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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to the following U.S. patent applications entitled: “A Method and Apparatus for forming an Annular Elastomeric Tire Component”, U.S. Ser. No. 10/291,279, filed on Nov. 8, 2002; “An Improved Method and Apparatus for Manufacturing Carcass Plies For a Tire”, U.S. Ser. No. 10/365,374, filed on Feb. 11, 2003; “Radially Expansible Tire Assembly Drum and Method For Forming Tires”, Ser. No. 10/388,773, filed Mar. 14, 2003; “Method and Apparatus For Tread Belt Assemblies”, Docket No. DN2003-078, filed on May 20, 2003; and “A Method For Curing Tires and a Self-Locking Tire Mold”, U.S. Ser. No. 10/417,849, filed Apr. 17, 2003; “Method for Manufacturing Tires on a Flexible Manufacturing System, U.S. Ser. No. 10/449,468, filed May 30, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to automated tire manufacturing machines and more particular to methods and apparatus for simultaneously assembling a purality of tires on a plurality of tire building drums moving along a predetermined path with workstations disposed along the predetermined path and a tire curing station incorporated into the assembly machines wherein a tire is produced from raw components completely assembled and cured.
BACKGROUND OF THE INVENTION
[0003] It is known that in making vehicle tires, for example for automobiles, that manufacture of a so-called carcass is first achieved by successively assembling several different components.
[0004] In other words, the different carcass types included in a production range can be distinguished from one another depending on the presence thereon of the various accessory components and/or the typology of the accessory components themselves.
[0005] By way of example, when carcasses for tubeless tires are to be produced, that is tires that in use do not require the presence of an inner tube, the main components can be considered to include a so-called “inner liner” that is a layer of elastomeric air-impervious material, a carcass ply, a pair of annular metal elements, commonly referred to as bead cores, around which the opposite ends of the carcass ply are folded, as well as a pair of sidewalls made of elastomeric material, extending over the carcass ply at laterally opposite positions. The accessory components may in turn comprise of one or more additional carcass plies, one or more reinforcing bands for overlying the carcass ply or plies at the areas turned up around the bead cores, chafer strips, and others.
[0006] As disclosed in U.S. Pat. No. 5,554,242, two stage tire building with a first stage tire building drum in combination with a second stage tire building drum is well known and established in the art with the building drums being both in line and offset from each other. It is further known to have two-stage tire building with a single drum swinging between the first stage position and second stage position where a band builder is in line with the first stage building drum. For this system, individual breaker application and single piece tread rubber are applied at the second stage while components such as apex, chafers and shoulder wedges are applied at the first stage. The above components are made in separate operations and stored for use as needed in the two-stage building process.
[0007] While the two-stage building process in its separate stages accommodated servers for the various components, it presented the problems of requiring a large work area for the two separate positions and the need to coordinate the separate functions as well as bringing all of the components together at the proper stations. As a result, the components were often stored and became subject to aging, sometimes losing their tack, for example, during the handling of the individually applied components. Moving the tire subassemblies from one stage to another has been a highly labor intensive operation even with the use of mechanical servers to assist operators in placing the components on the tire on the first and second stage drums. As a result, the operation was costly.
[0008] U.S. Pat. No. 5,354,404 discloses a system for assembling green tires with a two-stage process where the assembly is automatic and requires a small amount of floor space. While this system, has overcome some floor space problems, its output is still limited.
[0009] It has been known in the prior art, as disclosed in U.S. Pat. No. 2,319,643, to manufacture tires on a line with a plurality of building drums that are chucked up at each station.
[0010] Also, as disclosed in U.S. Pat. No. 1,818,955, tires can be manufactured on a line with a plurality of building drums “arranged in a train or series and a connecting means is provided for translating the cores from one device to the next.” The connectivity between the tire cores (building drums) leads to the inability to change the machine to accommodate various sized tire constructions. U.S. Pat. No. 3,389,032 also discloses a system using a large number of building drums which are interconnected.
[0011] Further, as disclosed in U.S. Pat. No. 5,354,404, there is illustrated another system for manufacturing tires on a line with a plurality of building drums “arranged in a train or series and a connecting means is provided for translating the cores from one device to the next.” The connectivity between the tire building cores leads to the inability to change the machine to accommodate various sized tire constructions.
[0012] In modern production processes, the assembling of the different components is carried out in automated plants including a plurality of assembling drums moved following a precise working sequence in accordance with the manufacturing process to be executed. For example, as disclosed in U.S. Pat. No. 5,411,626, these plants can consist of a plurality of workstations disposed consecutively in side by side relation, each of which lends itself to carry out the application of a predetermined component onto the assembling drums that in turn are brought in front of it.
[0013] EPO 0105048 discloses a tire assembly means employing a conveyor to transport a plurality of tire building drums to a plurality of applicator stations wherein various components are applied to the tire building drums at the various applicator stations in order to fabricate a tire when the tire building drums have made a complete transversal of the conveyor, wherein the tire building drums are maintained in an angled relationship with respect to the conveyor and the applicator stations.
[0014] In particular there are primary workstations intended for application of the main components, which are always active, irrespective of the carcass type being produced. Alternated with the various primary workstations, there are one or more auxiliary workstations intended for application of accessory components, if required. The activation or deactivation state of these auxiliary workstations stations depends on the carcass type.
[0015] The problem with these prior art manufacturing systems is that the location and position of the building drums was not precise enough to ensure that the tires being constructed were of adequate uniformity for the requirements of present day high performance tires. That is, while the tire building drums moving along the assembly path were stopped at a stop position at each work position, there is no teaching or suggestion of how the position of the tire building drum was positioned at a precise position. Further, it appears that the power to operate each building drum was carried aboard each drum. This would suggest that each drum is more complicated and expensive to produce.
