to apply a length correction to the entire cable (three bushing assemblies would be required for the example of FIG. 3 ).
[0123] FIG. 16 shows a length-adjustment component used to increase or decrease the effective cable length for the type of anchor shown in FIG. 15 . Correction block 94 includes a cavity to receive termination 36 . Overhang 96 abuts the posterior bearing surface on the termination. Cross bore 60 is provided a distance “D” from the posterior bearing surface. Thus, cross bore 60 extends the effective length of the cable assembly and provides the third attachment reference.
[0124] In the preceding examples the length-adjustment component has been added to an end of the cable assembly. It is also possible to add the length-adjustment component to an intermediate location. FIG. 17 shows an embodiment in which a third and fourth termination 36 have been added in the middle of the cable. These third and fourth terminations can simply be linked together for the tensioning process shown in FIG. 5 . An extension link 42 can then be added between the third and fourth terminations to increase the length of the cable assembly to match the desired length.
[0125] Cables have been used as the examples in this disclosure, but the reader should bear in mind the fact that the principles disclosed apply to many other types of tensile members. These include synthetic rope/cable/cord grommets, choked assemblies, reeved block assemblies, and looped slings or pendants where a loop of filaments, strands, or cables are wound around two end points, and the two end points thereby become terminations.
[0126] Additionally, the inventive process is not specific to the termination type/method or length correction component. The examples are merely meant to represent a design based on certain termination configurations. These designs are not to be viewed as limiting, like that of the tensile member, they will vary broadly from application to application—and countless variations are possible.
[0127] The invention includes many other functional variations that are assumed throughout the examples, such as:
[0128] 1. An embodiment in which a length-adjustment component is added to both ends of the cable. In many applications this is preferable and should be assumed to be the case in all embodiments in this disclosure. The simplified depiction of a second termination receiving a length adjustment feature is simply meant to assume that at least one end, if not both ends receive such a component;
[0129] 2. An embodiment in which multiple length-adjustment components are “stacked” or otherwise configured for use on at least one end of the cable;
[0130] 3. An embodiment in which the length-adjustment component is simply a modification of a component already on the cable (such as milling away a final load bearing surface or drilling a cross bore hole on the termination body itself as examples);
[0131] 4. An embodiment in which the length-adjustment component is tamper resistant so that it cannot be easily modified in the field;
[0132] 5. An embodiment in which the length-adjustment component is made visibly out of alignment should it be out of factory setting;
[0133] 6. A configuration in which adjustment is possible in both directions, such that a tensile member can be made at the target length, and length correction can be designed to be either shorter or longer. (For example, the cable length and bushing halves 92 in FIG. 15 can be configured to first target the nominal length, and adjustments can then be made to the cable by simply using shorter or longer bushing halves 92 . It need not be only adjustable in one direction as simplified in this disclosure.)
[0134] 7. An embodiment in which the inventive process and length adjustment component is made to the strand or sub-rope of a larger tensile member. In most eases this would include similar length adjustment components with all or most of the loaded subcomponents. This can be used to balance subcomponents within a large assembly, just as if they were individual tension members requiring matched and stable lengths.
[0135] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Those skilled in the art will be able to devise many other embodiments that carry out the present invention. Thus, the language used in the claims shall define the invention rather than the specific embodiments provided.
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A method for producing a synthetic tensile member having a precisely known and stable length. The invention, also comprises equipment configured to carry out the method. A tensile member is prepared by attaching terminations to an assembly of synthetic filaments. The tensile member is then attached to a loading apparatus that subjects the tensile member to a pre-defined loading process. The tensile member is thereby conditioned to a stable length. The length is then measured and a length adjusting component is incorporated into the tensile member to create a precise and stabilized length that is configured for the tensile member's particular application.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a method of feeding a medium in a recording apparatus, which starts to feed a subsequent medium while recording is being performed on a previous medium being fed, and to a recording apparatus.
[0003] 2. Related Art
[0004] A printer, which is a known example of recording apparatuses includes an auto sheet feeder (hereinafter, referred to as ASF) (for example, JP-A-2003-72964 or the like). When printing starts, the ASF is driven to feed an uppermost sheet from among sheets stacked in a cassette, and a leading end of the sheet is positioned at a printing start position.
[0005] The ASF starts to feed a subsequent sheet after a previous sheet has been printed and discharged. In the feeding method which starts to feed the subsequent sheet after the previous sheet has been printed, however, a relatively long standby time is present between the start of discharge of the previous sheet and the start of printing of the subsequent sheet. Accordingly, printing throughput is deteriorated.
[0006] In order to solve this problem, JP-A-2003-72964 discloses a recording apparatus that simultaneously performs a discharge operation of a previous sheet and a feeding operation of a subsequent sheet while maintaining a predetermined gap between the previous sheet and the subsequent sheet. That is, in the recording apparatus of JP-A-2003-72964, the position of a trailing end of the previous sheet is calculated on the basis of a transport distance of the previous sheet and sheet length data. Then, if two conditions that the trailing end of the previous sheet has passed through a specified position and a discharge command has been received are satisfied, the feeding operation of the subsequent sheet starts. According to this recording apparatus, the discharge operation of the previous sheet and the feeding operation of the subsequent sheet are simultaneously performed, while an inter-paper distance between the previous sheet and the subsequent sheet is ensured. Therefore, a standby time from the start of discharge of the previous sheet and the start of printing of the subsequent sheet can be shortened, and as a result printing throughput can be improved.
[0007] JP-A-2005-22792 (paragraphs [0029] to [0054]) discloses a sheet feeding device in which a leading end of a subsequent sheet is positioned in front of a feed/separation roller beforehand. In this case, before an instruction to control a feeding operation of the subsequent sheet is input, a pickup roller is driven to start a preliminary feeding operation. Then, if a pre-separation sensor detects a leading end of the subsequent sheet fed by the preliminary feeding operation, the pickup roller is stopped. In this sheet feeding device, if a post-separation sensor detects that the previous sheet has passed through the feed/separation roller, a control device starts to drive the pickup roller and the feed/separation roller.
[0008] JP-A-2001-278472 and JP-A-2002-145469 disclose a page printer in which, in order to improve throughput, a feeding operation of a next page starts before recording on a previous page is completed (so-called preceding feeding).
[0009] According to the recording apparatus of JP-A-2003-72964, if recording is performed to the end of the previous sheet (recordable last row), the discharge command may be received a long time after transporting of the previous sheet was started. For this reason, a gap between the previous sheet and the subsequent sheet exists, and printing throughput is deteriorated.
[0010] In the recording apparatus of JP-A-2005-22792, after the subsequent sheet is preliminary fed, the feeding operation of the subsequent sheet starts when the post-separation sensor detects the passage of the previous sheet. The gap between the previous sheet and the subsequent sheet is defined by a gap between the pre-separation sensor and the post-separation sensor. The inter-sensor gap is not necessarily identical to a gap which should be ensured between the previous sheet and the subsequent sheet. For this reason, at some positions of the sensors in the recording apparatus, when the feeding operation of the subsequent sheet starts on the basis of the instruction to control the feeding operation, a necessary gap between the previous sheet and the subsequent sheet may not be ensured. As described in the JP-A-2003-72964, an insufficient inter-paper gap results in a paper detection sensor not being able to detect the leading end of the subsequent sheet, and accordingly, it is difficult to manage the transport position of the subsequent sheet.
SUMMARY
[0011] An advantage of some aspects of the invention is that it provides a method of feeding a medium in a recording apparatus, which is capable of preventing a delay of start of a transport operation while maintaining a gap between a previous medium and a subsequent medium, thereby preventing throughput from being deteriorated, and a recording apparatus.
[0012] According to an aspect of the invention, a recording apparatus including feeding unit that feeds a medium, conveying unit that conveys the fed medium, recording unit that performs recording on the medium, and controlling unit that controls the feeding unit and the conveying unit, wherein, when a rear edge of a previous medium which is previously fed reaches a preparatory feed start position, the controlling unit drives the feeding unit to preparatorily feed a next medium until when a front edge of the next medium reaches a target position, the recording apparatus characterized by comprising: measuring unit that measures a distance between the previous medium and the next medium after completing the preparatory feeding; and determining unit that determines whether or not the measured distance is a predetermined distance or greater, wherein a conveying distance between the preparatory feed start position and the target position and the predetermined distance satisfy a relationship of the conveying distance<the predetermined distance, and wherein, if the distance is the predetermined distance or greater, the controlling unit completely feeds the next medium when the controlling unit performs a conveying operation of the previous medium, and if the distance is smaller than the predetermined distance, the controlling unit does not completely feed the next medium when the controlling unit performs the conveying operation of the previous medium. Herein, the recording operation includes an operation of the recording unit to perform recording onto the medium and an operation to transport the medium. Moreover, “alternation of recording and transport” is a concept including a case in which the recording operation of the recording unit and the transport operation of the medium are alternately performed, and a case in which the recording operation and the transport operation are substantially alternately performed but partially temporally overlap each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
[0014] FIG. 1 is a perspective view of a printer according to an embodiment of the invention.
[0015] FIG. 2 is a schematic side sectional view showing an auto sheet feeder and a paper transport mechanism.
[0016] FIG. 3 is a schematic side view of a feeder for explaining constants to be used to calculate an inter-paper distance.
[0017] FIG. 4 is a block diagram showing the electrical configuration of the printer.
[0018] FIG. 5 is a timing chart showing a feed control processing for ensuring an inter-paper distance.
[0019] FIG. 6 is a timing chart showing a feed control processing for ensuring an inter-paper distance.
[0020] FIG. 7 is a timing chart showing a feed control processing for ensuring an inter-paper distance.
[0021] FIG. 8 is a timing chart showing a feed control processing for ensuring an inter-paper distance.
[0022] FIG. 9 is a flowchart showing a printing processing.
[0023] FIG. 10 is a flowchart showing a feed control processing (paper transport processing).
[0024] FIG. 11 is a flowchart showing a feed control processing (paper transport processing).
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0025] Hereinafter, an embodiment in which the invention is embodied will be described with reference to FIGS. 1 to 11 .
[0026] FIG. 1 is a perspective view of a printer according to this embodiment. As shown in FIG. 1 , a printer 11 which is an example of recording apparatuses has a rectangular boxlike main body 12 . A carriage 13 is provided in a central portion of the main body 12 so as to freely reciprocate in a main scanning direction (left-right direction in FIG. 1 ) along a guide shaft 14 .
[0027] As shown in FIG. 1 , a long plate-shaped platen 15 is disposed at a lower position opposing the carriage 13 in the main body 12 . In a lower portion on a front surface of the printer 11 (a surface on a near side in FIG. 1 ), a sheet feeding cassette 16 is detachably mounted in a concave mounting portion 12 A. A sheet feeding tray 17 is provided in an upper portion on a rear surface of the main body 12 . In this embodiment, the printer selectively performs a feeding operation from the sheet feeding cassette 16 in the front portion thereof and a feeding operation from the sheet feeding tray 17 in the rear portion thereof.
[0028] A plurality of ink cartridges 18 are loaded in a cover 12 B which covers a front right surface of the main body 12 . Ink in the ink cartridges 18 is supplied to the carriage 13 through a plurality of ink supply tubes (not shown) which are provided in a flexible wiring board 19 , and ink droplets are ejected (discharged) from a recording head 20 (shown in FIG. 2 ) which is provided below the carriage 13 . In the recording head 20 , a pressurization element (piezoelectric element, electrostatic element, or heater element) for applying an ejection pressure to ink is incorporated in each nozzle. If a predetermined voltage is applied to the pressurization element, ink droplets are ejected (discharged) from the corresponding nozzle.
[0029] During printing, ink droplets are ejected from the recording head 20 onto a sheet fed from the sheet feeding cassette 16 and positioned on the platen 15 while the carriage 13 is reciprocating, and thus printing for one line is performed. After printing for one line is completed, the sheet is transported to a printing position of a next row. In this way, a printing operation achieved by one scanning operation of the carriage 13 and a paper transport operation to transport the sheet to the printing position of the next row are alternately performed, thereby performing printing on the sheet. Various operating switches 21 including a power switch are provided in a lower portion on a front left surface of the main body 12 . The printing operation and the paper transport operation may be temporally independently performed. In this embodiment, the printing operation and the paper transport operation are performed such that the other operation starts before one operation is completed, and the operations partially overlap each other at the start and end of the operations.
[0030] FIG. 2 is a side view showing the overall configuration of the printer. Hereinafter, the overall configuration of the printer 11 will be described in detail with reference to FIG. 2 . The printer 11 includes a rear feeder 22 in the rear portion thereof and a front feeder 23 in the bottom portion thereof. A sheet P (mainly, single sheet) serving as a recording medium is fed from one of the two feeders 22 and 23 to a pair of transport rollers 25 . The sheet P is transported to a recording section 24 by the pair of transport rollers 25 , and after recording is performed, is discharged to a stacker (not shown) by a pair of discharge rollers 26 .
[0031] Hereinafter, the components on a paper transport path will be further described in detail.
[0032] The rear feeder 22 includes a hopper 31 , a feed roller 32 , a retard roller 33 , and a sheet returning lever 34 . The hopper 31 pivots around a pivot fulcrum 31 a in an upper portion thereof, and is switched between a posture in which the sheet P obliquely supported by the hopper 31 is pressed against the feed roller 32 , and a posture in which the sheet P is positioned away from the feed roller 32 .
[0033] The retard roller 33 is provided to have predetermined rotation resistance, and forms a nip point with the feed roller 32 to separate an uppermost sheet P to be fed from a next sheet P. The sheet returning lever 34 is rotatably provided, when a sheet feeding path is viewed in side view. The next sheet P separated by the retard roller 33 is returned to an upstream side by the rotation of the sheet returning lever 34 .
[0034] The front feeder 23 , which is provided in the bottom of the printer 11 and in which the sheet is set from the front side of the printer 11 , includes the sheet feeding cassette 16 , a pickup roller 35 , an intermediate roller 36 , a retard roller 37 serving as a separation unit, a sheet returning lever 38 , and an assist roller 39 .
[0035] A plurality of sheets P (a maximum number of sheets ranging from 300 to 800) are stacked in the sheet feeding cassette 16 which is mounted on and removed from the front side, and the sheets P are delivered from the sheet feeding cassette 16 by the pickup roller 35 , which is driven by an ASF motor 54 (see FIG. 4 ), one by one starting from the uppermost one. The pickup roller 35 is provided in a pivot member 40 which pivots around a pivot shaft 40 a . When the pivot member 40 pivots while being urged toward the sheet by an urging unit (not shown), the pickup roller 35 is in constant contact with the uppermost sheet. The height of the pickup roller 35 in contact with the uppermost sheet from among the sheets stacked in the sheet feeding cassette 16 changes depending on a residual sheet amount, and accordingly the pivot member 40 pivots around the pivot shaft 40 a between a highest position when a maximum number of sheets are loaded and a lowest position when a minimum number of sheets are loaded, as indicated by two-dot-chain lines in FIG. 2 . As described above, in this embodiment, if a relatively large number of sheets are loaded in the sheet feeding cassette 16 , a paper feeding distance is different by a distance corresponding the thickness of a maximum number of sheets between when a sheet is fed at a position where the pickup roller 35 is in contact with the top surface of the uppermost sheet from among the maximum number of sheets and when a sheet is fed at a position where the pickup roller 35 is in contact with the top surface of a last sheet in the sheet feeding cassette 16 .