[0016] It is well known that the components of most pneumatic tire constructions must be assembled in a way, which promotes good tire uniformity in order to provide proper tire performance. For example, a tread which “snakes” as it goes around the tire circumference will cause wobbling as the tire is operated. For example, a carcass ply which is lopsided (longer cords on one side of the tire than the other side) can cause a variety of tire non-uniformity problems including static imbalance and radial force variations. For example, a tire which is not meridionally symmetric (e.g., tread not centered between beads) can cause a variety of tire non-uniformity problems including couple imbalance, lateral force variations, and conicity. Therefore, in order to meet typical tire performance requirements, the tire industry generally expends considerable effort in producing tires with good uniformity. Tire uniformity is generally considered to mean tire dimensions and mass distributions which are uniform and symmetric radially, laterally, circumferentially, and meridionally, thereby producing acceptable results for measurements of tire uniformity including static and dynamic balance, and also including radial force variation, lateral force variation, and tangential force variation as measured on tire uniformity machines which run the tire under load on a road wheel.
[0017] Although certain degrees of tire non-uniformity can be corrected in post-assembly manufacturing (e.g., by grinding), and/or in use (e.g., applying balance weights to the rim of a tire/wheel assembly), it is preferable (and generally more efficient) to build-in tire uniformity as much as possible. Typical tire building machines comprise a tire build drum around which the tire components are wrapped in successive layers including, for example, an inner liner, one or more carcass plies, optional sidewall stiffeners and bead area inserts (e.g., apex), sidewalls and bead wire rings (beads). After this layering, the carcass ply ends are wrapped around the beads, the tires are blown up into a toroidal shape, and the tread/belt package is applied. Typically the tire build drum is in a fixed location on the plant floor, and the various layers of components are applied manually or automatically using tooling registered to reference points on the fixed drum in order to ensure component placement with the desired degree of precision. The tooling is generally fixed relative to the tire building drum, for example a guide wheel on an arm extending from the same frame (machine base) which supports the tire building drum.
[0018] The prior art, as discussed herein still has problems of enabling the building of tires with complicated construction, such as runflat tires, to be built on a single manufacturing line that is capable of being easily changed to accommodate different constructions sizes.
[0019] According to the one prior art invention there is disclosed in patent EPO 1295701 a method for simultaneously building a plurality of tire carcasses. The method comprises the tire building steps of establishing a sequence of at least three and up to ten workstations; advancing at least three disconnected cylindrically shaped tire building drums along a working axis extending through the at least three workstations; and applying one or more tire components to the tire building drums at each of the workstations. Then the resulting flat built green tire carcass is removed at the last of the workstations. Finally, the tire building drum is advanced from the last workstation after the flat built green carcass has been removed to the first workstation. Thereafter, the belt and tread package is disposed about the cylindrical or flat built green tire carcass, expanding the tire carcass into a tread and belt to form a green tire.
[0020] According to that invention, the tire building drums were disconnected from each other and independently advanced along the linear working axis extending between the workstations. Each of the disconnected tire building drums were individually advanced along the working axis so that the axis of rotation of each tire building drums remains aligned with the linear working axis.
[0021] According to that invention, the plurality of disconnected tire building drums can be simultaneously advanced along a working axis with individual, self propelled devices to which the tire building drums are mounted from one workstation to another. The tire building drums are advanced along the working axis so that an axis of rotation through the building drum is maintained at a constant predetermined height and location and in parallel alignment with the working axis.
[0022] According to that invention, an intake server is located at each of the workstations for operating the tire building drums. The intake servers were coupled to the building drums while maintaining the axis of rotation through the building drums at the constant predetermined height and location and in parallel alignment with the working axis. The intake server at each of the workstations move from their normally retracted position outward across the working axis into a position to couple to that tire build drum. Then the building drums were uncoupled from the intake servers after the tire component(s) had been applied to the building drums. Next, the intake server at each of the workstations were retracted to their normally retracted position, prior to the now uncoupled tire building drum advancing to the next workstation.
[0023] According to the invention, the step of applying one or more tire components to the tire building drums at each of the workstations included applying the tire components to the tire building drums while maintaining the axis of rotation through the building drums at the constant predetermined height and location and in parallel alignment with the working axis. This was accomplished by providing one or more application drums at each of the workstations for applying the tire component(s) to the building drums.
[0024] The application drums are moved from their normal retracted position away from the working axis to a location where the tire components can be applied to the building drums while maintaining the axis of rotation through the building drums at the constant predetermined height and location and in parallel alignment with the working axis. Then the application drums are retracted at each of the workstations to their normally retracted position, prior to advancing the tire building drum to the next workstation.
[0025] A primary limitation of the above-described prior art method of automated tire assembly is believed to be the applying of the components for the carcass assembly on a flat building drum and then inflating said drum to a toroidal shape prior to applying the belt tread assembly.
[0026] Another primary limitation is the application of the tread belt assembly to the toroidially shaped carcass means. The green tire assembly must be inflated and further expanded to fit the internal surfaces of the mold cavity.
[0027] In essence the entire automated assembly resulted in a most conventional green tire carcass and belt assembly to result with all the inherent deficiencies in the manufacture flat tire building methods.
[0028] The present invention proposes a novel way to build a tire in a shape closely simulating a finished product while achieving high levels of automation and precision part placement.
[0029] Another objective of the present invention is to achieve the ability to change tire sizes in the line to permit a variety of sizes to be built simultaneously without disrupting the line for size changeovers. This capability enables tires to be built in an automated way in lot sizes as small as one tire.
[0030] Another objective of the present invention is to provide a cure station so that the tire is completed from start to finish from raw components to a cured tire within the manufacturing module.
SUMMARY OF THE INVENTION
[0031] A module for manufacturing a cured tire from a plurality of tire components is disclosed. The module has a plurality of component appliers located at spaced locations along a predetermined path, and a mobile tire building trolley for movement along the predetermined path and two detachable tire building drums for mounting on the movable trolley. A tire curing station has one tire mold for curing the assembled tire components while mounted on one of the detachable tire building drums. The tire is cured as the other detachable tire building drum on the mobile tire building trolley is having tire components applied.
[0032] One or more of the plurality of component appliers includes a means for forming the tire component at the location of the applier. The applied components may include a liner, a pair of bead cores, a ply, a pair of sidewalls, a pair of chafers, and one or more belt layers and a tread. Also, the applied components may include gum strips, wedges, overlays, underlays, apex and runflat or elastomeric inserts.
[0033] The module has a means for transferring the detachable tire building drums to the tire mold and further has a means for extracting the cured tire while mounted on a tire building drum from the mold. The tire curing station includes an induction curing means. In one embodiment of the module, one or more of the component appliers applies strips of elastomer on the rotating tire building drum as the trolley moves along the predetermined path. The advancement along the path provides a lateral movement of the strips along the toroidal shape of the tire building drum to form the applied component. The plurality of component appliers includes one or more extruders or gear pump to form or smear the components as strips. Alternatively, the trolley and rotating building drum can remain stationary as one or more appliers move laterally around or about the circumferential surface of the toroidally shaped building drum. In one embodiment of the invention the module has two mobile tire building trolleys for movement along the predetermined path and has three detachable tire building drums for mounting on the movable trolleys. The tire curing station has a pick-up and transfer device for moving the detachable drums and one tire curing mold for receiving and curing the tire as the trolleys are having components applied along the predetermined path. In this embodiment the detachable tire building drums are transferable to and from the first trolley, second trolley, and the tire curing station. In this module one tire is being cured as two tires are being assembled. In one of the modules, according to the present invention, a plurality of component appliers are located at spaced locations along a predetermined path and a tire curing station having one tire curing mold for curing the tire and a means for curing located between one or more component appliers along that predetermined path.
[0034] The above described module for manufacturing and curing a tire permit the tire to be manufactured using a unique method of manufacturing. The method of manufacturing and curing a tire has the steps of applying the tire components at spaced locations along a predetermined path onto detachable tire building drums on one or more mobile tire building trolleys movable along the predetermined path. The method further includes placing the assembled tire components while mounted on one of the detachable building drums into a tire curing mold located along the tire building predetermined path. The method further includes the step of curing the tire in the mold as one or more trolleys with detachable building drums has tire components being applied.
[0035] It is preferable that the step of applying the tire components includes the step of forming one or more of the tire components at the locations where the component is applied. It is further contemplated that the step of forming includes the step of extruding strips of elastomeric rubber. The above method permits the tire to be formed, applied, and cured in a small module. This module permits the manufacture of tires in very small lot sizes.
[0036] In order to change tire sizes or to build another tire construction the module has software pre-programmed to the specific tire construction. A simple changing of the mold permits the manufacture of different tires of different sizes and styles. Additionally, different tire building drums are applied to the trolley to permit the manufacture of different sizes of tires. The above-manufacturing module permits small production lots to be produced in a very efficient manner.
[0000] Definitions
[0037] The following terms may be used throughout the descriptions presented herein and should generally be given the following meaning unless contradicted or elaborated upon by other descriptions set forth herein.
[0038] “Apex” (also “Bead Apex”) refers to an elastomeric filler located radially above the bead core and between or adjacent the plies and the turnup ply ends if the tire employs ply turnup ends.
[0039] “Axial” and “axially” refers to directions that are on or are parallel to the tire's axis of rotation.
[0040] “Axial” refers to a direction parallel to the axis of rotation of the tire.
[0041] “Bead” refers to that part of the tire comprising an annular substantially inextensible tensile member, typically comprising a cable of steel filaments encased in rubber material.
[0042] “Belt structure” or “reinforcement belts” or “belt package” refers to at least two annular layers or plies of parallel cords, woven or unwoven, underlying the tread, unanchored to the bead, and having both left and right cord angles in the range from 18 to 30 degrees relative to the equatorial plane of the tire.
[0043] “Carcass” refers to the tire structure apart from the belt structure and the tread, but including the sidewall rubber, beads, plies, and, in the case of EMT or runflat tires, the wedge inserts sidewall reinforcements.
[0044] “Casing” refers to the carcass, belt structure, beads, and all other components of the tire excepting the tread and undertread.
[0045] “Chafer” refers to reinforcing material (rubber alone, or fabric and rubber) around the bead in the rim flange area to prevent chafing of the tire by the rim parts.
[0046] “Chipper” refers to a narrow band of fabric or steel cords located in the bead area whose function is to reinforce the bead area and stabilize the radially inwardmost part of the sidewall.
[0047] “Circumferential” refers to circular lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction, and can also refer to the direction of sets of adjacent circular curves whose radii define the axial curvature of the tread, as viewed in cross section.
[0048] “Cord” refers to one of the reinforcement strands, including fibers or metal or fabric, with which the plies and belts are reinforced.
[0049] “Crown” or “tire crown” refers to the tread, tread shoulders and the immediately adjacent portions of the sidewalls.
[0050] “EMT tire” refers to Extended Mobility Technology and EMT tire refers to a tire which is a “runflat”, which refers to a tire that is designed provide at least limited operational service under conditions when the tire has little to no inflation pressure.
[0051] “Equatorial plane” refers to the plane perpendicular to the tire's axis of rotation and passing through the center of its tread, or midway between the tire's beads.
[0052] “Gauge” refers generally to a measurement, and often to a thickness dimension.
[0053] “Inner liner” refers to the layer or layers of elastomer or other material that form the inside surface of a tubeless tire and that contain the inflating gas or fluid within the tire. Halobutyl, which is highly impermeable to air.
[0054] “Insert” refers to the crescent-shaped or wedge-shaped reinforcement typically used to reinforce the sidewalls of runflat-type tires; it also refers to the elastomeric non-crescent-shaped insert that underlies the tread; it is also called a “wedge insert.”
[0055] “Lateral” refers to a direction parallel to the axial direction.
[0056] “Meridional profile” refers to a tire profile cut along a plane that includes the tire axis. “Ply” refers to a cord-reinforced carcass-reinforcing member (layer) of rubber-coated radially deployed or otherwise parallel cords.
[0057] “Pneumatic tire” refers to a laminated mechanical device of generally toroidal shape (usually an open-torus) having two beads, two sidewalls and a tread and made of rubber, chemicals, fabric and steel or other materials.
[0058] “Shoulder” refers to the upper portion of sidewall just below the tread edge.
[0059] “Sidewall” refers to that portion of a tire between the tread and the bead.
[0060] “Tire axis” refers to the tire's axis of rotation when the tire is mounted to a wheel rim and is rotating.