[0036] The sheet P which is delivered by the pickup roller 35 constituting a feed unit is preliminarily separated by a separation inclined surface 16 a, and travels toward the retard roller 37 . The retard roller 37 is provided at a position opposing a peripheral surface of the intermediate roller 36 so as to advance and retreat with respect to the intermediate roller 36 . When the sheet is delivered from the sheet feeding cassette 16 , the retard roller 37 is pressed against the intermediate roller 36 so as to form the nip point, such that the uppermost sheet P (previous page) to be fed and a next sheet P are separated from each other.
[0037] The sheet returning lever 38 is rotatably provided, when the paper feeding path is viewed in side view, such that when the sheet returning lever 38 rotates, the nip point of the intermediate roller 36 and the retard roller 37 falls within the trace of a leading end of the lever. At a feeding standby position, the sheet returning lever 38 takes a posture in which the leading end thereof protrudes toward the feeding path, as indicated by a solid line in FIG. 2 . When the sheet P is fed, the sheet returning lever 38 rotates to a position indicated by a two-dot-chain line in a clockwise direction in FIG. 2 , and retreats from the paper feeding path to open the paper feeding path. When a predetermined time (or predetermined distance) elapses after the paper feeding operation starts, the sheet returning lever 38 rotates to a position indicated by the solid line in a counterclockwise direction of FIG. 2 , that is, rotates in a direction to close the paper feeding path. Accordingly, the leading end of the next sheet at the nip point between the retard roller 37 and the intermediate roller 36 is returned to the upstream side (the sheet feeding cassette 16 ).
[0038] The intermediate roller 36 which constitutes a transport unit for further delivering the sheet P fed by the pickup roller 35 to the downstream side, together with the pair of transport rollers 25 , is driven by a PF motor 53 (shown in FIG. 4 ), flexes and inverts the sheet to be fed, and delivers the sheet P to the pair of transport rollers 25 on the downstream side. The assist roller 39 is in contact with the intermediate roller 36 to assist the transport of the sheet P to the downstream side by the intermediate roller 36 .
[0039] The pair of transport rollers 25 includes a transport driving roller 41 that is rotated by the PF motor 53 ( FIG. 4 ), and a transport driven roller 42 that is rotated while being pressed against the transport driving roller 41 when the transport driven roller 42 rotates. The sheet P whose leading end has reached the pair of transport rollers 25 is transported to the recording section 24 on the downstream side by the rotation of the transport driving roller 41 while being nipped by the transport driving roller 41 and the transport driven roller 42 .
[0040] The recording section 24 includes a recording head 20 that ejects ink onto the sheet P, and a platen 15 that supports the sheet P to restrict a distance between the sheet P and the recording head 20 . The recording head 20 is provided in a bottom portion of the carriage 13 . The carriage 13 is driven to reciprocate in a main scanning direction by a carriage motor 52 (see FIG. 4 ) while being guided by a guide shaft 14 extending in the main scanning direction (a direction perpendicular to the paper plane of FIG. 2 ). In this example, a so-called off-carriage type in which the ink cartridges 18 are provided in the main body 12 is used, but a so-called on-carriage type in which the ink cartridges are mounted on the carriage may be used.
[0041] A pair of discharge rollers 26 provided on the downstream side of the recording section 24 includes a discharge driving roller 43 that is rotated by the PF motor 53 ( FIG. 4 ), and a discharge driven roller 44 that is in contact with the discharge driving roller 43 and is rotated when the discharge driving roller 43 rotates. The sheet P on which recording was performed by the recording section 24 is discharged to a stacker (not shown) provided on the front side of the printer 11 by the rotation of the discharge driving roller 43 while being nipped by the discharge driving roller 43 and the discharge driven roller 44 .
[0042] FIG. 3 is a schematic view of an auto paper feeder (front feeder) and a transport device as viewed from a side surface. In the printer 11 of this embodiment, inter-page control processing is performed in which, while a gap between a previous sheet P 1 serving as a previous medium and a subsequent sheet P 2 serving as a subsequent medium is maintained small, a feeding operation of the subsequent sheet P 2 is performed during performance of a recording operation on the previous sheet P 1 . Hereinafter, various positions and distances to be defined in the inter-page control processing will be described with reference to FIG. 3 . The previous sheet P 1 indicates a first sheet from among two sheets P to be successively fed during multi-sheet printing, and the subsequent sheet P 2 indicates a second sheet to be fed subsequent to the previous sheet P 1 .
[0043] In a paper transport path with the nip point interposed between the intermediate roller 36 and the retard roller 37 , a trailing end sensor 45 is provided at a position on a downstream side to detect a trailing end of the previous sheet P 1 , and a leading end sensor 46 is provided at a position on an upstream side to detect a leading end of the subsequent sheet P 2 . The distance between the trailing end sensor 45 and the leading end sensor 46 in the transport path is set to A (mm) (for example, a value ranging from 10 to 30 mm).
[0044] A paper detection sensor 47 is provided at a predetermined position between the assist roller 39 and the pair of transport rollers 25 in the paper transport path. The paper detection sensor 47 is positioned opposing the transport path of the sheet P to be fed from the rear feeder 22 (see FIG. 2 ) or the front feeder 23 , and detects the leading end and the trailing end of the sheet P. In this embodiment, the trailing end sensor 45 , the leading end sensor 46 , and the paper detection sensor 47 are formed of non-contact sensors, such as optical sensors. An optical sensor includes a pair of a photoreceiver and a phototransmitter. When light emitted from the phototransmitter is shielded by the sheet P and not received by the photoreceiver, a state “paper present” is detected, and when light is not shielded by the sheet P and is received by the photoreceiver, a state “paper absent” is detected. The sensors 45 to 47 are not limited to non-contact sensors, but at least one of them may be changed to a contact sensor.
[0045] The trailing end sensor 45 detects the trailing end of the sheet P (the previous sheet P 1 ) when a detection state is switched from “paper present” to “paper absent”. The leading end sensor 46 detects the leading end of the sheet P (the subsequent sheet P 2 ) when a detection state is switched from “paper absent” to “paper present”. The paper detection sensor 47 detects the leading end of the sheet P (the previous sheet P 1 ) when a detection state is switched from “paper absent” to “paper present”, and detects the trailing end of the sheet P (the previous sheet P 1 ) when the detection state is switched from “paper present” to “paper absent”.
[0046] In the printer 11 of this embodiment, a plurality of printing modes are set. Of these, in a fast printing mode (a draft printing mode), paper feed control is used in which, if the previous sheet P 1 has been transported to a prescribed position, a feeding operation of the subsequent sheet P 2 starts even though printing is being performed on the previous sheet P 1 . That is, if the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 , the pickup roller 35 is driven to start the feeding operation of the subsequent sheet P 2 . Then, the subsequent sheet P 2 is stopped at a position a prescribed distance B (mm) (for example, a value ranging 0 to 10 mm) more advanced from a position at which the leading end is detected by the leading end sensor 46 . The prescribed distance B (mm) is set such that the leading end of the subsequent sheet P 2 is not nipped between the intermediate roller 36 and the retard roller 37 . When the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 , and a preliminary feeding operation of the subsequent sheet P 2 starts, the retard roller 37 is in contact with the intermediate roller 36 , and the sheet returning lever 38 rotates from a closed position indicated by the solid line in FIG. 2 to an open position indicated by the two-dot-chain line.
[0047] In this embodiment, an inter-paper distance Lg between the previous sheet P 1 and the subsequent sheet P 2 is ensured by a prescribed amount K longer than a distance (A-B) mm. For this reason, there is a case in which the inter-paper distance Lg between the subsequent sheet P 2 preliminarily fed and the previous sheet P 1 does not meet the prescribed amount K. For this reason, in this embodiment, after the preliminary feeding operation, the inter-paper distance Lg is calculated before the previous sheet P 1 is next transported (paper transport), and it is determined whether or not the condition Lg≧K is satisfied. If the condition Lg≧K is not satisfied, during the next transport operation, only the previous sheet P 1 is transported while the subsequent sheet P 2 is stopped. If the condition Lg≧K is satisfied, when the previous sheet P 1 is transported, the subsequent sheet P 2 is fed by the same distance. After the condition Lg≧K is satisfied, each time the previous sheet P 1 is transported, the subsequent sheet P 2 is fed by the same distance while maintaining the inter-paper distance Lg. In this way, the inter-paper distance Lg between the sheets P 1 and P 2 is ensured by the prescribed amount K or more, and thus the leading end of the subsequent sheet P 2 can be reliably detected by the paper detection sensor 47 . Therefore, if a subsequent transport distance is counted on the basis of the detection position of the leading end of the subsequent sheet P 2 , a transport position of the subsequent sheet P 2 can be grasped.
[0048] The feeding operation of the subsequent sheet P 2 does not start immediately when the condition Lg≧K is established during the paper transport operation, but the feeding operation of the subsequent sheet P 2 starts after the next transport operation of the previous sheet P 1 starts. The reason is as follows. If the pickup roller 35 is driven during the paper transport operation in which the intermediate roller 36 is rotating at a predetermined speed, a difference in speed occurs between a portion of the subsequent sheet P 2 nipped between the intermediate roller 36 and the retard roller 37 and a portion of the subsequent sheet P 2 in contact with the pickup roller 35 being accelerated on the upstream side in the feeding direction. This difference in speed may cause the subsequent sheet P 2 being fed to be pulled between the portions and the subsequent sheet P 2 may be damaged. In order to solve this problem, the feeding operation of the subsequent sheet P 2 starts at the same timing as the timing at which the paper transport operation of the previous sheet P 1 starts.
[0049] Next, the electrical configuration of a printer having an auto paper feeder will be described with reference to FIG. 4 .
[0050] As shown in FIG. 4 , the printer 11 includes a control section 50 that performs various kinds of control. The control section 50 is communicably connected to a host computer 48 (PC) through an interface 51 , and controls the printer 11 on the basis of print data received from the host computer 48 .
[0051] The control section 50 is connected to the carriage motor 52 , the PF motor 53 (paper transport motor), the ASF motor 54 (automatic feeding motor), and a sub motor 55 (ASF-SUB motor) as an output system. The control section 50 is also connected to a linear encoder 56 , encoder 57 and 58 , the trailing end sensor 45 , the leading end sensor 46 , and the paper detection sensor 47 as an input system.
[0052] The control section 50 includes a controller 60 , a head driver 61 , and motor drivers 62 , 63 , 64 , and 65 . The controller 60 drives the recording head 20 on the basis of print data through the head driver 61 , and draws an image or a document based on print data by dots of ink droplets. The controller 60 drives the carriage motor 52 through the motor driver 62 , and controls the movement of the carriage 13 in the main scanning direction. At this time, input pulses from the linear encoder 56 are counted by a counter (not shown), and accordingly the controller 60 grasps a movement position of the carriage 13 with respect to an origin position (home position). The input pulses from the linear encoder 56 are also used to generate an ejection timing signal of the recording head 20 .
[0053] The controller 60 also drives the PF motor 53 through the motor driver 63 . An output shaft of the PF motor 53 is connected to the transport driving roller 41 , the discharge driving roller 43 , and the intermediate roller 36 through a series of wheels (not shown) so as to transmit power to them. If the PF motor 53 is forward driven, the transport driving roller 41 , the discharge driving roller 43 , and the intermediate roller 36 are rotated in the paper transport direction. If the PF motor 53 is reversely driven, the transport driving roller 41 and the discharge driving roller 43 are reversely driven due to the action of a clutch 66 , but the intermediate roller 36 is not reversely driven.
[0054] The controller 60 also drives the ASF motor 54 through the motor driver 64 . An output shaft of the ASF motor 54 is connected to the feed roller 32 and the pickup roller 35 through a series of wheels (not shown) so as to transmit power to them. A clutch 67 is interposed in a power transmission path between the ASF motor 54 and each of the rollers 32 and 35 . When the ASF motor 54 is driven, a selected one of the rollers 32 and 35 is rotated in the paper feeding direction due to the movement of the clutch 67 . Therefore, if the ASF motor 54 is forward driven, one of the feed roller 32 and the pickup roller 35 selected by the clutch 67 is rotated in the paper feeding direction.
[0055] The controller 60 also drives the sub motor 55 through the motor driver 65 . An output shaft of the sub motor 55 is connected to the hopper 31 and the retard rollers 33 and 37 through a series of wheels (not shown) so as to transmit power to them. When the sub motor 55 is driven, one of a power transmission path of the rear feeder 22 and a power transmission path of the front feeder 23 is selected on the basis of the movement of a clutch 68 . If the power transmission path of the rear feeder 22 is selected, the sub motor 55 is forward/reversely driven by a predetermined amount. Then, the hopper 31 , the retard roller 33 , and the sheet returning lever 34 are driven between a retreat position and a feeding position. If the power transmission path of the front feeder 23 is selected, the retard roller 37 and the sheet returning lever 38 are driven from the retreat position to the feeding position when the sub motor 55 is forward driven by a predetermined amount. Meanwhile, when the sub motor 55 is reversely driven by a predetermined amount, the retard roller 37 and the sheet returning lever 38 are driven from the feeding position to the retreat position.
[0056] During printing, a user can activate a printer driver (not shown) in the host computer 48 to select the rear (sheet feeding tray) and the front (sheet feeding cassette) as a sheet feeding source by an operation of an input device. The controller 60 receives, from the host computer 48 , print data which includes information regarding the selected sheet feeding source as one of printing conditions. The controller 60 controls a driving system to select the designated sheet feeding source on the basis of print data. That is, the controller 60 selects the connection states of the clutches 66 to 68 to select a sheet feeding source to be driven from among the rear feeder 22 and the front feeder 23 .
[0057] The printer driver of the host computer 48 acquires various printing parameters, such as sheet size, sheet type, and layout, which are set by an operation of the user with the input device, and if an instruction to perform printing is received, generates printing image data by predetermined processing, such as resolution conversion, color conversion, halftone, and rasterization. Then, a command is attached to a header with printing image data as a body, thereby generating print data. The header includes various printing parameters starting with sheet type and sheet feeding source designation information, as well as the command.
[0058] The controller 60 includes a head controller 71 , a carriage controller 72 , a transport controller 73 , a paper feed controller 74 , a first controller 75 , a second controller 76 , a third controller 77 , a PF counter 78 , an ASF counter 79 , a trailing end detection state monitoring section 80 , a leading end detection state monitoring section 81 , a paper feed start condition determining section 82 , an inter-paper distance calculator 83 , a motor driving state determining section 84 , a paper feed driving condition determining section 85 , and a memory 86 . The controller 60 includes, for example, a CPU, an ASIC (Application Specific IC (specific-use IC)), a ROM, a RAM, a nonvolatile memory, and the like. The controller 60 is configured such that the CPU executes a program which is stored in the ROM, and shown in flowcharts of FIGS. 9 to 11 . The controller 60 is not limited to software. For example, the controller 60 may be formed of hardware, such as an electronic circuit (for example, a custom IC), or a combination of software and hardware.
[0059] The head controller 71 drives the recording head 20 through the head driver 61 . The carriage controller 72 drives the carriage motor 52 through the motor driver 62 .
[0060] The first to third controllers 75 to 77 are a control section for a paper transport system. The first controller 75 drives the PF motor 53 through the motor driver 63 . The second controller 76 drives the ASF motor 54 through the motor driver 64 . The third controller 77 drives the sub motor 55 through the motor driver 65 .
[0061] The rotation of the PF motor 53 is detected by the encoder 57 (rotary encoder), and a detection signal (encoder signal) is input to the PF counter 78 . The PF counter 78 counts pulse edges of the encoder signal, and obtains a value corresponding to a paper transport amount with a sheet position during reset as an origin.