[0061] “Tread cap” refers to the tread and the underlying material into which the tread pattern is molded.
[0062] “Turn-up end” refers to a portion of a carcass ply that turns upward (i.e., radially outward) from the beads about which the ply is wrapped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] Reference will be made in detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing figures. The figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these preferred embodiments, it should be understood that it is not intended to limit the spirit and scope of the invention to these particular embodiments.
[0064] Certain elements in selected ones of the drawings may be illustrated not-to-scale, for illustrative clarity. The cross-sectional views, if any, presented herein may be in the form of “slices”, or “near-sighted” cross-sectional views, omitting certain background lines which would otherwise be visible in a true cross-sectional view, for illustrative clarity.
[0065] The structure, operation, and advantages of the present preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying drawings, wherein:
[0066] FIG. 1 is a schematic view of an automated tire manufacturing module, according to a first embodiment of the invention;
[0067] FIG. 2 is a perspective view of an automated tire manufacturing module according to a second embodiment of the present invention;
[0068] FIG. 2A is a top view of an exemplary initial workstation of the automated tire manufacturing module showing a tire building drum coupled to an applier station, according to the invention;
[0069] FIG. 2B is a plan view of the application of a tire component at the exemplary initial workstation.
[0070] FIGS. 3A, 3B , 3 C are views of an intermediate exemplary workstation according to the invention.
[0071] FIGS. 4A-4E are views of the detachable tire building drum according to the present invention;
[0072] FIGS. 5 and 6 are a perspective view and an exploded view of the self-locking tire mold;
[0073] FIG. 7 is a cross-sectional view of the carcass drum assembly and carcass shown installed into the mold and ready to be cured.
DETAILED DESCRIPTION OF THE INVENTION
[0074] With reference to FIGS. 1 and 2 schematic views of an automated tire manufacturing module 10 according to the present invention are illustrated. This system or module 10 provides for the complete manufacture of pneumatic tires and provides up to two simultaneously operating tire building stations and one tire curing station in one module. This module 10 forms the tire carcass subassembly 4 and the tire belt tread subassembly 3 . As shown in FIG. 7 , these two subassemblies 3 , 4 after being assembled on a detachable building drum 22 and inserted while on the building drum into a tire curing mold 50 after their assembly is completed. When at the tire curing mold, the mold 50 will then be closed and heated at a mold curing station 100 which permits the tires 200 to be cured or otherwise vulcanized and removed from the mold 50 and the building drum 22 .
[0075] As shown the FIGS. 1 and 2 at the initial building of a tire there is a mobile tire building trolleys 60 , 60 A with a specific detachable tire building drum assembly 22 designed to permit the fabrication of the tire carcass 4 onto the toroidally expanded building drum assembly 22 so when the tire carcass 4 is formed it is in the toroidal shape very close to the finished tire dimensions as it is assembled. The detachable building drums 22 are mounted on transporter devices called mobile tire building trolleys 60 , 60 A, 60 B. These trolleys 60 , 60 A, 60 B accept the building drum 22 and will traverse along a predetermined path or line 20 , 110 as shown in FIGS. 1 and 2 . The trolleys 60 , 60 A, 60 B provide a means 62 for rotating the tire building drum 22 at each workstation as the specific tire component is being applied. The workstations and the tire trolleys 60 , 60 A, 60 B have the software programmed into each of the workstations and trolleys and are coordinated by supervisory software such that the proper component is provided to the tire building drum 22 at the precise time and location desired.
[0076] As illustrated in the exemplary schematic of FIG. 1 an initial workstation 11 applies a chafer component 41 to the tire building drum 22 and an innerliner 42 .
[0077] An exemplary workstation 11 for applying a component is illustrated in FIGS. 2A and 2B . FIG. 2A shows a top view of the workstation. FIG. 2A shows that workstation applying a tire innerliner 42 . As illustrated, the robotic mechanisms 70 smear or apply extruded rubber while hot or apply the liner 42 in strips directly onto the tire building drum 22 . As noted, if a chafer component 41 has been previously applied using a similar technique, the liner 42 will be applied directly over the chafer 41 as required by the tire building specification. If an optional runflat insert component is required or additional elastomeric components are applied, additional workstations can be provided to provide these features. A more complete detailed description of the apparatus for smearing components onto a tire building drum is described in the “Method and Apparatus for Forming an Annular Elastomeric Tire Component, U.S. Ser. No. 10/291,271, filed on Nov. 8, 2002, which is incorporated herein by reference in its entirety. These initial workstations apply the components onto a toroidally shaped building drum 22 that is transported along the predetermined path or line 20 as shown. Each tire building drum 22 is positioned at an axis fundamentally perpendicular to the workstation and is transported directly in front of the workstation and stops at or moves to a precise location to permit the application of the tire components. While the elastomeric components are shown being applied and extruded directly onto and smeared onto the building drum 22 and other underlying carcass components using a smearing die 90 at the end of a supplier hose 94 connected to a computer controlled robot 70 , it is possible to apply these components using more conventional elastomeric strip application means by providing necessary server mechanisms and by supplying the components in layers onto the building drum 22 , each component being cut and fed to length. When the components are formed as strips the drum 22 and the trolleys 60 , 60 A, 60 B can be moved along the path to permit that motion to be coupled with the rotation of the building drum 22 to form this component.
[0078] After the initial components have been applied to the tire building drum assembly 22 , the assembly is then transferred to an intermediate workstation 12 wherein the carcass ply 44 and beads 45 are applied to the building drum 22 . These may be applied using strips or laminate layers of ply 44 and preformed beads 45 or, alternatively, the ply 44 may be produced using a cord placement mechanism 80 as shown in FIGS. 3A, 3B and 3 C. In using this mechanism, the ply cords 42 A are placed precisely onto the building drum 22 overlaying a ply coat of rubber and the previously applied carcass components. The ply cord paths are positioned very precisely onto the tire building drum in a very fast and accurate manner as illustrated. Once the ply cords 42 A are positioned, an additional elastomeric ply coat layer may be applied over the ply cords 42 A and the annular bead cores 45 can then be positioned onto the carcass assembly 4 .
[0079] The entire assembly 22 is then moved to the next building station or workstation 13 wherein wedges 47 , additional chafers 48 and sidewall 49 components can be applied to the carcass subassembly 4 using either the smearing or strip application techniques previously discussed or by using elastomeric layers applied by more applier means, preferably by applying freshly formed elastomeric wound strips. After the sidewalls 49 are applied, final elastomeric components such as the belts 1 , 2 , overlays 6 and tread 7 are applied to the carcass assembly 4 on the toroidally shaped building drum 22 at exemplary workstations 14 , 15 . The entire building drum assembly 22 with carcass 4 and tread belt reinforcing structure 3 is then removed from the mobile trolley 60 at the cure station. As shown in FIG. 1 , the trolley 60 then is loaded with an empty building drum 22 and traverses back into starting workstation 11 of the module 10 to return to the next tire build whereupon it will be routed for an additional pass through the system 10 to build a second tire carcass 4 and tread belt reinforcing structure 3 .
[0080] While this entire process of building the carcass 4 and tread belt structure 3 is being accomplished a simultaneous curing of the uncured tire 200 is occurring.
[0081] With further reference to FIG. 1 , the module 10 , in conjunction with the trolley 60 mechanism, is programmed to build not only the carcass 4 but also a particular tread belt structure 3 . At the belt workstation 15 the belt layers 1 and 2 are applied to the outer peripheral surface of the carcass assembly 4 on the detachable building drum 22 , as illustrated. After the first wide belt 1 is applied and the second narrow belt 2 is applied, a gum strip 5 is applied to each edge of the first belt layer 1 at the workstation 15 . If required, an optional overlay workstation 15 can be provided wherein overlays 6 having substantially 0° or very low angles in the circumferential direction are wound onto and overlaying the underlying belt structure 1 , 2 . Once these components 1 , 2 , 5 and 6 are laid onto the outer peripheral surface of the carcass 4 , the tread 7 is applied over the underlying components as illustrated. Once the tread 7 is freshly extruded it is applied while still hot as either an annular strip or as a spirally wound plurality of strips to form an unvulcanized tread component 7 , this completes the tread belt reinforcing structure assembly 3 . At this final workstation 14 the building drum 22 is removed from the trolley 60 and the trolley 60 receives a new empty detachable building drum 22 and is moved laterally back along the predetermined path 20 on the rails 20 A to repeat the process for the next tire building assembly, assuming that the same tire size or style is required. If a different size assembly is required, the building drum staging area 30 will be accessed and a specific building drum 22 will be provided by removing the initial building drum 22 and replacing it with a second building drum 22 of a different size as required.
[0082] Once the tread belt assembly 3 is completely formed, the entire uncured tire 200 on the detachable building drum 22 including the carcass 4 and tread belt reinforcing structure 3 freshly formed and preferably still hot mounted to it is removed from the trolley 60 and delivered to an open segmented mold 50 at location 140 . As shown in FIGS. 5 and 6 , a self-locking type mold is described in a “Method for Curing Tires In a Self-Locking Tire Mold”, U.S. Ser. No. 10/417,849, filed Apr. 17, 2003, which is incorporated herein by reference in its entirety. This mold 50 is shown in perspective view has a top plate 52 which is removed and the segments 54 are radially expanded to accept drum 22 with the tread belt reinforcing structure 3 and carcass 4 mounted to it. Once inserted into the open mold 50 as illustrated in FIG. 7 , the top plate 52 of the mold 50 is closed upon the tire building drum assembly 22 and the segments 54 are radially contracted inwardly compressing against the still warm tread 7 against the tread forming surface of the mold 56 of the mold 50 as shown in FIG. 7 .
[0083] As shown in FIG. 7 , the carcass 4 and tread belt structure 3 mounted on the building drum assembly 22 now removed from trolley 60 can be inserted into the mold 50 and the empty trolley 60 received an empty detachable building drum 22 and is moved back to an initial workstation 11 to receive the instructions for the next tire assembly.
[0084] With the top plate 52 of the mold 50 open, the entire building drum assembly 22 with the carcass 4 and tread belt assembly 3 mounted thereto can be inserted directly into the mold 50 . This is made possible due to the fact that an upper portion 55 of the tread mold forming section of the mold is attached to the top plate 52 . This permits the entire uncured tire 200 to be able to fit directly into the mold 50 with the carcass 4 and tread belt assembly 3 in place. Once inserted into the mold 50 , the mold 50 can be closed and locked and the carcass subassembly 4 inflated by applying internal pressure to the building drum assembly 22 further pressing the tread 7 into the internal surfaces of the mold 50 . Once this is accomplished the mold 50 can be heated and pressurized to curing mold temperatures and pressures and the mold 50 will then finish the overall vulcanization of the tire 200 encased into the mold 50 . As the mold 50 finishes the heating curing cycle it is ready for mold opening and removal of the tire. At this point, the mold 50 is open, the mold segments 54 are radially expanded and the building drum core 22 with the tire mounted thereto is removed from the mold 50 .
[0085] With reference to FIGS. 4A, 4B , 4 C, 4 D and 4 E, for a better understanding of the invention it must be appreciated that the carcass building drum core 22 is radially expandable and collapsible. As illustrated in FIG. 4A internal mechanisms 21 can be folded radially inwardly as the building drum 22 is expanded axially outwardly. As the building drum 22 is moved axially inwardly at both ends, the sidewall support mechanisms shown as interlocking triangles 21 A, 21 B, 21 C move radially outwardly until in a fully closed position these mechanisms 21 A, 21 B and 21 C are almost fully radially extending as illustrated in FIG. 4C . The result is that during the tire building an elastomeric cover 23 which is also partially reinforced at least in the crown area is mounted over these sidewall supporting structures 21 as shown in FIG. 4D . This creates a generally rigid building surface upon which all the carcass components can be fabricated. The building drum 22 being portable, as previously discussed, can be removed from the trolley 60 in this radially expanded condition and then can be transferred directly into the mold 50 for the curing as previously described. Once this is completed, however, the tire 200 must be removed and as is illustrated in FIG. 4E this is done by simply expanding outwardly the axial ends which draws the sidewalls supports 21 down and the supporting elastomeric cover 23 can be radially lowered such that the tire 200 can be removed from the tire building drum assembly 22 at the tire separating workstation 32 .