[0062] The rotation of the ASF motor 54 is detected by the encoder 58 (rotary encoder), and a detection signal (encoder signal) is input to the ASF counter 79 . The ASF counter 79 counts pulse edges of the encoder signal, and obtains a value corresponding to a paper transport amount with a sheet position during reset as an origin.
[0063] The trailing end detection state monitoring section 80 monitors on the basis of a detection signal input from the trailing end sensor 45 whether or not the trailing end sensor 45 detects the trailing end of the previous sheet P 1 . Specifically, the trailing end detection state monitoring section 80 monitors whether or not the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”, and if the detection state is switched to “paper absent”, changes a monitoring flag from “0” to “1”. The leading end detection state monitoring section 81 monitors on the basis of a detection signal input from the leading end sensor 46 whether or not the leading end sensor 46 detects the leading end of the subsequent sheet P 2 . Specifically, the leading end detection state monitoring section 81 monitors whether or not the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present”, and if the detection state is switched to “paper present”, changes a monitoring flag from “0” to “1”.
[0064] The paper feed start condition determining section 82 inputs the monitoring results (monitoring flags) of the trailing end detection state monitoring section 80 and the leading end detection state monitoring section 81 . In this embodiment, when the detection state of the trailing end by the trailing end sensor 45 is switched from “paper present” to “paper absent” during the paper transport operation of the previous sheet P 1 , the feeding operation of the subsequent sheet P 2 starts. On the other hand, there may be a case in which, during the feeding operation of the previous sheet P 1 , the subsequent sheet P 2 is double fed. In this embodiment, when double feeding occurs, the leading end of the subsequent sheet P 2 is in contact with the sheet returning lever 38 in the closed position, and thus the position of the subsequent sheet P 2 is restricted. In this case, however, the subsequent sheet P 2 already passes by the preliminary feeding position (target position) (in FIG. 3 , a position by a distance B away from the leading end sensor 46 ). For this reason, even though double feeding occurs and the trailing end of the previous sheet P 1 is detected, the preliminary feeding operation of the subsequent sheet P 2 is not performed.
[0065] The paper feed start condition determining section 82 determines whether or not to permit or inhibit the preliminary feeding operation of the subsequent sheet P 2 . That is, if the monitoring flag from the trailing end detection state monitoring section 80 is changed from “0” to “1”, the paper feed start condition determining section 82 starts the determination processing. If the monitoring flag from the leading end detection state monitoring section 81 is “0” (leading end non-detection state), it is determined that a preliminary feeding start condition is established. If the monitoring flag is “1” (leading end detection state) it is determined that the preliminary feeding start condition is not established.
[0066] The paper feed start condition determining section 82 sends the determination result to the paper feed controller 74 . The paper feed controller 74 selects one of the second and third controllers 76 and 77 as a destination of a motor driving instruction in accordance with the determination result. That is, if the preliminary feeding start condition is not established, the motor driving instruction is not output to the second controller 76 , and the preliminary feeding operation of the subsequent sheet P 2 is inhibited. If the preliminary feeding start condition is established, the motor driving instruction is output to both the second and third controllers 76 and 77 to start the preliminary feeding operation of the subsequent sheet P 2 . For this reason, if the preliminary feeding start condition is established, the second controller 76 drives the ASF motor 54 , and the pickup roller 35 is forward driven in the feeding direction. In addition, the third controller 77 drives the sub motor 55 . Accordingly, the sheet returning lever 38 is driven from the closed position (feeding restriction position) to the open position (feeding permission position), and the retard roller 37 is driven from the retreat position to the feeding position.
[0067] The paper feed controller 74 performs control the start and stop of the preliminary feeding operation. That is, after the preliminary feeding operation starts, the paper feed controller 74 monitors the flag of the leading end detection state monitoring section 81 . Then, if the leading end sensor 46 detects the leading end of the subsequent sheet P 2 and the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present” (that is, if the flag is changed from “0” to “1”), the paper feed controller 74 resets the ASF counter 79 . In addition, if the count value of the ASF counter 79 has reached a value corresponding to the prescribed distance B, in order to stop the feeding operation of the subsequent sheet P 2 , the paper feed controller 74 transmits an instruction to stop motor driving to the second controller 76 . For this reason, the subsequent sheet P 2 is stopped when the leading end thereof passes through the detection position of the leading end sensor 46 by the prescribed distance B (mm). The third controller 77 is stopped when the sheet returning lever 38 is driven to the feeding permission position and the retard roller 37 is driven to the feeding position.
[0068] When the subsequent sheet P 2 is positioned at the feeding standby position (target position), it is determined in advance whether or not a main feeding start condition is established on which the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 can be simultaneously performed during the next transport operation. If the main feeding start condition is established, the feeding operation is performed simultaneously with the next transport operation. The determination regarding whether or not the main feeding start condition is established is performed on the basis of the calculation value of the inter-paper distance Lg. For this calculation, the inter-paper distance calculator 83 is provided. The inter-paper distance calculator 83 calculates the inter-paper distance Lg on the basis of the count value of the PF counter 78 , the count value of the ASF counter 79 , and the set value stored in the memory 86 . The memory 86 stores various kinds of set data, such as the transport distance between the trailing end sensor 45 and the leading end sensor 46 and the like, which are used to calculate the inter-paper distance.
[0069] When the transport controller 73 is requested to perform the next transport operation of the previous sheet, if the ASF motor 54 is not being driven, inter-paper distance calculation is performed immediately before the next transport operation starts. If the inter-paper distance Lg of a prescribed amount C or more is ensured, the main feeding operation is performed during the next transport operation. When the transport controller 73 is requested to perform the next transport operation of the previous sheet, if the ASF motor 54 is being driven, the inter-paper distance Lg is not calculated, and the transport operation of the previous sheet P 1 is immediately performed, without waiting for until the preliminary feeding operation of the subsequent sheet P 2 is stopped. In any cases, the time when the paper transport processing of the previous sheet is defined based on when the transport controller 73 is requested to perform the next transport operation of the previous sheet. A feeding distance until the subsequent sheet P 2 reaches the feeding standby position varies depending on the number of sheets in the sheet feeding cassette 16 at the time of the start of the feeding operation. That is, when a small number of sheets remain in the sheet feeding cassette 16 , as shown in FIGS. 2 and 3 , an uppermost sheet is supplied from a low position close to the bottom of the sheet feeding cassette 16 . Accordingly, as shown in FIG. 2 , the feeding distance extends extra (for example, 40 to 80 mm), as compared with an uppermost sheet from among a substantially maximum number of sheets stacked in the sheet feeding cassette 16 near the maximum number of sheets. In such a case, the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 during the transport operation of the previous sheet P 1 , and the transport operation ends when the preliminary feeding operation of the subsequent sheet P 2 starts. Accordingly, even though it comes a time to start the next transport operation, that is, even though it comes a time to calculate the inter-paper distance, the preliminary feeding operation of the subsequent sheet P 2 may be still continuing. In this case, the position (stop position) of the subsequent sheet P 2 during the preliminary feeding operation is not fixed, and as a result, the inter-paper distance Lg cannot be calculated.
[0070] For this reason, in this embodiment, the driving state of the ASF motor 54 is monitored, and if the ASF motor 54 is being driven even though it comes a time to calculate the inter-paper distance Lg, the transport operation of the previous sheet P 1 immediately start without waiting for until the preliminary feeding operation of the subsequent sheet P 2 is stopped. When it comes a time to calculate the inter-paper distance Lg, the motor driving state determining section 84 determines the driving state of the ASF motor 54 . Before the next transport operation, if it is determined that the ASF motor 54 is stopped, the motor driving state determining section 84 transmits a calculation start instruction to the inter-paper distance calculator 83 . Meanwhile, if the ASF motor 54 is being driven and is not stopped until a predetermined time limit in the next transport operation reaches, the calculation start instruction is not transmitted. For this reason, if the instruction to start calculation is not received until the predetermined time limit elapses, the inter-paper distance calculator 83 does not calculate the inter-paper distance Lg.
[0071] If the preliminary feeding start condition is established and the preliminary feeding operation is performed, or the preliminary feeding start condition is not established and the preliminary feeding operation is not performed is indicated by the determination signal from the paper feed start condition determining section 82 , the inter-paper distance calculator 83 changes a computational expression to be used to calculate the inter-paper distance Lg according to the details. That is, when the preliminary feeding operation is performed, a first computational expression is used on an assumption that the leading end of the subsequent sheet P 2 is at the feeding standby position. Meanwhile, when the preliminary feeding operation is not performed, a second computational expression is used on an assumption that the leading end of the subsequent sheet P 2 is at the feeding restriction position at which it is in contact with the sheet returning lever 38 in the closed state. The first computational expression and the second computational expression are described below.
First Computational Expression
[0072] Lg=n+A−B (1)
Second Computational Expression
[0073] Lg=n+A−C (2)
[0074] Here, n is a PF driving distance from a detection position, at which the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”, to the position of the trailing end of the previous sheet Pl. “A” is a transport distance between a trailing end sensor 45 and a leading end sensor 46 , and “B” is a prescribed distance. “C” is a transport distance (mm) from the leading end sensor 46 to the feeding restriction position (medium restriction position), at which the leading end of the subsequent sheet P 2 is positioned when the leading end is in contact with and is restricted by the sheet returning lever 38 . The distances A, B, and C are constants which are uniquely defined in design in accordance with the positions of the sensors 45 and 46 or the operation position of the sheet returning lever 38 . In this example, the condition B<C<A is satisfied. When the inter-paper distance is calculated, the inter-paper distance calculator 83 sends the calculated inter-paper distance Lg to the paper feed driving condition determining section 85 .
[0075] The paper feed driving condition determining section 85 determines on the basis of the inter-paper distance Lg whether to perform the feeding operation or not. In this embodiment, it is necessary to ensure the inter-paper distance Lg of the prescribed amount K (mm) or more. After the preliminary feeding operation is completed, the start of the main feeding operation is determined on the basis of whether or not the main feeding start condition Lg≧K is satisfied. Here, a minimum gap exists so as to ensure the paper detection sensor 47 to reliably detect the leading end of the subsequent sheet P 2 . The prescribed amount K (mm) is obtained by adding a predetermined margin to the minimum gap. The prescribed amount K is also set such that a skew removal operation is performed during the feeding operation of the subsequent sheet P 2 without damaging the sheet. The skew removal operation indicates a series of operations, including nip and release operations, in which a part of the leading end of the subsequent sheet P 2 is temporarily nipped between the pair of transport rollers 25 , and the pair of transport rollers 25 are reversely driven to release the leading end of the subsequent sheet P 2 . In this example, when the previous sheet P 1 is at a last row printing position according to the paper size, the prescribed amount K is set under a condition that the inter-paper distance Lg exists and the leading end of the subsequent sheet P 2 on the upstream side in the transport direction is not nipped between the pair of transport rollers 25 . For example, if the prescribed amount is set to such a value that the leading end of the subsequent sheet P 2 is nipped between the pair of transport rollers 25 , a relatively large amount of the leading end protrudes toward the downstream side in the transport direction from the nip point of the subsequent sheet P 2 due to the release operation in the skew removal operation after last row printing. Accordingly, it is necessary to increase the amount of reverse rotation of the pair of transport rollers 25 for the release operation. In this embodiment, the intermediate roller 36 is only rotatable forward (paper transport direction) but is not rotatable reversely. If the amount of reverse rotation of the pair of transport rollers 25 is excessive, the subsequent sheet P 2 may be excessively flexed between the pair of transport rollers 25 and the intermediate roller 36 during the release operation and may be damaged. In contrast, the prescribed amount K is set such that the amount of reverse rotation of the pair of transport rollers 25 during the release operation is not excessive. Therefore, the subsequent sheet P 2 can be prevented from being excessively flexed and damaged during the release operation. The paper feed driving condition determining section 85 sends a main feeding instruction signal to the paper feed controller 74 only if it is determined the main feeding start condition Lg≧K is satisfied.
[0076] If the main feeding instruction signal is received from the paper feed driving condition determining section 85 , the paper feed controller 74 drives the ASF motor in synchronization with driving of the PF motor during the next transport operation, and transmits the motor driving instruction to the second controller 76 such that the feeding operation is performed simultaneously with the transport operation. If the main feeding instruction signal is not received, no motor driving instruction is transmitted to the first to third controllers 75 to 77 . For this reason, the inter-paper distance Lg of the prescribed amount K or more is ensured, and thus the main feeding operation is performed.
[0077] The next transport operation is as follows. If the instruction to start the transport operation is received from the carriage controller 72 , the transport controller 73 transmits the motor driving instruction to the first controller 75 to drive the PF motor 53 , and accordingly the pair of transport rollers 25 , the pair of discharge rollers 26 , and the intermediate roller 36 are forward driven at a predetermined speed profile in the transport direction. In this way, the next transport operation is performed. At this time, the second controller 76 acquires information regarding the amount of the next transport operation from the transport controller 73 , and controls the speed of the ASF motor 54 at a feeding speed profile conforming to a transport speed profile defined by the information regarding the transport amount so as to be synchronous with the PF motor 53 , such that the subsequent sheet P 2 is fed at the same speed, in the same amount, and at the same transport timing as the previous sheet P 1 . At this time, in view of a difference in reduction ratio due to a difference in roller diameter between the PF system and the ASF system, the PF motor 53 and the ASF motor 54 are controlled such that the transport speed, the transport distance, and the transport timing are identical.
[0078] For example, if the main feeding operation is performed in a state where the inter-paper distance Lg is insufficient (Lg<K) and the subsequent sheet P 2 is temporarily nipped between the intermediate roller 36 and the retard roller 37 , the intermediate roller 36 is forward driven each time the previous sheet P 1 is transported. For this reason, the inter-paper distance Lg is fixed to the insufficient initial value (Lg<K). The insufficient inter-paper distance Lg causes various problems. In this embodiment, therefore, the subsequent sheet P 2 preliminarily feeds to the feeding standby position (target) near to the nip point between the intermediate roller 36 and the retard roller 37 and stands by at the feeding standby position. Then, after it is determined that the inter-paper distance Lg satisfies the condition Lg≧K, the main feeding operation is performed.
[0079] Next, the operation of the printer 11 will be described. First, a printing processing of the printer 11 will be described with reference to a flowchart of FIG. 9 . If print data is received, the controller 60 executes a program shown in FIG. 9 and drives a printer engine on the basis of print data to perform the printing processing.
[0080] First, a paper feed processing is performed (Step S 10 ). That is, in a state where the sub motor 55 is driven, and the retard roller 37 and the sheet returning lever 38 are at the feeding position indicated by the two-dot-chain line of FIG. 2 , the ASF motor 54 and the PF motor 53 are driven. Then, the pickup roller 35 rotates, and accordingly the uppermost sheet P in the sheet feeding cassette 16 is fed. The leading end of the sheet P 1 is detected by the paper detection sensor 47 , and then the sheet P 1 is transported by a predetermined distance. Thus, the paper feed processing ends. For example, if the sheet P 1 is transported to a position to be nipped between the pair of transport rollers 25 and the paper feed processing ends, the sub motor 55 is driven. Then, the retard roller 37 is separated from the intermediate roller 36 , and the sheet returning lever 38 is at the closed position to close a feeding port.
[0081] Next, a leading end setting processing is performed (Step S 20 ). With a position of the sheet P 1 at the time of end of the feeding operation as an origin, if a count value corresponding to a distance from the origin to a leading end setting position is counted by the PF counter 78 , the PF motor 53 is stopped, and the sheet P 1 is set to the leading end setting position. The sheet P 1 is positioned at the printing start position by the leading end setting processing, and thus a paper transport processing in Step S 30 is not performed in the leading end setting processing.
[0082] Next, a printing processing is performed (Step S 40 ). That is, the carriage motor 52 is driven to move the carriage 13 in the main scanning direction, and ink droplets are ejected are ejected from the nozzles of the recording head 20 while the carriage 13 is moving. In this way, printing for one pass is performed.
[0083] It is determined whether or not printing for one page is completed (Step S 50 ), and if printing is not completed, the paper transport processing (Step S 30 ) and the printing processing (Step S 40 ) are alternately performed until a discharge command is received and it is determined that printing for one page is completed. During the paper transport processing, the ASF motor 54 and the PF motor 53 are driven in accordance with a paper transport command, and the sheet is transported by the instructed transport amount.
[0084] If the discharge command is received and printing for one page is completed, it is determined whether or not the paper feeding operation is performed during the paper transport operation (Step S 60 ). That is, when the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 during the transport operation, it is determined whether or not the paper feeding operation of the subsequent sheet P 2 is performed. If the paper feeding operation is not performed during the paper transport operation, the previous sheet P 1 is not transported to a position at which the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 . In this case, therefore, a paper discharge processing is performed (Step S 70 ). If the paper feeding operation is performed during the paper transport operation, the previous sheet P 1 already passes by a position at which the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 . In this case, the paper discharge processing is not performed, and the process progresses to the paper feed processing (Step S 10 ). Then, the subsequent sheet P 2 is fed by the paper feed processing, and the previous sheet P 1 is discharged.
[0085] After the paper discharge processing, it is determined whether or not all pages are printed (Step S 80 ). If all the pages are not printed, the paper feed processing of a next page is performed (Step S 10 ). If all the pages are printed, the routine ends.
[0086] Next, the feed control processing in the printer 11 will be described. FIGS. 5 to 8 are timing charts when the feed control processing is performed. In the feed control of this embodiment, four kinds of control are branched off depending on the situations (a difference in transport amount, a difference in residual length of the sheet, presence/absence of double feeding, and the like). FIGS. 5 and 6 show a processing in a cast in which the preliminary feeding operation and the main feeding operation of the subsequent sheet P 2 start during the paper transport operation with detection of the trailing end of the previous sheet P 1 as a trigger. FIG. 7 shows a processing in a case in which the preliminary feeding operation is not performed in a state where the leading end sensor 46 is already in a detection state at the time of detection of the trailing end of the previous sheet P 1 . FIG. 8 shows a processing in a case in which the ASF motor 54 is continuously driven when it comes a time to calculate the inter-paper distance after the preliminary feeding operation of the subsequent sheet P 2 starts with detection of the trailing end of the previous sheet P 1 as a trigger, and before the next transport operation.
[0087] Hereinafter, the feed control processing of the printer in the above-described cases will be sequentially described with reference to FIGS. 5 to 8 .
[0088] FIG. 5 is a timing chart showing the operation timing of the recording head 20 , the carriage motor 52 (in the drawing, CR motor), the PF motor 53 , the ASF motor 54 , and the sub motor 55 during the feed control processing, together with the detection states of the trailing end sensor 45 and the leading end sensor 46 . The operation timing of the carriage motor 52 and the recording head 20 is shown only in FIG. 5 .
[0089] During printing, the printing operation and the paper transport operation are alternatively performed, and then printing is performed on the previous sheet P 1 . For this reason, the carriage motor 52 and the PF motor 53 are alternately driven. In FIG. 5 , during a constant-speed period in which the carriage motor 52 is driven at a constant speed, ink droplets are ejected from the recording head 20 (in FIG. 5 , a hatched region). The PF motor 53 for the transport operation of the previous sheet P 1 starts to be driven after the ink droplets are ejected from the recording head 20 . At this time, the transport amount is defined by the command in print data, and the previous sheet P 1 is transported to a printing position of a next row (next line).
[0090] During the transport operation of the previous sheet P 1 , it is monitored whether or not the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”. As shown in FIG. 5 , if the previous sheet P 1 is transported during printing, the trailing end of the previous sheet P 1 reaches a preliminary feeding start position Q, and the trailing end sensor 45 detects the trailing end of the previous sheet P 1 . In this state, if it is detected that the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”, the ASF motor 54 and the sub motor 55 are driven. As the ASF motor 54 is driven, the preliminary feeding operation of the subsequent sheet P 2 starts from the set position in the sheet feeding cassette 16 . During the preliminary feeding operation, it is monitored whether or not the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present”. If it is detected that the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present”, the ASF counter 79 starts to measure the ASF transport distance. If the measured distance has reached the prescribed distance B (mm), the ASF motor 54 is stopped. With this preliminary feeding operation, the subsequent sheet P 2 is delivered to the feeding standby position W (target position).
[0091] As the sub motor 55 is driven, the retard roller 37 is raised and positioned at the feeding position (a position indicated by a two-dot-chain line in FIG. 2 ) to be in contact with the intermediate roller 36 . Simultaneously, the sheet returning lever 38 is positioned at the open position (a position indicated by a two-dot-chain line in FIG. 2 ) and the feeding port is opened. As the sheet returning lever 38 is opened, the subsequent sheet P 2 can enter a gap (nip point) between the intermediate roller 36 and the retard roller 37 , and the main feeding operation to further transport the subsequent sheet P 2 from the feeding standby position is prepared.
[0092] During the preliminary feeding operation, the subsequent sheet P 2 is delivered to the feeding standby position W in front of the nip point between the intermediate roller 36 and the retard roller 37 . For this reason, even though the intermediate roller 36 which has the same power source (PF motor 53 ) as the transport driving roller 41 rotates during the transport operation of the previous sheet P 1 , the subsequent sheet P 2 is not fed. In this state, the subsequent sheet P 2 is fed when the ASF motor 54 is driven.
[0093] Subsequently, the printing operation is performed and it comes a calculation time before a predetermined time (for example, 5 to 20 milliseconds) from the next transport operation, the inter-paper distance Lg is calculated. That is, the inter-paper distance Lg=n+A−B is calculated by the first computational expression (Expression (1)). In this case, the PF counter 78 is reset when the leading end sensor 46 detects the trailing end of the previous sheet P 1 , and subsequently, counts the pulse edges of the signal input from the encoder 57 . In this way, the PF driving distance “n” corresponding to the amount of rotation of the PF motor 53 from the detection position of the trailing end of the previous sheet P 1 (the preliminary feeding start position Q) is obtained as the count value. The inter-paper distance Lg is calculated on the basis of the PF driving distance n and the constants A and B by the first computational expression.
[0094] FIG. 5 shows an example where, during an initial transport operation after the preliminary feeding operation, the main feeding start condition is satisfied, that is, the inter-paper distance Lg is equal to or more than the prescribed amount K (Lg≧K).
[0095] If the condition Lg≧K is satisfied, and the necessary inter-paper distance Lg is ensured, as shown in FIG. 5 , the ASF motor 54 is driven in synchronization with the PF motor 53 for the next transport operation of the previous sheet P 1 is driven. Then, the main feeding operation in which the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed is performed. In this case, the PF motor 53 and the ASF motor 54 are controlled such that the transport speed of the previous sheet P 1 is substantially identical to the feeding speed of the subsequent sheet P 2 . For this reason, during the main feeding operation, the inter-paper distance Lg between the previous sheet P 1 and the subsequent sheet P 2 is maintained. Subsequently, each time the PF motor 53 is driven for the transport operation, the ASF motor 54 is simultaneously driven. Therefore, the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed while the inter-paper distance Lg is maintained.
[0096] FIG. 6 shows an example in which, during an initial transport operation after the preliminary feeding operation, the inter-paper distance Lg does not satisfy the main feeding start condition Lg≧K. Up to the preliminary feeding operation of the subsequent sheet P 2 is the same as the example of FIG. 5 . However, if the inter-paper distance Lg calculated by the first computational expression before the next transport operation is less than the prescribed amount K (Lg<K), and an insufficient inter-paper distance is ensured, as shown in FIG. 6 , when the PF motor 53 for the next transport operation is driven, the ASF motor 54 is not driven, and only the transport operation of the previous sheet P 1 is performed. As a result, the inter-paper distance Lg between the previous sheet P 1 and the subsequent sheet P 2 increases by the transport amount of the previous sheet P 1 .
[0097] Before the next transport operation, the inter-paper distance Lg is recalculated by the first computational expression. In this case, the PF driving distance n represented by the count value of the PF counter 78 increases by the previous transport amount. If the calculated inter-paper distance Lg is equal to or more than the prescribed amount K (Lg≧K), as shown in FIG. 6 , the ASF motor 54 is driven in synchronization with the PF motor 53 for the next transport operation, and the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed. As a result, the previous sheet P 1 and the subsequent sheet P 2 are transported together while the inter-paper distance Lg is maintained. Subsequently, each time the PF motor 53 for the transport operation is driven, the ASF motor 54 is simultaneously driven, and thus the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed while the inter-paper distance Lg is maintained. Meanwhile, if Lg<K, only the transport operation of the previous sheet P 1 is performed again. That is, only the transport operation of the previous sheet P 1 is performed until the inter-paper distance Lg calculated before the next transport operation satisfies the main feeding start condition Lg≧K. Then, if the condition Lg≧K is satisfied, during a subsequent transport operation, the feeding operation of the subsequent sheet P 2 is performed together while the inter-paper distance Lg is maintained.
[0098] FIG. 7 shows a processing in a case in which, even though it comes to a time to calculate the inter-paper distance Lg, the ASF motor 54 for the preliminary feeding operation is continuously driven. In this case, when the ASF motor 54 is stopped and the position of the subsequent sheet P 2 is not decided, the inter-paper distance Lg may not be decided, and the inter-paper distance Lg may not be calculated. When this happens, if it waits for until the ASF motor 54 is stopped, a time to start the next transport operation is delayed and throughput is deteriorated. In this embodiment, if the ASF motor 54 is continuously driven when it comes a time to calculate, the PF motor 53 is driven immediately without waiting for until the ASF motor 54 is stopped. With this transport operation, the trailing end of the previous sheet P 1 is moved by the transport amount toward the downstream side in the transport direction.
[0099] When it comes a time to calculate before the next transport operation, if the ASF motor 54 is stopped, the inter-paper distance Lg is calculated by the first computational expression. If the calculated inter-paper distance Lg satisfies the main feeding start condition Lg≧K, the ASF motor 54 is driven in synchronization with the PF motor 53 for the next transport operation. Therefore, the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed while the inter-paper distance Lg is maintained. If the main feeding start condition Lg≧K is not satisfied, the ASF motor 54 is not driven, and only the PF motor 53 is driven to perform the transport operation of the previous sheet P 1 . With this transport operation, the inter-paper distance Lg increases by the transport amount. Subsequently, the same processing as that in FIG. 6 is performed.
[0100] FIG. 8 shows a processing in a case in which the preliminary feeding operation is not performed in a state where the detection state of the leading end sensor 46 is already “paper present” at the time of detection of the trailing end of the previous sheet P 1 . For example, when the subsequent sheet P 2 is double fed while the previous sheet P 1 is fed, the subsequent sheet P 2 is separated from the previous sheet P 1 by the retard roller 37 . Therefore, there is no case in which subsequent sheet P 2 exceeds the retard roller 37 toward the downstream side in the transport direction. If the previous sheet P 1 is fed, the sub motor 55 is driven, and the retard roller 37 is lowered and separated from the intermediate roller 36 . Simultaneously, the sheet returning lever 38 is rotated to the closed position. As a result, the leading end of the double fed subsequent sheet P 2 is in contact with the sheet returning lever 38 . In addition, when the subsequent sheet P 2 is double fed at the time of the transport operation of the previous sheet P 1 after the sheet returning lever 38 is closed, the leading end of the subsequent sheet P 2 is in contact with the sheet returning lever 38 . Therefore, the subsequent sheet P 2 is restricted so as to be no longer transported toward the downstream side in the transport direction.
[0101] As shown in FIG. 8 , if the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent” during the transport operation of the previous sheet P 1 , when the detection state of the leading end sensor 46 is already “paper present”, it may be considered that the subsequent sheet P 2 has reached the feeding restriction position R and is in contact with the sheet returning lever 38 due to double feeding. In this case, at the feeding restriction position R, the leading end of the subsequent sheet P 2 exceeds the feeding standby position W by a predetermined distance toward the downstream side in the transport direction, and thus the ASF motor 54 for the preliminary feeding operation is not driven.
[0102] If it comes a time to calculate before the next transport operation, the inter-paper distance Lg is calculated. In this case, the leading end of the subsequent sheet P 2 is regarded as being at the feeding restriction position R at which the subsequent sheet P 2 is in contact with the sheet returning lever 38 , and accordingly the second computational expression Lg=n+A−C is used. In the second computational expression, the constant C is identical to the ASF driving distance between the detection position of leading end of the subsequent sheet P 2 and the feeding restriction position R. With the second computational expression, the inter-paper distance Lg which is identical to a transport distance between the feeding restriction position R and the position of the trailing end of the previous sheet P 1 is calculated.
[0103] It is determined whether or not the calculated inter-paper distance Lg is equal to or more than the prescribed amount K. If the condition Lg≧K is established, the PF motor 53 and the ASF motor 54 are simultaneously driven. If the condition Lg≧K is not established, the ASF motor 54 is not driven, and only the PF motor 53 is driven. When the subsequent sheet P 2 is double fed, the subsequent sheet P 2 is already transported to the feeding restriction position R beyond the feeding standby position W. For this reason, the inter-paper distance Lg is relatively short, and the main feeding start condition Lg≧K is likely to be established, as compared with the subsequent sheet P 2 is at the feeding standby position W. If the condition Lg≧K is not established, while the position of the subsequent sheet P 2 is maintained, only the transport operation of the previous sheet P 1 is performed. Thus, the inter-paper distance Lg increases. If the inter-paper distance Lg calculated before a subsequent transport operation satisfies the condition Lg≧K, the ASF motor 54 is driven in synchronization with the PF motor 53 . Therefore, the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are simultaneously performed, while the inter-paper distance Lg is maintained.
[0104] FIGS. 10 and 11 are flowcharts showing the feed control processing. Hereinafter, the feed control processing of the printer will be described with reference to FIGS. 10 and 11 , in addition to FIGS. 5 to 8 with respect to the above-described cases. In the following description, the driving of the PF motor 53 may be referred to as “PF driving”, and the driving of the ASF motor 54 may be referred to as “ASF driving”.
[0105] In Step S 110 of FIG. 10 , it is determined whether or not the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent” during the PF driving of the previous transport operation. This determination is performed on the basis of the value of the flag for storing the monitoring result of the trailing end detection state monitoring section 80 , which monitors the detection state of the trailing end sensor 45 . The trailing end detection state monitoring section 80 monitors the detection state of the trailing end sensor 45 during the PF driving. If the detection state is “paper present”, a trailing end flag is set to “1”, and if the detection state is “paper absent”, the trailing end flag is set to “0”. If the value of the flag is changed from “1” to “0” , a previous transport flag is changed from “0” to “1”. The determination in Step S 110 is performed by the paper feed start condition determining section 82 on the basis of the value of the previous transport flag. If the detection state is changed from “paper present” to “paper absent” during previous PF driving (that is, the previous transport flag=1), the process progresses to Step S 160 of FIG. 11 . If the switching of the detection state from “paper present” to “paper absent” is not detected (that is, the previous transport flag=0), the process progresses to Step S 120 . The previous transport flag is changed from “1” to “0” when the detection state of the trailing end sensor 45 is switched from “paper absent” to “paper present” during the PF driving.