[0086] Once this is accomplished, the tire building drum 22 can go back to the trolley 60 for a second tire build, it will be picked up by a transfer means and placed on the trolley 60 or moved directly to a trolley mechanism 60 whereupon it will repeat the process for building a second tire. The tire building drum 22 is explained in greater detail in a patent application entitled “Radially Expansible Tire Assembly Drum and Method for Forming Tires”, Ser. No. 10/388,773, filed Mar. 14, 2003, and the contents of which are incorporated herein by reference in their entirety.
[0087] The automated module 10 as shown in FIG. 1 permits the manufacture of tires in lot sizes as small as one tire to be produced while simultaneously producing other tire sizes at different workstations. The software package communicates to each workstation the amount of rubber, the shape or profile and the type of component required for that specific tire build. As the building drums 22 progress in front of the workstation the appropriate material at the appropriate location is applied, either to the carcass drum building assembly 22 or to the previously applied components. All these functions can be occurring simultaneously as a tire 200 is being cured. These components, once formed, create a complete tire carcass 4 and a complete tread belt reinforcing structure 3 .
[0088] An advantage of the present invention over prior art invention is that that tread belt subassembly 3 and carcass 4 are inserted directly into a mold 50 while freshly formed and located on the tire building drum 22 whereupon the mold 50 is closed upon the tire assembly in such a preassembled fashion that it is cured directly into the mold 50 . The unique self-locking mold 50 then is opened to permit the entire carcass 4 and tread belt 3 for that particular tire size to be inserted into the mold 50 while mounted on its building drum 22 . The mold 50 is then closed and heated for a curing process which may be done by either conventional steam methods, induction curing with electromagnetic fields, or otherwise. Once the curing cycle is completed, the mold 50 is opened and the cured tire on building drum 22 is removed. This is all accomplished while another tire 200 is being continuously fabricated on the trolley 60 with a detachable building drum 22 at the various workstations of the system 10 along the predetermined path 20 .
[0089] As noted and shown in FIG. 1 , this permits lot sizes from very small production runs to be fabricated with great ease. It does require, however, that staging areas 30 provide multiple drums for building carcasses of various sizes that can be attached to the trolley 60 . The building drum 22 staging area 30 provides a ready supply of building drum 22 for the tire manufacture. What this means is a day's production of tires can be scheduled wherein a variety of lot sizes and tire specifications can be built without any downtime for tire size changeovers. Conventional high production, high volume tire lines require significant amount of downtime to replace both the molds and to reset all the building specifications for the different components at the tire building stations. It is particularly true in conventional first and second stage tire building systems. The present invention provides that such changeovers can occur with no downtime. While the embodiment of FIGS. 1 and 2 shows the exemplary tire building manufacturing process or module 10 that would commonly be applied for passenger and light truck tires, as well as aircraft, medium truck, motorcycle and off-the-road tires, it must be appreciated that additional workstations can be provided and that these workstations can be used to add other components in the tire building manufacturing without jeopardizing the overall flexibility of tire building as previously discussed. It is understood that the additional components may be used or not used as the as the specific tire selected is being built. Often times, many tires require components that are optional in other tires and therefore the builds may be different. The present invention permits this tire assembly to handle such variations and that the progression of the components through the line provides a rapid tire building capability.
[0090] One of the interesting differences of the present invention compared to prior art tire manufacturing is that it contemplates applying the components while hot onto the building drums and that while these hot components are freshly being produced at the carcass building and tread belt assembly workstations, they are then directly placed into a mold while hot, the mold is closed while all the components maintain their own heat from being formed and then are routed directly. This has a tremendous advantage in that component materials can be provided that would otherwise bloom or cause a powdery substance called sulfur to leach out of the component prior to vulcanization. Historically, tires are made of strips and then stored. These strips set over a period of time and the material tends to bloom or have sulfur or other components leach out to the surface. This creates situations where the tires can have problems during manufacture due to the variations in freshness of the various components. The present invention ensures that the rubber materials are applied approximately as fresh as possible, preferably with no lap or butt splices. In other words they are still warm when they are placed in the mold. There has been no opportunity for contamination or deformation to occur due to subassembly storage and handling. This greatly improves the manufacturing quality of the finished product and ensures that the components will be properly place and properly mixed at the time they are applied. Furthermore, there are energy savings due to keeping materials hot instead of deliberately cooling for storage as in prior methods.
[0091] With reference to FIG. 2 a second embodiment of the present invention is shown wherein the tire manufacturing module 100 includes two trolleys 60 that traverse along a predetermined path 110 . As illustrated, the trolleys 60 A, 60 B can have the carcass components applied as previously discussed on the tire building drum 22 at the various workstations 11 through 13 and then as the trolley 60 A progresses toward the central location of the predetermined path 110 the building drum 22 can be picked up and transferred to a second trolley 60 B. The trolley 60 B then can move down the remainder of the line 110 stopping at the multiple workstations 14 through 15 applying belts 1 , 2 , overlay 6 and the tread 7 to finish the tread belt structure 3 . The components can be applied on one or both sides of the trolleys 60 A, 60 B as it moves outward in one direction and as it returns other components can be applied until it reaches the central transfer location 111 . Once the entire carcass 4 and tread belt assembly 3 are applied to the detachable building drum 22 the trolley 60 B reaches a cure station 150 that has a transfer means 160 that can pick up the carcass 4 and tread belt 3 mounted to the detachable building drum 22 and transfer that directly into a mold 50 . As the building drum 22 is being transferred, it pivots about its axis of rotation approximately 180° to the open segmented mold 50 wherein it is pivoted from a horizontal plane to a vertical plane and then moved into the mold whereupon the mold 50 closes upon the assembly and cures the tire 200 . As this is occurring an empty building drum 22 is placed back onto the trolley 60 A and it proceeds to continue building the next tire assembly. While this is occurring, the second trolley 60 B is continuing to have components applied in a progression. In this embodiment, two trolleys 60 A and 60 B are employed and three building drums 22 , one building drum 22 with an assembled tire 200 is cured as the other two trolleys 60 A, 60 B are receiving drums 22 and are applying components in a continuous process. This is analogous to a juggler juggling three balls. There is constant movement and constant activity occurring in the tire building process such that a continual flow product can be produced at this module 10 .