[0106] In Step S 120 , the PF motor 53 is driven to transport the previous sheet P 1 by a designated transport distance. In this case, the ASF motor 54 is not driven, and only the transport operation of the previous sheet P 1 is performed. Step 120 corresponds to performing of a transport operation.
[0107] In Step S 130 , it is determined whether or not the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent” during the PF driving. This determination is performed by the trailing end detection state monitoring section 80 . If the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent” during the PF driving, the process progresses to Step S 140 . If the switching of the detection state is not detected, the paper transport processing ends. In Step S 130 , if the determination is false, the trailing end detection state monitoring section 80 changes the previous transport flag from “0” to “1”.
[0108] In Step S 140 , it is determined whether or not the detection state of the leading end sensor 46 is “paper absent”. This determination is performed by the paper feed start condition determining section 82 on the basis of the monitoring result of the leading end detection state monitoring section 81 . The leading end detection state monitoring section 81 monitors the detection state of the leading end sensor 46 . If the detection state is “paper present”, a leading end flag is set to “1”, and if the detection state is “paper absent”, the leading end flag is set to “0”. The paper feed start condition determining section 82 performs the determination in Step S 140 on the basis of the value of the leading end flag. If the determination result is “paper absent”, the process progresses to Step S 150 , and if the determination result is “paper absent” (that is, “paper present”), the paper transport processing ends. As in the example of FIG. 8 , when the subsequent sheet P 2 is double fed while the previous sheet P 1 is fed and transported, if the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”, the detection state of the leading end sensor 46 is already “paper present”. In such a case, during the PF driving, the ASF driving is not performed. Steps S 130 and S 140 correspond to a processing in which the paper feed start condition determining section 82 determines on the monitoring results of the trailing end detection state monitoring section 80 and the leading end detection state monitoring section 81 whether or not the paper feed start condition for starting the preliminary feeding operation of a sheet in the sheet feeding cassette 16 is established.
[0109] If the detection state of the leading end sensor 46 is “paper absent” (that is, the paper feed start condition is established), in Step S 150 , the ASF motor 54 is driven. Specifically, Step S 150 is performed by the paper feed controller 74 . In Step S 150 , when receiving a paper feed start instruction from the paper feed start condition determining section 82 , the paper feed controller 74 executes a predetermined paper feed sequence and outputs an instruction to the second controller 76 and the third controller 77 . The paper feed controller 74 executes the predetermined paper feed sequence to first drive the ASF motor 54 . During the ASF driving, if the fact that the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present” is acquired from the leading end detection state monitoring section 81 , the ASF counter 79 is reset. If the ASF counter 79 has reached a count value corresponding to the prescribed distance B (mm) the ASF motor 54 is stopped. In this way, the subsequent sheet P 2 is preliminary fed to the feeding standby position shown in FIG. 3 , at which the leading end of the subsequent sheet P 2 is positioned on the downstream side in the transport direction by the prescribed distance B (mm) from the leading end sensor 46 (the detection position of the leading end). This corresponds to the “preliminary feeding operation” in which the ASF motor 54 is initially driven, in the examples of FIGS. 5 to 7 . The uppermost sheet (subsequent sheet P 2 ) in the sheet feeding cassette 16 is fed from the set position. Then, the leading end of the sheet reaches the detection position of the leading end sensor 46 and is further fed by the prescribed distance B (mm) after the detection state of the leading end sensor 46 is switched from “paper absent” to “paper present”. The determination in Step S 130 and the ASF driving in Step S 150 correspond to preliminary feeding of a subsequent medium.
[0110] In Step S 110 , if the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent” during the PF driving of the previous transport operation (in Step S 110 , if the determination is false), the process progresses to Step S 160 of FIG. 11 . That is, when the ASF motor 54 is driven during the previous PF driving to start the preliminary feeding operation, the process progresses to Step S 160 .
[0111] In Step S 160 , it is determined whether or not the ASF motor 54 is stopped. This determination is performed by the motor driving state determining section 84 . If the ASF motor 54 is stopped, the process progresses to Step S 170 , and if the ASF motor 54 is being driven, the process progresses to Step S 220 .
[0112] In Step S 220 , the PF motor 53 is driven to transport the previous sheet P 1 by the designated transport distance. In this case, the ASF motor 54 is not driven for the main feeding operation, and only the transport operation of the previous sheet P 1 is performed. That is, as shown in FIG. 7 , even though it comes a time to calculate before the next transport operation starts, when the ASF motor 54 is still driving (that is, the preliminary feeding operation) if it comes a time to start the transport operation, the PF motor 53 is driven to start the transport operation of the previous sheet P 1 , and places priority on printing throughput of the previous sheet P 1 , without waiting for until the preliminary feeding operation is completed. Steps S 160 and S 220 correspond to placing priority on a transport operation.
[0113] In Step S 170 , it is determined whether or not the ASF motor 54 is driven when the detection state of the trailing end sensor 45 is switched from “paper present” to “paper absent”. That is, it is determined whether or not the preliminary feeding operation is performed when the trailing end of the previous sheet P 1 is detected. When the detection state of the leading end sensor 46 is “paper absent”, the preliminary feeding operation is not performed. Meanwhile, when the detection state of the leading end sensor 46 is “paper present”, the subsequent sheet P 2 is regarded as being already fed to the feeding restriction position R due to double feeding, and thus the preliminary feeding operation is not performed. When the ASF driving (the preliminary feeding operation) is performed, the paper feed start condition determining section 82 set an ASF driving flag to “1”, and the paper feed driving condition determining section 85 performs determination on the basis of the value of the ASF driving flag. When the ASF driving is performed (the determination is false), the process progresses to Step S 180 . When the ASF driving is not performed (the determination is true), the process progresses to Step S 190 .
[0114] In Step S 180 , the inter-paper distance Lg is calculated by the first computational expression. That is, the inter-paper distance Lg is calculated by the expression Lg=n+A−B. In the examples of FIGS. 5 to 7 , in which the preliminary feeding operation is performed, and the leading end of the subsequent sheet P 2 is positioned at the feeding standby position on the downstream side in the transport direction by the prescribed distance B from the leading end detection position, in Step S 180 , the inter-paper distance Lg is calculated by the first computational expression.
[0115] In Step S 190 , the inter-paper distance Lg is calculated by the second computational expression. That is, the inter-paper distance Lg is calculated by the expression Lg=n+A−C. In the example of FIG. 8 , in which the sheets P 1 and P 2 are double fed, the preliminary feeding operation is not performed, and the leading end of the subsequent sheet P 2 is positioned at the feeding restriction position R at which the leading end is in contact with the sheet returning lever 38 , in Step S 190 , the inter-paper distance Lg is calculated by the second computational expression. Steps S 180 and S 190 correspond to acquiring of a determination value (measuring).
[0116] In Step S 200 , it is determined whether or not the inter-paper distance Lg is equal to or more than the prescribed amount K. If the condition Lg≧K is satisfied, the process progresses to Step S 210 . If the condition Lg≧K is not satisfied (that is, Lg<K), the process progresses to Step S 220 .
[0117] In Step S 210 , the PF motor 53 and the ASF motor 54 are driven together. In this case, the transport controller 73 drives the PF motor 53 by the designated transport distance, and the paper feed controller 74 drives the ASF motor 54 in synchronization with the PF motor 53 such that the transport speed and amount of the previous sheet P 1 are the same as the transport speed and amount of the subsequent sheet P 2 . With this driving, the previous sheet P 1 and the subsequent sheet P 2 are transported by the designated transport distance while the inter-paper distance Lg is maintained.
[0118] If the inter-paper distance Lg is less than the prescribed amount K (Lg<K), in Step S 220 , the PF motor 53 is driven to transport the previous sheet P 1 by the designated transport distance. In this case, the ASF motor 54 is not driven, and only the transport operation of the previous sheet P 1 is performed. For example, as shown in FIGS. 6 and 8 , with respect to the inter-paper distance Lg calculated before the initial transport operation after the trailing end of the previous sheet P 1 is detected (in FIG. 6 , after the preliminary feeding operation starts), if Lg<K, during the driving of the PF motor 53 for initial transport operation after the trialing end is detected, the ASF motor 54 is not driven. As a result, while the position of the subsequent sheet P 2 (for example, the feeding standby position or the feeding restriction position) is maintained, only the transport operation of the previous sheet P 1 is performed. Thus, the inter-paper distance Lg increases by the transport distance. After the paper transport processing (Step S 220 ), when a subsequent transport operation is performed, similarly, the inter-paper distance Lg is calculated (Step S 180 or S 190 ), and the inter-paper distance Lg is determined (Step S 200 ). If the condition Lg≧K is satisfied, during the corresponding transport operation, the PF motor 53 and the ASF motor 54 are synchronously driven. Therefore, the previous sheet P 1 and the subsequent sheet P 2 are transported together while the inter-paper distance Lg is maintained. Steps S 200 and S 220 correspond to performing of main feeding control.
[0119] In this way, during the printing of the previous sheet P 1 , the feeding operation of the subsequent sheet P 2 (at least the preliminary feeding operation from among the preliminary feeding operation and the main feeding operation) is performed. If one page of the previous sheet P 1 is printed (YES in Steps S 50 and S 60 of FIG. 9 ), the process progresses to the paper feed processing (Step S 10 ) of the subsequent sheet P 2 , not the paper discharge processing (Step S 70 ). During the paper feed processing (Step S 10 ) of the subsequent sheet P 2 and the leading end setting processing (Step S 20 ), the previous sheet P 1 is discharged. While the last page is being printed, the feeding operation of the subsequent sheet P 2 is not performed during the transport operation. Therefore, after printing is completed, the paper discharge processing (Step S 70 ) is performed. When the page is printed before the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 , the paper discharge processing (Step S 70 ) is performed. The paper discharge processing is performed to a position at which the trailing end of the subsequent sheet P 2 is detected by the trailing end sensor 45 or the leading end sensor 46 . Subsequently, the process progresses to the paper feed processing (Step S 10 ).
[0120] For example, the feeding distance of the subsequent sheet P 2 varies depending on whether a maximum number of sheets or a minimum number of sheets are stacked in the sheet feeding cassette 16 . That is, as shown in FIG. 2 , when a maximum number of sheets are stacked, the pickup roller 35 is positioned at a position indicated by the upper two-dot-chain line near to the intermediate roller 36 . Meanwhile, when a minimum number of sheets are stacked, the pickup roller 35 is positioned at a position indicated by the lower two-dot-chain line (the same as the position of the pickup roller in FIG. 3 ) away from the intermediate roller 36 . When a minimum number of sheets are stacked, the transport distance of the subsequent sheet P 2 extends. In this case, when the trailing end of the previous sheet P 1 passes through the preliminary feeding start position Q, the preliminary feeding operation is performed to deliver the subsequent sheet P 2 to the feeding standby position in advance. Subsequently, the previous sheet P 1 and the subsequent sheet P 2 are simultaneously transported while the necessary inter-paper distance Lg of the prescribed amount K or more is ensured. Therefore, only if the trailing end of the previous sheet P 1 passes by the preliminary feeding start position Q, even though printing of the previous sheet P 1 ends at some point, the subsequent sheet P 2 is fed to a position on the upstream side in the transport direction by the inter-paper distance Lg from the trailing end of the previous sheet P 1 . As a result, the feeding distance after the paper feed processing of the subsequent sheet P 2 is performed can be shortened, without depending on the number of sheets in the sheet feeding cassette, and thus printing throughput can be improved.
[0121] As described above in detail, according to this embodiment, the following effects are obtained.
[0122] (1) The trailing end sensor 45 and the leading end sensor 46 are individually provided on the downstream side and the upstream side in the transport direction with the position opposing the retard roller 37 serving as a separation unit in the feeding path interposed therebetween. If the trailing end of the previous sheet P 1 is detected by the trailing end sensor 45 , the feeding operation of the subsequent sheet P 2 starts from the set position in the sheet feeding cassette 16 , and the subsequent sheet P 2 is further fed by the prescribed distance B (mm) after the leading end of the subsequent sheet P 2 is detected by the leading end sensor 46 . Next, the inter-paper distance Lg is calculated before the next transport operation, and it is confirmed that the calculated inter-paper distance Lg is equal to or more than the prescribed amount K. Subsequently, the PF driving and the ASF driving are simultaneously performed, and the transport operation of the previous sheet P 1 and the feeding operation of the subsequent sheet P 2 are performed while the inter-paper distance Lg is maintained. As a result, when the previous sheet P 1 (one page) is printed, the subsequent sheet P 2 is immediately fed at the inter-paper distance Lg. For this reason, if the paper feed processing is performed, the subsequent sheet P 2 is set to a printing start position in a relatively small transport amount, and thus printing on the subsequent sheet P 2 can early start. Therefore, printing throughput can be improved.
[0123] (2) After the feeding operation to the feeding standby position, the inter-paper distance Lg is calculated before the next transport operation starts, and it is determined whether or not the calculated inter-paper distance Lg is equal to or more than the prescribed amount K. If the condition Lg≧K is satisfied, during the transport operation, the ASF motor 54 is driven together with the PF motor 53 , and the feeding operation of the subsequent sheet P 2 is performed. If the condition Lg≧K is not satisfied (that is, Lg<K), as the PF motor 53 is driven, the ASF motor 54 is not driven, and only the transport operation of the previous sheet P 1 is performed. Thus, the inter-paper distance Lg increases. In this way, the feeding operation of the subsequent sheet P 2 is performed while it is confirmed that a necessary inter-paper distance Lg is ensured. Therefore, even though the transport distance between the detection position of the trailing end of the previous sheet P 1 and the feeding standby position, which is the target position of the subsequent sheet P 2 to be preliminary fed, is less than the prescribed amount K, a necessary inter-paper distance Lg can be reliably ensured. In addition, during the main feeding operation, the ASF driving and the PF driving are performed at the substantially same driving distance, driving start timing, and driving speed. As a result, the feeding operation of the subsequent sheet P 2 can be performed while the necessary inter-paper distance Lg can be ensured.
[0124] (3) Even though it comes a time to calculate the inter-paper distance Lg set after the preliminary feeding operation starts and immediately before the next transport operation start, when the ASF motor 54 is continuously driven (the preliminary feeding operation is still continuing), the PF motor 53 for the next transport operation starts, without waiting for until the ASF motor 54 is stopped. For this reason, printing of a next row onto the previous sheet P 1 can early start, as compared with a case in which the transport operation starts after the ASF motor 54 is stopped, and thus printing throughput can be improved.
[0125] (4) When the trailing end sensor 45 detects the trailing end of the previous sheet P 1 , it is determined whether or not the leading end sensor 46 detects the leading end of the subsequent sheet P 2 . If the leading end of the subsequent sheet P 2 is detected, the ASF motor 54 is not driven, and the preliminary feeding operation is not performed. Accordingly, even though the sub motor 55 for preparation of the main feeding operation is driven with detection of the trailing end of the previous sheet P 1 as a trigger, and the retard roller 37 and the sheet returning lever 38 are positioned at the time of the feeding operation, it is possible to prevent the subsequent sheet P 2 from being nipped between the intermediate roller 36 and the retard roller 37 before the inter-paper distance Lg is confirmed. For example, if the transport operation is necessarily performed in a predetermined amount enough to reach the target position when the trailing end sensor 45 detects the previous sheet P 1 , the subsequent sheet P 2 is nipped between the intermediate roller 36 and the retard roller 37 . Accordingly, even though the inter-paper distance Lg does not meet the prescribed amount K, when the PF motor 53 for the transport operation of the previous sheet P 1 is driven, the intermediate roller 36 is rotated with the PF motor 53 as a driving source. In this case, even though the ASF motor 54 is not driven, the subsequent sheet P 2 is forcibly fed. According to this embodiment, however, if the leading end of the subsequent sheet P 2 is already detected, the ASF motor 54 is not driven. As a result, it is possible to prevent the subsequent sheet P 2 from being fed when the inter-paper distance Lg does not meet the prescribed amount K.
[0126] (5) When the trailing end of the previous sheet P 1 is detected, if the leading end of the subsequent sheet P 2 is not detected, and the preliminary feeding operation is performed, the inter-paper distance Lg is calculated by the first computational expression Lg=n+A−B with the prescribed distance B corresponding to the target position as a constant. Meanwhile, when the trailing end of the previous sheet P 1 is detected, if the leading end of the subsequent sheet P 2 is already detected, and the preliminary feeding operation is not performed, the leading end of the subsequent sheet P 2 is regarded as being at the feeding restriction position R at which the leading end of the subsequent sheet P 2 is in contact with the sheet returning lever 38 . In this case, the inter-paper distance Lg is calculated by the second computational expression Lg=n+A−C with the distance C from the trailing end detection position to the feeding restriction position R as a constant. Therefore, even though the subsequent sheet P 2 exceeds the target position due to double feeding before the preliminary feeding operation is performed, the inter-paper distance Lg between the previous sheet P 1 and the subsequent sheet P 2 can be relatively accurately calculated.
[0127] (6) Even though the inter-paper distance Lg is equal to or more than the prescribed amount K, during the transport operation, the main feeding operation does not start. Specifically, after the condition Lg≧K is satisfied, when it comes a time to start the next transport operation of the previous sheet P 1 , the main feeding operation starts such that the feeding start timing of the subsequent sheet P 2 is synchronized with the start timing of the next transport operation. For example, if the feeding operation starts during the transport operation, the driving of the ASF motor 54 starts in a state where the PF motor 53 is already rotated at high speed. In this case, the subsequent sheet P 2 may be pulled between the intermediated roller 36 , which rotates at high speed with the PF motor 53 as a driving source, and the pickup roller 35 , which rotates at constant speed in the course of acceleration with the ASF motor 54 as a driving source, and be damaged due to a difference in speed between the intermediate roller 36 and the pickup roller 35 . In this embodiment, however, it is possible to prevent the subsequent sheet P 2 from being damaged due to excessive tension caused by the difference in speed between the rollers. In particular, in this embodiment, at the time of main feeding, the PF motor 53 and the ASF motor 54 are controlled such that the PF motor 53 and the ASF motor 54 have the substantially same driving start timing, transport speed, and driving stop timing. Therefore, it is possible to reliably prevent the subsequent sheet P 2 from being damaged due to excessive tension caused by the difference in speed between the rollers.
[0128] The invention is not limited to the embodiment, but the following modifications may be applicable.
[0129] (Modification 1) The target position is not limited to a fixed position, but it may be variable. For example, the target position may vary depending on a target transport position of the previous sheet P 1 . That is, when the trailing end sensor 45 detects the trailing end of the previous sheet P 1 during the transport operation of the previous sheet P 1 , a position on the downstream side in the feeding direction at a necessary inter-paper distance (for example, the prescribed amount K) from the trailing end position of the previous sheet P 1 after completion of the transport operation defined by the target transport position of the previous sheet P 1 at that time may be calculated as the target position, and the preliminary feeding operation may be performed in accordance with the calculated target position. In this case, even though the transport distance from the detection position of the trailing end of the previous sheet P 1 when the preliminary feeding operation is performed and the target transport position varies depending on the transport amount at that time, the subsequent sheet P 2 can be preliminarily fed to the target position separated by an appropriate inter-paper distance substantially identical the prescribed amount from the trailing end of the previous sheet P 1 . Therefore, when an initial (next) transport operation after the preliminary feeding operation starts, the inter-paper distance Lg can be appropriately ensured, and the inter-paper distance can be prevented from excessively increasing. In this case, even though it comes a time to calculate the inter-paper distance Lg, if the preliminary feeding operation of the subsequent sheet is still continuing, the transport operation of the previous sheet starts immediately after it comes a time to start the transport operation, without waiting for until the preliminary feeding operation is stopped.
[0130] (Modification 2) In the foregoing embodiment, a necessary inter-paper distance (that is, the prescribed amount K) is fixed, but it may be variable. For example, the prescribed amount K may vary depending on a printing mode, a transport speed, or a paper size. Like the sheet feeding device described in JP-A-2005-22792 (paragraphs [0029] to [0054]), when the inter-paper distance is determined in accordance with the detection position of the sensor, it is difficult to set the inter-paper distance variable. In this embodiment, however, if the trailing end position of the previous sheet P 1 is measured, an inter-paper distance is calculated on the basis of the measurement value (that is, the PF driving distance n), and the start timing of the main feeding operation is determined on the basis of the calculated inter-paper distance, a prescribed amount can be selected from a plurality of prescribed amount Kn(n=1, 2,. . . ) stored in a memory in accordance with the printing condition. Therefore, a necessary inter-paper distance can be relatively simply variable.
[0131] (Modification 3) The determination value is not limited to the gap. For example, a distance between the leading ends of the sheets, an inter-center distance of the sheets, or a distance between the leading end of the previous sheet P 1 and the trailing end of the subsequent sheet P 2 may be used as the determination value.
[0132] (Modification 4) The calculation time (measurement time) when the inter-paper distance is calculated is not limited to immediately before start of the next transport operation. For example, any time from when the current transport operation is completed with the trailing end of previous sheet detected until the final calculation start time, which is permitted so as to complete calculation and determination of the inter-paper distance before the next transport operation starts may be set. In addition, even though the ASF motor is driven at the calculation time, when a standby time (for example, several 100 milliseconds) exists until the transport operation starts, a second calculation time is set immediately before the transport operation starts. Even though the second calculation time comes, if the ASF motor is continuously driven, the transport operation starts immediately when it comes a time to start the transport operation. Meanwhile, when the second calculation time comes, if the ASF motor is stopped, the main feeding operation may be performed. In this case, the second calculation time may be set several times.
[0133] (Modification 5) The trailing end sensor and the leading end sensor may not be separately provided, but may be formed of a single common sensor. If the common sensor detects the trailing end of the previous sheet, and it is detected that the trailing end has reached the preliminary feeding start position, the preliminary feeding operation of the subsequent sheet starts. If the leading end of the subsequent sheet is detected by the common sensor, or if the leading end of the subsequent sheet is detected by the common sensor, and then the subsequent sheet is further fed by the prescribed distance B and reaches the target position, a structure for stopping the preliminary feeding operation may be used. In addition, after the trailing end of the previous sheet P 1 is detected, the transport amount of the previous sheet P 1 may be measured to confirm that the trailing end moves to a predetermined position separated by a predetermined transport distance from the sensor detection position toward the downstream side in the transport direction, and then the preliminary feeding operation of the subsequent sheet P 2 may start. The paper detection sensor 47 may be used for the single common sensor.
[0134] (Modification 6) The trailing end sensor and the leading end sensor are provided on both sides of the paper transport path with the intermediate roller, but at least the leading end sensor may be positioned on the upstream side in the transport direction by the intermediate roller. That is, with respect to a transport unit (roller) (in the foregoing embodiment, the intermediate roller 36 ), which is positioned on an uppermost stream side in the transport direction, from among a transport unit (in the foregoing embodiment, the transport driving roller 41 , the discharge driving roller 43 , and the intermediate roller 36 ), which is driven to transport the previous sheet during the recording operation, the leading end sensor may be positioned on the upstream side in the transport direction. The target position at the time of the preliminary feeding operation may be positioned on the upstream side with respect to the transport unit (roller) on the uppermost stream side in the transport direction.
[0135] (Modification 7) Even if the inter-paper distance is equal to or more than the prescribed amount, each time the transport operation is performed, the inter-paper distance may be measured in advance, and it may be determined on the basis of measured inter-paper distance whether to perform the transport operation of the previous sheet and the feeding operation of the subsequent sheet together or not.
[0136] (Modification 8) In the foregoing embodiment, the prescribed distance B is set, and the subsequent sheet P 2 is further fed from the leading end detection position by the prescribed distance B and then stopped, but the prescribed distance may not be provided. That is, when the leading end sensor 46 detects the leading end of the subsequent sheet P 2 , the ASF motor 54 may be stopped. In this case, in a printer in which a distance in the transport path between the sensors 45 and 46 (that is, a distance between the feeding start position and the target position at the time of the preliminary feeding operation) is less then the prescribed amount K required as the inter-paper distance, a sufficient inter-paper distance can also be ensured.
[0137] (Modification 9) The invention may be applied to a printer in which the distance between the feeding start position and the target position at the time of the preliminary feeding operation is equal to or more than the prescribed amount K required as the inter-paper distance. For example, even though the previous sheet and the subsequent sheet are double fed, a sufficient inter-paper distance can also be ensured.
[0138] (Modification 10) The computational expression for calculating the inter-paper distance Lg varies depending on whether or not the detection state of the leading end sensor 46 is “paper present” when the trailing end of the previous sheet P 1 is detected. Alternatively, the same computational expression may be used insofar as a necessary inter-paper distance Lg is ensured. For example, if the second computational expression is constantly used, when double feeding occurs, the time to start the main feeding operation is delayed once, but a necessary inter-paper distance can be reliably ensured.
[0139] (Modification 11) The PF motor 53 and the ASF motor 54 are provided, and the PF driving system and the ASF driving system use separate driving sources. Alternatively, the same driving source (same motor) may be used, and a clutch may be used to switch power transmission to separately drive the PF driving system and the ASF driving system.
[0140] (Modification 12) In case of a serial printer, a dot impact recording type or a thermal transfer recording type may be applicable, in addition to an ink jet recording type.
[0141] (Modification 13) A recording apparatus is not limited to the printer. Alternatively, the invention may be applied to another liquid ejection type recording apparatus for ejecting a liquid other than ink. Herein, “recording” is not limited to recording based on printing. For example, “recording” includes an operation to form a wiring pattern or an image on a circuit board serving as a medium by ejecting a liquid-state material including a material having a predetermined characteristic. For example, the invention may be applied a liquid ejection apparatus (recording apparatus) for ejecting a liquid-state material, in which a material, such as an electrode material or a color material is dispersed or dissolved, used to manufacture a liquid crystal display, an EL (Electro Luminescence) display, and a field emission display. When a feeding unit sequentially feeds sheet-like substrates one by one, and a recording unit forms a predetermined pattern on a substrate to be fed, throughput can be improved while a gap between the substrates serving as a medium can be ensured. As a result, productivity can be improved.
[0142] Hereinafter, technical ideas capable of being understood from the embodiment and the modifications will be described.
[0143] (1) In the method according to any one of claims 1 to 5 , the transport unit and the feeding unit include separate driving sources.
[0144] (2) In the method according to any one of claims 2 to 5 , when the main feeding operation is performed in the controlling of the main feeding operation, before every transport operation of the previous medium, the calculating and the controlling of the main feeding operation are repeatedly performed until the main feeding operation is performed.
[0145] (3) In the method according to any one of claims 1 to 5 , in the measuring, the trailing end position of the previous medium is measured by a trailing end measuring unit ( 78 ), and a distance in a transport path between the trailing end position and the target position is measured as the gap by using the measurement value of the trailing end position.
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A recording apparatus including feeding unit that feeds a medium, conveying unit that conveys the fed medium, recording unit that performs recording on the medium, and controlling unit that controls the feeding unit and the conveying unit, a measuring unit that measures a distance between the previous medium and the next medium after completing the preparatory feeding; and determining unit that determines whether or not the measured distance is a predetermined distance or greater, wherein, if the distance is the predetermined distance or greater, the controlling unit completely feeds the next medium.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to outer decorative door assemblies for domestic electrical appliances. The term domestic electrical appliances includes such items as refrigerators, washing machines, tumble dryers, dishwashers, spin dryers and the like.
2. Description of the Related Art
Most kitchens are equipped with several different domestic electrical appliances. Many modern kitchens are "fitted", that is to say they include a number of fitted cupboards, units, worktops and the like which are decorated or co-ordinated to provide a uniform decorative theme/color scheme. Wood panelling is one typical popular decorative theme. The matching of domestic appliances to fitted kitchens often causes problems because most existing domestic electrical appliances are finished in white painted or plastic coated steel. Unless the fitted kitchen itself is to be white the existing appliances will not match the kitchen's decorative theme (and if the decorative theme was white painted wood panelling the appliance would not properly match the decoration even then).
When fitting a new kitchen two options are available to obtain a uniform decorative theme which the kitchen's domestic appliances match. The kitchen's existing appliances can be built into units in the fitted kitchen: alternatively the existing appliances can be replaced with new "integrated" appliances, an "integrated" appliance being one which matches the kitchen's decorative theme.
The first option, that is building existing appliances into units, usually involves building a cupboard under a worktop into which the appliance is inserted. This is expensive and time consuming at the fitting stage. First, an extra cupboard is needed which adds to the expense of the fitted kitchen. Also, to enable the appliance to fit fully in the cupboard under the worktop a much wider worktop (usually 700 mm or more) is needed, than would normally be required with an integrated appliance. Further, the cupboard has to be sufficiently large to provide space on either side of the appliance. Also access to the appliance is awkward.
The second option, replacing the existing appliances with new integrated appliances which match the decoration of the kitchen is also expensive because it involves buying new appliances and discarding the existing appliances even though they may be perfectly servicable.
Various types of matched appliance exist. Some are painted in colours other than white: the majority include a panel, which is often made of wood, fitted to the door of the machine. A dishwashing machine having such a wood panelled door is disclosed in GB-A-2079589. EP-A-0080770 discloses a washing machine which has a fitted plastic door panel to which an (interchangeable) decorative panel is screwed.
However, whichever of the two options is chosen, buying integrated appliances, or building in the existing appliances, considerable expense is involved.
SUMMARY OF THE INVENTION
It is an object of the present invention to alleviate some or all of the above-mentioned problems.
Thus, according to a first aspect of the present invention, there is provided an assembly for attachment to a domestic appliance comprising:--
a plate, which is provided with magnetic means for releasably securing the plate to the appliance; and
hinge means mounted on the plate, said hinge means being adapted to receive a door or the like, the arrangement being such that the plate may be attached to a ferromagnetic domestic appliance and a door or the like may be secured to the hinge means to cover the front of the appliance.
Using the present invention a door (which matches a kitchen's decorative scheme), may be fitted to an existing domestic electrical appliance to enable the appliance to be matched to its surroundings. There is thus no requirement to either replace existing appliances.
The use of magnetic means enables the assembly to be easily fitted to a casing of domestic appliance without the need for tools and without drilling into or otherwise affecting the existing appliance and thus can avoid impinging on any manufacturer's warranties on that appliance. The door and assembly may be easily removed from the appliance for servicing and in the event that the appliance breaks down and needs replacing it is a simple matter to remove the assembly from the broken appliance and attach it to a replacement domestic appliance.
In a preferred embodiment, the plate is securable to the appliance by means of rubber faced magnets.
In one embodiment the plate is generally planar this type is suitable for fitting to a side of the casing of domestic appliances such as refrigerators and dishwashers which have doors forming their front faces to enable the weight of any decorative panel to be supported by the casing via the hinges and not by the appliance's door.
Alternatively it may be an "L" shaped cross section defining two perpendicular surfaces one of which is securable to a front face of an appliance the other of which fits to a side of the appliance.
The plate may be made of extruded aluminium.
The plate may have a white coated finish to match a white appliance.
The assembly may include a door ready mounted to the hinge means.
The door may include a decorative panel releasably secured to the door, the panel being removable for replacement by a different panel having a different decorative design.