[0092] When applying the components using elastomeric strips, the strips are applied to the rotated building drum as a freshly formed tape. One of the advantages of the present method of assembly is that the software is programmed such that movement along the predetermined path 20 , 110 can progress incrementally such that as the tire building drum 22 is being rotated the strips are being applied uniformly across the building drum or the carcass crown. This ensures that the entire lateral movement of the trolleys 60 , 60 A, 60 B enables the component appliers to simply apply the strips at a specific location as the trolley moves as shown in FIGS. 1 and 2 . This incremental movement can be controlled precisely by the software and enables multiple layers of strips to be applied to change the thickness at any location along the predetermined path. This method of assembly is considered quite unique in tire building and heretofore has been unknown.
[0093] While the components are undoubtedly applied where formed creating a tremendous manufacturing advantage in terms of freshness, an additional advantage is that the component materials can be provided to each workstation in rather bulk form. The component material can be made without the use of processing aides such as anti-aging ingredients and curing accelerators needed to survive storage as no storage is needed, greatly reducing material cost. Furthermore, much of the component handling equipment commonly found in tire building can be eliminated. Therefore, inventory of intermediate components is reduced to a very low amount and in the case of the elastomer components the storage of these intermediate articles is virtually eliminated. This very compact reduced floor space tire building module greatly reduces the tonnage of raw material needed to be stored as components and eliminates such ancillary devices as storage racks and hand trucks, greatly reducing the manpower and maintenance required to support them.
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A module for manufacturing a cured tire from a plurality of tire components is disclosed. The module has a plurality of component appliers located at spaced locations along a predetermined path, and a mobile tire building trolley for movement along the predetermined path and two detachable tire building drums for mounting on the movable trolley. A tire curing station has one tire mold for curing the assembled tire components while mounted on one of the detachable tire building drums. The tire is cured as the other detachable tire building drum on the mobile tire building trolley is having tire components applied. One or more of the plurality of component appliers includes a means for forming the tire component at the location of the applier. The applied components include a liner, a pair of bead cores, a ply, a pair of sidewalls, a pair of chafers, and one or more belt layers and a tread. Optionally the applied components may also include an apex, wedges, overlays, underlays, gum strips, and elastomeric inserts. The module has a means for transferring the detachable tire building drums to the tire mold and further has a means for extracting the cured tire while mounted on a tire building drum from the mold. The tire curing station includes an induction curing means.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of my prior application Ser. No. 13/295,962, filed Nov. 14, 2011 now pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to control valve systems, and particularly to a shut-off valve testing system for testing and operating the main shutdown valve that controls gas flow in a refinery, industrial plant or other facility.
2. Description of the Related Art
In the oil, gas, petroleum and power industries, natural gas or other combustible gas is often used to provide the required heat or combustion motive power for many operations in a processing refinery, plant, or other industrial facility. Various conditions may occur that necessitate immediate shut down of the operations of the facility. In those facilities, a majority of the final control elements of a shutdown system are implemented with fast acting shut-off valves. In such industries, a majority of the shut-off valves remain open while the operation is operating safely in a nominal controlled state. Such shut-off valves are closed only upon actuation of the shutdown system of the facility, arising from an out-of-control process or during a normal maintenance outage.
In practice, the testing of emergency shut-off valves is normally done during shut down of the facility operation. However, there is a tendency for such valves to stick or freeze due to corrosion or other reasons, which may lead to an unsafe condition where the valve cannot be closed during an emergency shutdown. This problem is exacerbated by economic conditions in the operation of the facility that have lead to a reduction in the frequency of valve shut-offs for maintenance or testing purposes. For example, some operations may run continuously for one or more years without shutting down the operation for maintenance.
State of the art emergency shut-off systems that control the shut-off valves have a number of features to detect system failures, and typically include redundancies for added reliability. However, such systems may not provide for the testing of a shut-off valve, other than by operating the valve through its normal stroke or travel. The problem is that operating the valve through its full stroke or travel, i.e., completely closing the valve, causes an undesirable disruption in the operation of the facility.
Thus, a shut-off valve testing system solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The shut-off valve testing system uses a system of valves and other components for controlling the main shut-off valve installed in the combustible gas or fuel supply line in an industrial plant or facility. The testing system includes a double-ended hydraulic cylinder having one side or end that receives hydraulic pressure from an appropriate source to regulate the system at times during the testing of the system. The opposite side or end of the cylinder communicates hydraulically with and regulates the travel or stroke of the hydraulic actuator during testing. The actuator, in turn, operates the main shut-off valve. Hydraulic pressure to both sides of the actuator for the main shut-off valve is provided from a pressurized source of hydraulic fluid, which may be the same source as the hydraulic fluid provided to the double-ended cylinder. Some of the fluid is routed through one side of the actuator to the hydraulic cylinder during some portions of the operation.
The hydraulic cylinder is closed relative to the actuator during normal operations, i.e., with the main shut-off valve open to allow gas flow through the gas delivery line. Partial Instrument Trip Testing (PITT) of the main shut-off valve by operating the valve through its partial stroke or travel is accomplished by relieving hydraulic pressure from one side of the actuator by opening a valve between the actuator and the cylinder. This allows the actuator to relieve hydraulic pressure to the cylinder to allow the actuator to move, thereby moving the shut-off valve through at least a portion of its full travel. Full travel of the shut-off valve (i.e., shut down of the system) is prevented by a differential pressure transmitter across the two portions or volumes of the hydraulic cylinder. The differential pressure transmitter provides a signal to the control system to reverse the positions of the various control valves before complete closure of the main shut-off valve occurs. As the operation of the shut-off valve requires some finite amount of time, partial travel of the valve may be determined, alternatively, by actuating the valve for a time period less than that required for full travel or shutoff.