Preferably the door includes a frame or trim which extends around the perimeter of the door and in which the decorative panel may be mounted by sliding to avoid the use of screws or tools.
The trim or frame may include a handle which is removable and interchangeable with the trim for the lowermost part of the door to enable the door to be reversable in orientation so it can be adjusted to fit a domestic appliance and open in either a left handed or a right handed manner.
The trim and panel may be supplied in a variety of colors to blend with the existing cosmetic colors of the appliance and kitchen units and fittings.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Specific embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings in which:--
FIG. 1 is a perspective view of an assembly embodying the present invention;
FIG. 2 is a further perspective view of the assembly of FIG. 1;
FIG. 3 is a plan view illustrating the use of a safety strap when the assembly of FIG. 1 is secured to a washing machine;
FIG. 4 shows a plate for attachment to dishwashers;
FIG. 5A is a plan view of a plate for attachment to fridges;
FIG. 5B is a side view of the plate of FIG. 5A;
FIG. 5C is a front view of the plate of FIG. 5A;
FIG. 6 is a perspective view of a washing machine to which a door assembly embodying the present invention has been attached;
FIG. 7 is a view of the machine and door assembly shown in FIG. 1 with the door closed;
FIG. 8 show details of the handle on top of the frame;
FIG. 9 show details of one corner of the frame of the door; and
FIG. 10 is a view of the washing machine and door assembly shown in FIG. 1, partly disassembled.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows a right angled plate 100 having an "L" shaped cross section defining two perpendicular plates 102 and 104. The length of plate 100 is 450 mm. Plate 102 has a width of 100 mm: plate 104 has a width of 115 mm.
As seen in FIG. 2, the plates 102, 104, each carry two large rubber faces magnets 106. The magnets 106 are located on "facing" surfaces 102A and 104A of the plate 100 so that they can be used to secure the plate 100 to a right angled corner of a ferromagnetic object, that is a washing machine shown in FIG. 3.
As is best seen in FIG. 1, on the opposite face 102B of side 102 are upper and lower hinges 108A, 108B spaced 350 mm apart. The hinges are located approximately 50 mm from the top and bottom of the plate 102 respectively: they are standard face to face kitchen hinges.
FIG. 3 shows the plate assembly 100 in use attached to a corner of a washing machine 110: the washing machine has a steel casing/cabinet and because steel is ferromagnetic, the magnets will hold the plate to the washing machine. A door (not shown) can then be placed over the washing machine and fitted to the hinges in the appropriate place, either, in it's original place or after removing the magnetic plate from the washing machine. Since the plate assembly is held to the washing machine by means of magnet it is easy to adjust the position of the door by adjusting the location of the plate assembly. The weight of the door is supported by the casing/cabinet of the washing machine.
FIG. 3 also shows an optional safety assembly which helps prevent the plate becoming accidentally dislodged from the washing machine 110. The assembly comprises a torsion strap 112, one end 114 of which is attached to the plate 104 by means of a counter sunk screw or tape (not shown), the other end of the strap being attached by means of one 116B of a series 116A, B, C, D, of holes in the strap to a pin on a tensioning screw holder 120. The tensioning screw holder 120 fits on a rear corner of the washing machine cabinet and adjusting the tensioning screw 124 tensions the strap 112 to hold the plate 100 securely on the washer.
The right angled plate 100 is formed of aluminium which is extruded in the desired "L" shape. To receive the hinges, a hole is drilled in the aluminium plate and then the stainless steel bush is pressed into the aluminium, the bush being threaded so that the hinges 108A, 108B can be screwed against the plate.
The magnets 106 are permanent ferromagnets (to avoid deterioration with age or vibration), are mounted on 0.5 mm sheet steel to improve the magnetic strength and have a 2 mm rubber backing to prevent damage to the washing machine or the like which will also absorb some vibrations.
FIG. 4, shows a plate 150 for attaching a door (not shown) to the front of a dishwasher, (not shown). The plate is a right angled trapezium in shape. The base of the plate is 450 mm long, one of the parallel sides 153 of the trapezium is 300 mm long, the other side 154 is 120 mm long. Three rubber faced magnets 156, are secured to the plate.
At the shorter side 154 of the plate, the plate is much thicker being sufficiently thick to define a face 157 which is perpendicular to the general surface of the plate and to allow a hinge to be mounted to it on which a door can be mounted.
In use, the plate 150 is attached to one side of a front loading dishwasher, and a similar plate (not shown), being a mirror image of plate 150, is attached to the opposite side of the dishwasher by means of magnets 156. The longer sides 153 are located at the rear of the dishwasher. A wooden door (not shown) or the like is attached to the plates by means of the hinges on the faces 157. The wooden door is attached to the door of the dishwasher in such a manner as to allow relative movement between the two but with the weight of the wooden door supported by the plate and dishwasher casing to avoid strain being put on the dishwasher's door/door mounting.
Referring to FIGS. 5A, B and C, a rectangular plate 170, of sides 800 mm is shown. As is best seen in FIG. 5C, the plate comprises a thin generally planar portion 170A and a built-up portion 170B which is generally trapezoidal in cross section and which at its widest at one end is 20 mm thick and defines a face 173 which is perpendicular to the planar portion 170A, compared to the rest 170A of the plate which is between 2 and 3 mm thick. On one side of the planar portion 170A of the plate, there are three large magnetic pads, 172.
As is best seen in FIG. 5B, the plate has four holes drilled in the face 173 into which stainless steel threaded inserts are fitted to enable hinges, (not shown) to be fixed to the plate 170.
In use, the plate 170 is mounted to the side of the casing of a refrigerator to which the refrigerator door is hinged and a decorative door or wood panel or door is attached to the plate 170 via the hinges.
In order to enable the decorative door to open the refrigerator door when the same is opened, the refrigerator door handle is removed and a handle slider is mounted to the door in place of the handle, the handle slider comprising a protruding plate which fits, is held, and slides in a channel mounted on the back of the door panel, in a manner which is known in connection with integrated appliances.
Importantly, all the weight of the decorative door or wood panel, is carried by the plate and not by the refrigerator.
FIG. 6 shows a door assembly, generally indicated at 1, attached to the front 2A of a front loading washing machine 2. The washing machine 2 has a round glass door 3 which projects from the front 2A of the machine. The door assembly 1 comprises a bent plate 4 on which a door 6 is mounted by means of two hinges, an upper hinge 8A and a lower hinge 8B, located adjacent the corner 4A of the plate.
The plate 4 is "L" shaped in cross section. It comprises a generally rectangular piece of material formed into two substantially perpendicular surfaces 10A, 10B joined at the corner 4A. Surface 10A is rectangular and fits along the side of the washing machine:, as shown in FIG. 10 surface 10B is generally rectangular but includes a generally semi-oval shaped cut out portion 12. As can be seen from FIG. 6 the semi-oval shaped cut out portion 12 prevents the plate impinging on the projecting glass door 3 when the plate 4 is fitted to the front of a front loading washing machine 2.
The plate 4 is made from a sheet of magnetic material covered with colored plastic to match surfaces 10A and 10B to the color of the appliance 2. This magnetic attraction between the plate and the metal front and one side of the washing machine secures the plate in place against the washing machine. An additional strong conventional magnet, not shown, may be added to the plate to increase the forces holding the plate to the machine, for safety reasons.
The door 6 comprises two plastic panels, an inner skin or panel 14 and an outer skin or panel 16 (See FIGS. 6, 8 and 9). A recess 18 which is adapted to receive the projecting door 3 of the washing machine when the door 6 is closed, is formed in the inner panel 14 as shown in FIG. 6. The outer panel 16 is flat. The outer panel 16 is glued to the base of the recess 18 of the inner panel 14. Apart from where the recess is glued to the outer panel, there is a space between the panels 16, 14. This space may be filled with a suitable material such as foam 19, as shown in FIG. 9.
A trim, or frame, comprising a handle 20, side trims 22, 24 and base trim 26 are fitted around the perimeter of the door panels 14, 16, as shown in FIG. 7. The base of the handle 20 and base trim 26 may be formed with a "T" shaped projection 28 for sliding insertion into a corresponding shaped recess 30 in the door 6, as shown in FIG. 8. A similar arrangement may be used for the side trims 22, 24, as shown in FIG. 9.
The base trim 26 and handle 20 are interchangeable to enable the door assembly 1 to be fitted to an appliance in either a left handed or right handed manner by rotating the assembly through 180° and placing the plate 4 on the other side of the washing machine 2.
The side trims 22, 24, the handle 20 trim 26 defines walls 32 behind which the perimeter area of a decorative panel may be inserted so that it is held between the walls and the outer panel 16.
Two magnets 34 are provided on the door, as shown in FIG. 6 and 10 to form a catch when the door is shut.
The handle 20 and trim 22, 24, 26 are made of a plastics material.
The recess 18 and cut out portion 12 may be made sufficiently large to accomodate most makes of washing machine.
Although the description relates to a washing machine, the assembly may be used on any suitable domestic appliance.
The door assembly 1 will fit straight onto a domestic appliance without the need to drill holes in, or provide fixing means on, or alter the appliance itself.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An apparatus for fitting a decorative door to an existing washing machine or other domestic electrical appliance, when it is desired, to match the appliance to the decorative theme/color scheme of a kitchen. The assembly includes an "L" shaped extruded aluminum plate which can be secured to a domestic appliance by means of rubber faced magnets. Hinges on the plate are adapted to receive a door to cover the appliance and match the same to the kitchen's decoration thus creating an "integrated" appliance.
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This application is a continuation of application Ser. No. 07/888,625, filed on May 27, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an upper thread holding device of a sewing machine having a thread cutting device.
2. Discussion of the Prior Art
An end of a thread sometimes becomes tangled, which constitutes a so-called nest on the back of a work piece such a cloth to be sewn when a sewing machine begins to sew the object. In order to avoid entanglement, a sewing machine including an upper thread holding device has been developed. In operation of this sewing machine, the upper thread holding device holds an upper thread which is cut in the last sewing operation, and the upper thread holding device releases or detaches therefrom the upper thread at the start of the next sewing operation. But the thread is cut only once at the end of the last sewing operation so that the length of the upper thread which extends from a hole of a needle is not even. Moreover, in case that the length of the upper thread which projects out from the workpiece is long, the tangled thread occurs at the back of the object and the finish is not good.
In order to shorten the length of the upper thread which is extended from the object, another sewing machine has been proposed in which the cutting of the upper thread is established at the start of the sewing operation as well as that at the end of the previous sewing operation. For instance, such a machine is disclosed in Japanese Utility Model Publication No. 2-14771 published in 1990 after examination. Referring to FIG. 8 showing the above mentioned machine, a needle-through groove 71 is formed at the center of a pressure foot 70 and a guide groove 72 is formed at the terminal end of the needle-through groove 71. A stationary blade 73 is fixed on the back of the pressure foot 70 and an edge 73a of the stationary blade 73 is disposed so as to traverse the guide groove 72. A thread holding member 74 catching an upper thread T is set above the pressure foot 70 so as to be able to be moved toward and from the upper thread T.
In operation of this machine, the thread holding member 74 advances and holds the upper thread T when a needle A is at its upper dead point. After catching the thread T the thread holding member 74 retracts. Sewing operation starts according to the above mentioned situation while another thread C between an object 75 to be sewn and the thread holding member 74 is being guided into the guide groove 71 of the pressure foot 70 as the object 75 is fed. At least the thread C is cut by the stationary blade 73 fixed to the pressure foot 70.
In the above mentioned construction, however, the distal end of the thread T is always cut while the thread T projects from upper surface of the object 75. It is not good for the quality of the sewed object that the distal end of the thread T projects therefrom.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved upper thread holding device of a sewing machine which obviates the above conventional drawbacks.
It is another object of the invention to provide an improved upper thread holding device of a sewing machine which can finish sewing so that the end of the thread is not visible from the front side of the object.
It is further object of the to provide an improved upper thread holding device of a sewing machine which can finish sewing so that the tangled thread is not visible from the back side of the object.
In order to attain the foregoing objects, an upper thread holding device for use in a sewing machine having a body and a needle from which an upper thread depends, comprises a holding member pivoted to the body and movable between a waiting position and an upper thread holding position in such a manner that the holding member passes an upper thread taken off position located between the needle and the waiting position, driving means for moving the holding member, a stationary blade which is connected to the body so as to be in sliding engagement with a lower surface of the holding member and designed for cutting the upper thread in cooperation with the holding member in its return movement at the waiting position, and a press plate fixed to the stationary blade and defining a space therebetween in which the holding member is accommodated in its waiting position for holding between the press plate and the holding member.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent and more readily appreciated from the following detailed description of preferred exemplary embodiments of the present invention, taken in connection with the accompanying drawings, in which:
FIG. 1 is a front view of an upper thread holding device of a sewing machine at a waiting position according to the present invention;
FIG. 2 is a front view of an upper thread holding device of a sewing machine at an upper thread holding position according to the present invention, in which a holding member is catching an upper thread;
FIG. 3 is a front view of an upper thread holding device of a sewing machine at a waiting position according to the present invention, in which the upper thread has just been cut by a stationary blade;
FIG. 4 is a view seen from a direction of B in FIG. 1.
FIG. 5 is a plan view showing the holding member catching the upper thread according to this invention:
FIG. 6 is a front view showing an upper thread holding device of a sewing machine in which the upper thread has just been taken off from the holding member at an upper thread taken off position according to the present invention;
FIG. 7 is a part view showing a connection between a rod and a driving member according to this invention; and
FIG. 8 is a perspective view of an upper thread holding device of a sewing machine according to the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated an upper thread holding device of a sewing machine which mainly includes a holding member 10 which catches an upper thread T, a first solenoid 20 and a second solenoid 30, both of which operate as driving means, a stationary blade 40 fixed to the plate 61 and a press plate 50 installed to the stationary blade 40.
The plate 61 is fixed to a machine body 80 and the holding member 10 is pivoted to the plate 61 by a screw 62 acting as a fulcrum axis. The screw 62 has, as its lower, middle and upper portions, a screw portion screwed into the plate 61, a cylinder portion for mounting the holding member 10 rotatably and the flange portion, respectively. The holding member 10 includes a horizontal part 11 pivoted to the plate 61, an inclined plane 11a formed on an upper left end of the horizontal part 11, a vertical part 12 formed at the right end of the horizontal part 11 so as to be perpendicular thereto in FIG. 1, and a holding part 13 which extends downward from the vertical part 12 while being bent. The horizontal part 11 has a push receiving part 15 which extends from the upper end of the horizontal part 11. The counterclockwise rotational motion of the horizontal part 11 is restricted by a stopper 14 formed at a lower end of the plate 61 so as to be located below the horizontal part 11 and the clockwise rotational motion is restricted by a stopper 27 formed at a left side end of the plate 61. The holding part 13 is terminated in a hook 13a as best shown in FIG. 5 in order to hold the upper thread T easily. Thus, on operation of the first solenoid 20 which is described herein after, the holding member 10 moves, by rotating about the screw 62 from waiting position shown in FIG. 1 to the holding position shown in FIG. 2 at which the upper thread is caught by holding member 10.
The driving means includes the first solenoid 20 and the second solenoid 30. The first solenoid 20 is fixed on the left side of the wall of the plate 61 (FIG. 1). A driving member 21 which is driven by the first solenoid 20 extends from the lower end of the first solenoid 20. As best shown in FIG. 7, a stopper portion 21b which expands in the downward direction and terminates in a groove 21a is formed in the stopper portion 21b. One end of a rod 22 is inserted into the groove 21a and pivoted to the stopper portion 21b by a screw 23 which is similar to the screw 62 in structure and function. A spring 25 is set around the driving member 21 and a lower end portion of the spring 25 is held by the stopper portion 21b. The other end portion of the rod 22 is pivoted to the horizontal part 11 by a screw 26 which is similar to the screw 62 in structure and function, and which is spaced from the screw 62 by a first distance.
The second solenoid 30 is fixed on the plate 61 at a right side of the first solenoid 20 as shown in FIG. 1. A driving member 31 is set to be moved in the vertical direction by the second solenoid 20. A stopper 32 is formed integrally with an upper end of the driving member 31 above the second solenoid 30 and is set to restrict the downward motion of the driving member 31. The lower surface of the driving member 31 is set to push the receiving part 15 of the horizontal part 11, which is spaced from the screw 62 by a second distance which is greater than the first distance, upon downward motion of the driving member 31. The first solenoid 20 and the second solenoid 30 are connected to a controller (not shown) and controlled thereby.
The stationary blade 40 is fixed at one end portion thereof to the lower portion of the plate 61. The stationary blade 40 is extended in the downward direction and terminates in an angled portion whose plane is perpendicular to the axis of the driving member 31. The angled portion extends toward the needle shaft 64. Referring to FIG. 5, a groove 41 is formed in the distal end of the stationary blade 40 which opens toward the needle shaft 40 and a blade part 42 is formed at the closed terminal end of the groove 41. In order that the upper thread T caught by the hook 13a may go through the groove 41, the groove 41 and the hook 13a of the holding part 13 are located on a common straight line.
The press plate 50 is fixed on the stationary blade 40 by a screw 51 and formed like a letter L as shown in FIG. 5. The other portion of the press 50 is set above the groove 41. The space l is made between the press plate 50 and the stationary blade 40 and the holding part 13 slides in the space l.
An air pipe 60 is installed near the stationary blade 40 and the holding member 10. The distal end of the air pipe 60 opens toward the blade part 42 for absorbing waste resulting from a thread cutting operation of the stationary blade 40.
When the upper thread holding device of this invention does not operate, referring to FIG. 1, the holding member 10 is positioned at its waiting position where the lower surface of the horizontal part 11 is in abutment with the stopper 14 and the distal end of the holding part 13 is positioned between the stationary blade 40 and the press plate 50. If the upper thread is cut by an automatic thread cutting device 81 installed under a base plate after a sewing operation, the first solenoid 20 operates immediately to raise the rod 22 (FIG. 2) and the left end of the horizontal part 11 of the holding member 10. Thus the holding member 10 rotates about the screw 62 in the clockwise direction and the holding part 13 is moved from the waiting position to the holding position where the holding part 13 is positioned under a needle A. The rotation angle of the holding member 10 is limited by the engagement of the inclined plane 11a of the horizontal part 11 with the stopper 27. After this, energization of the first solenoid 20 is stopped and the rod 22 is returned to its home position by the expansion force of the spring 25. During this time, the driving member 31 of the second solenoid 30 separates from the holding member, as shown in FIG. 2. With the above mentioned operation, the holding part 13 goes back to the waiting position from the holding position. At this time, the hook of the holding part 13 catches the upper thread T (FIG. 5) and just when the holding member is returned to the waiting position, the upper thread T is pushed on to the blade part 42 after being guided in the groove 41 and cut at a length from the needle A (FIG. 6). Referring to FIG. 3, the upper thread T after being cut is caught between the holding part 13 and the press plate 50, and the waste thread is absorbed by the air pipe 60 which has a negative pressure.
Then a new or next sewing operation starts. The needle A goes down and the upper thread T turns around a shuttle (not shown). The second solenoid 30 is activated immediately before the upper thread T is drawn from the shuttle and the driving member 31 goes down until the stopper 32 fits or abuts on the upper surface of the second solenoid 30. The driving member 31 pushes the press part 15 of the horizontal part 11, which rotates the holding member 10 in the clockwise direction about the screw 62. Thus the holding member 10 is projected to an upper thread taken-off position where the upper thread T is taken off from the space between the press plate 50 and the holding part 13. The upper thread taken-off position is located between the waiting position and the place under the needle A, nearer the waiting position than the holding position.
As mentioned above, according to the present invention, the length of the upper thread, which is defined as a distance between the hole of the needle A and the end of the upper thread T, is constant because the upper thread is cut by the stationary blade 40 and the length of the end of the upper thread which projects from the lower surface of the clothes is short and stable. Moreover the upper thread T is set to be held between the holding part 13 and the press plate 50 at the start of sewing and is taken off in the above mentioned timing manner so that the upper thread T is not taken off from the hole of the needle A. The end of the upper thread T is pulled under the clothes by the rotation of the shuttle and does not appear above the surface of the cloth. Thus it is possible to established a nice finished sewed cloth.
In this embodiment, the upper thread T is taken off by the operation of the second solenoid 30 immediately before the upper thread T is left from the shuttle. The timing when the upper thread T is taken off can be adjusted by the rotation of a button and so on, easily. Instead of the first solenoid 20 and the second solenoid 30, a sole linear solenoid having more than two operation modes can be used. An employment of such solenoid enables the miniaturization of the device.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An upper thread holding device for use in a sewing machine having a body and a needle from which an upper thread depends, the device includes a holding member pivoted to the body and movable between a waiting position and an upper thread holding position in such a manner that the holding member passes an upper thread taken-off position located between the needle and the waiting position, a driving device for moving the holding member, a stationary blade connected to the body so as to be in sliding engagement with a lower surface of the holding member and designed for cutting the upper thread in cooperation with the holding member in its return movement at the waiting position, and a press plate fixed to the stationary blade and defining a space therebetween in which the holding member is accommodated in its waiting position for holding between the press plate and the holding member.
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CROSS REFERENCE TO RELATED APPLICATION(S)
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
TECHNICAL FIELD
The present invention is directed toward heat exchangers, and particularly toward a stacked plate oil cooler.
BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART
Heat exchangers such as oil coolers built from pan-shaped plates are known from, for example, EP 0 828 980 B1. In such heat exchangers, the plates have bent edges and individual plates are stacked on top of one another with their edges overlapping. The media such as oil to be cooled and coolant are distributed in the heat exchanger through tubes, with the plates defining alternating channels for the two different fluids. The entire oil cooler is often screwed on a housing (e.g., on the housing of a filter using a mounting plate), with a distributor plate integrated between the oil cooler and the mounting plate. Bores are sometimes provided in the distributor plate to distribute both fluids (the coolant and the oil).
Another housingless oil cooler is disclosed in DE 1 97 11 258 C2, which has a reinforcing plate and a base plate for mounting the cooler. In this case, the reinforcing plate is designed as a thickened heat-transfer plate, and the base plate and reinforcing plate are soldered to the oil cooler. The base plate also has a surrounding edge with protruding brackets for securely screwing the oil cooler onto the housing of an engine block, with the connecting pieces for oil and coolant being inserted directly in suitable borings in the housing. The oil cooler is sealed against the engine block housing using seals which sit first on the connecting pieces and are also placed in a groove in the engine block housing. Moreover, the application of a groove in the housing, including the creation of a flat sealing surface on the housing, can lead to some undesirable expenditures.
The present invention is directed toward improving upon the above heat exchangers, including overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, a heat exchanger for cooling oil is provided, including a plurality of pan-shaped heat-transfer plates stacked onto one another to define alternating channels for coolant and oil, a mounting plate soldered on one side to a side of the stacked plates and adapted to mount on its opposite side to a separate component, and openings through the heat-transfer plates and the mounting plate for the passage of the oil and of the coolant, where the openings in the mounting plate have recesses therearound on the side opposite the heat-transfer plates. The recesses are adapted to receive seals therein.
In one form of this aspect of the present invention, the mounting plate is formed from a single metal plate, and the recesses comprise areas on the opposite side of the metal plate from which metal has been removed.
In another form of this aspect of the present invention, the mounting plate is formed from two sheet metal plates secured to one another along adjacent faces. In a further form, both of the metal plates are solder coated on the one side and, in a still further form, impressions are provided in the adjacent face of one of the metal plates around the recesses to provide a solder depot.
In still another form of this aspect of the present invention, the recesses are stamped out from the mounting plate and, in yet another aspect, the openings are stamped out from the mounting plate.
In a further form of this aspect of the present invention, the recesses include first and second recess portions around two of the openings and a slit between the annular recesses. In a further form, the mounting plate is formed from two sheet metal plates secured to one another along adjacent faces with the recess being stamped out of one of the sheet metal plates, and in another form, seals are receivable in the recesses, where each of the seals comprise two annular members receivable in the first and second recess portions and a connecting portion receivable in the recess slit.
In yet another form of this aspect of the present invention, the mounting plate includes bores for fasteners securable to the separate component.
In a still further form of this aspect of the present invention, annular sealing members are received in the recesses and sealing around the openings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view generally from below an oil cooler embodying the present invention;
FIG. 2 shows a bottom view of the oil cooler of FIG. 1 ;
FIG. 3 a is an exploded cross sectional view taken along line 3 - 3 of FIG. 2 ;
FIG. 3 b is a non-exploded cross sectional view taken along line 3 - 3 of FIG. 2 ;
FIG. 4 a is an exploded cross sectional view taken along line 4 - 4 of FIG. 2 ;
FIG. 4 b is a non-exploded cross sectional view taken along line 4 - 4 of FIG. 2 ;
FIG. 5 is a partial plan view of the base plate side of the outer plate of the mounting plate; and
FIG. 6 shows the mounting plate of an alternative embodiment of the present invention in which separate seals are provided at each opening.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a finished soldered oil cooler 10 according to the present invention prior to installation, for example, into a housing or on an engine block. The oil cooler 10 may be suitably mounted, for example, by screws through bores 12 in the cooler mounting plate 14 .
The mounting plate 14 may be advantageously formed of two plates, a base plate 14 a and an outer plate 14 b of different thickness, with the plates 14 a, 14 b soldered together. (As used herein, the terms solder and soldering include braze alloy and brazing.) The plates 14 a, 14 b may also have the same external shape such as particularly illustrated in FIGS. 1 and 2 . The inner surface 18 of the outer plate 14 b (which is the side facing away from, e.g., the engine block) may be coated with solder to facilitate securing of the plates 14 a, 14 b together.
Openings 20 , 22 in the base and outer plates 14 a, 14 b allow for oil flow into and out of the oil cooler 10 , respectively (as indicated by the arrows). A second set of openings 24 , 26 allow for coolant flow into and out of the oil cooler 10 , respectively (as also indicated by arrows).
In accordance with the present invention, an advantageous recess 30 in the mounting plate 14 may be defined by stamping an enlarged opening 32 in the outer plate 14 b. It should also be appreciated, however, that it would be within the scope of the present invention to provide a single mounting plate 14 , with the recess 30 suitably produced in the plate 14 , for example, by a metal-removing process such as milling.
As illustrated in FIGS. 3 a, 4 a, 5 and 6 , impressions 36 may advantageously be provided in the inner surface 18 of the outer plate 14 b near and around the openings 32 in the outer plate 14 b. During manufacture of the oil cooler 10 , the impressions 36 provide a solder depot for solder from the inner surface 18 of the outer plate 14 b to prevent solder from flowing during the soldering process onto the sealing surface 38 of base plate 14 a. The impressions 36 are illustrated in FIG. 5 as having interruptions 39 (see, e.g., FIG. 5 ), but they can also be made continuous.
Seals 40 may advantageously be mounted in the mounting plate recess 30 in accordance with the present invention. The seals 40 may advantageously include projections 44 (see FIG. 3 a ) formed on their outside to assist in securing the seal 40 in the recess 30 so that it cannot fall out during installation of the oil cooler 10 . Further, as best illustrated in FIGS. 4 a - 4 b, the openings (e.g., 20 ) in the base plate 14 a are smaller in cross-section than the corresponding openings in the outer plate 14 b, so that the seal 40 may be pressed into the recess 30 without risk that it will be pressed too far (e.g., into the oil cooler 10 ). As a result, a tight bond may be readily achieved between the oil cooler 10 and the component to which it is secured (e.g., the engine block).
As illustrated particularly in FIGS. 2 , 3 a and 3 b, bone-shaped seals 40 may advantageously be used with the present invention. The bone-shaped seal 40 includes a pair of thick, annular beads 46 connected by a thinned middle or connecting member 48 . The previously described projections 44 are provided on the beads 46 . The recesses 30 are similarly bone-shaped for suitable securing of bone-shaped seals 40 therein. FIG. 3 a illustrates how such a seal 40 may be placed into the stamped-out recess 30 in the outer plate 14 b, and FIGS. 3 b and 5 illustrated the seal 40 in its inserted and seated position. If a single mounting plate 14 is used, the recesses 30 may be composed of two circular recesses and a rectangular recess connecting them.
It should be appreciated, however, that seals of other shapes may also be advantageously used with the present invention in conjunction with different shaped plate recesses. Different shapes may, for example, be desirable based on the position of the openings 20 , 22 , 24 , 26 , which themselves are determined by the shape and requirements of the engine block.
FIG. 4 b illustrates the oil cooler 10 with soldered-on base plate 14 a and outer plate 14 b and with inserted seal 40 , including channels for the coolant and the oil defined by stacking suitable pan-shaped heat-transfer plates 50 . Arrows 54 illustrate exemplary flow paths for oil between the plates 50 , and arrow 56 illustrates an exemplary flow path for coolant between the plates 50 .
FIG. 5 illustrates the bone shape of the recess 30 advantageously usable with the previously described bone-shaped seal 40 . Such a recess 30 includes two circular holes 60 and a slit 62 connecting the holes 60 in the outer plate 14 b. It will be appreciated that the shape of the seal 40 and the shape of the recess 30 may be advantageously adjusted to accommodate one another according to design requirements.
Bores 66 may be advantageously provided in the plate 14 b for aeration during the soldering process.
FIG. 6 shows an alternative embodiment, in which the recesses 30 ′ consist of separate unconnected circular holes 60 ′, which configuration may be expedient depending on the system requirements. The recesses 30 ′ are larger than the openings (e.g., openings 20 , 26 ) to ensured that the separate annular seals are similarly not undesirably pressed into the oil cooler. The impressions 36 ′ for possible excess solder are arranged around the circular holes 60 ′. With this embodiment, four individual seals (not shown) are used (one each at the oil inlet and outlet and the coolant inlet and outlet), where each seal may advantageously be a thick annular bead providing a secure sealing function when the oil cooler is installed (e.g., on the engine block).
It should be appreciated that heat exchangers incorporating the above described invention may be reliably and inexpensively manufactured and installed. For example, the recesses 30 on the mounting plate 14 enables the component to which the heat exchanger is mounted (e.g., a housing or engine block) to be manufactured without grooves or similar depressions for seals, thereby simplifying the mounting of the heat exchanger on the component. The two-part design of the combined base plate 14 a and outer plate 14 b has additional manufacturing-technological advantages, which lead to a reduction of the manufacturing costs for the heat exchanger, because the recesses can be stamped out. Moreover, in the embodiment with the bone-shaped seals 40 , the number of the individual parts being handled during installation is minimized and the insertion of the seal 40 is simplified.
Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.
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A heat exchanger for cooling oil, including a plurality of pan-shaped heat-transfer plates stacked onto one another to define alternating channels for coolant and oil, a mounting plate soldered on one side to a side of the stacked plates and adapted to mount on its opposite side to a separate component. Openings through the heat-transfer plates and the mounting plate are provided for the passage of the oil and of the coolant, where the openings in the mounting plate have recesses therearound on the side opposite the heat-transfer plates. The recesses are adapted to receive seals therein.
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