When a complete shutoff of the fuel supply is demanded due to an emergency or other requirement in the plant or facility, the hydraulic actuator is cycled to its full travel to cause the shut-off valve to close completely. The double-ended hydraulic cylinder is not a factor during complete shutdown operations, as hydraulic pressure is shut off to the hydraulic cylinder. However, other valves are actuated that result in hydraulic pressure being relieved in one side of the actuator, thereby causing the actuator piston to move to actuate the shut-off valve through its complete stroke or travel to completely shut off gas flow through the line.
The system further includes a control system for limiting the complete travel of the main shut-off valve during testing of the device, and for actuating the system in the event of an emergency requiring complete shutoff of flow through the combustible gas line controlled by the main shut-off valve. The control system is computerized for automatic operation, depending upon input from various conventional sensors of the fuel and valve control system. However, the system also provides for manual control when desired.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a shut-off valve testing system according to the present invention, illustrating its general features.
FIG. 2 is a flowchart briefly listing the steps involved in the partial stroke testing of a shutdown valve in the shut-off valve testing system according to the present invention.
FIG. 3 is a flowchart describing the steps involved in operating various valves in the shutdown process of the shut-off valve testing system according to the present invention.
FIG. 4 is a flowchart describing the steps involved in operating various valves in the startup process of the shut-off valve testing system according to the present invention.
FIG. 5 is a schematic diagram of the major components of the control system for the shut-off valve testing system according to the present invention.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The shut-off valve testing system provides for the partial instrument trip testing (PITT) of a main shut-off valve in a combustive gas main fuel supply line as often installed to provide heat and combustive power for equipment found in refineries, factories, and similar industrial facilities. The system allows the main shut-off valve to be cycled through only a portion of its full travel or stroke, thus confirming that the valve is not stuck while also allowing the valve to remain at least partially open to avoid disrupting the gaseous fuel supply for the operation of the facility.
FIG. 1 of the drawings is a schematic diagram of an exemplary shut-off valve testing system 10 according to the present invention, as it would be installed with a gaseous fuel supply line 12 and the main shut-off valve 14 installed in series in the line 12 . The main shut-off valve 14 is mechanically linked to a hydraulically operated actuator 16 . The actuator 16 has an internal piston 18 that separates the internal volume into a loading pressure side 20 and an opposite actuating pressure side 22 . The actuator 16 receives hydraulic pressure from a conventional hydraulic pressure source 24 . A loading pressure hydraulic line 26 extends from the pressure source 24 to the loading pressure side 20 of the actuator 16 , and an actuating pressure hydraulic line 28 extends from the pressure source 24 to the actuating pressure side 22 of the actuator 16 .
The loading pressure hydraulic line 26 may include a pressure regulator or reducer 30 to lower the pressure in the loading pressure side 20 of the actuator 16 to a level somewhat less than the opposite actuating pressure side 22 . This assures that the actuator 16 will remain in its normal operating condition, i.e., holding the main shut-off valve 14 open, so long as a higher hydraulic pressure is applied to the actuating pressure side 22 of the actuator 16 . The actuator 16 may also contain an internal mechanical spring 32 in the loading pressure side or volume 20 to assure positive shut-down in the event that all hydraulic pressure is lost.
The actuating pressure side 22 of the actuator 16 is connected hydraulically to the actuator side or volume of a combination hydraulic-hydraulic control cylinder 34 . Hydraulic pressure is supplied to the opposite return side or volume of the control cylinder 34 from the source of hydraulic pressure 24 used to supply the actuator 16 , as shown in FIG. 1 , or other hydraulic pressure source, as desired. The hydraulic line extending from the source of hydraulic pressure 24 to the spring-loaded return side or volume of the hydraulic-hydraulic cylinder 34 preferably includes a regulator 36 and first and second pressure gauges or transmitters 36 a and 36 b to measure unregulated and regulated hydraulic pressure on each side of the regulator 36 .
A differential pressure transmitter 38 is connected across the control cylinder 34 , and communicates with the actuator side or volume 40 and the return side or volume 42 of the control cylinder 34 to provide information about the differential pressure across the control cylinder 34 to a control facility, discussed further below. An internal spring 44 is provided in the return volume side 42 of the hydraulic-hydraulic control cylinder 34 to bear against the piston 46 separating the two internal volumes 40 and 42 to assure proper operation in the event that return side hydraulic pressure is lost. The total volume of the two sides 40 and 42 of the control cylinder 34 is somewhat less than the total internal volumes of the two sides 20 and 22 of the actuator 16 to assure that the actuator 16 cannot travel to its limits during test actuation by the control cylinder 34 , thus limiting the main shut-off valve 14 to partial travel or stroke.
The shut-off valve testing system 10 includes a number of additional control valves that control hydraulic flow through the system. A first hydraulic control valve 48 is installed in the hydraulic line between the actuating pressure side or volume 22 of the actuator 16 and the actuator side or volume 40 of the control cylinder 34 . This first hydraulic control valve 48 is normally closed, opening only during the partial stroke or travel testing (PITT) of the main shut-off valve 14 by the actuator 16 , as explained further below. The first hydraulic control valve 48 is operated by a solenoid 48 a . The first hydraulic valve 48 is preferably normally closed, requiring no electrical power for it to remain closed. Electrical power to the solenoid 48 a is only required to open the valve 48 during the brief time of testing the main shut-off valve 14 , thus assuring that this valve 48 will remain in the desired closed condition in the event of loss of electrical power. However, this valve 48 may also be reconfigured to require electrical power to hold it in its closed condition so that electrical power is removed to open the valve 48 , if desired.
A second hydraulic valve 50 , comprising a three-way valve, is disposed in the hydraulic pressure line between the source of hydraulic pressure 24 and the return side or volume 42 of the hydraulic-hydraulic control cylinder 34 , and serves to control hydraulic pressure to the return side 42 of the control cylinder 34 . This three-way hydraulic valve 50 is normally closed between the hydraulic pressure source 24 and the control cylinder 34 , except during the brief time that the actuator 16 is being returned to its normally open condition to reopen the main shut-off valve 14 fully after testing, as explained in detail further below. The third port in this three-way hydraulic valve 50 comprises a vent or relief line extending from the valve 48 back to a hydraulic reservoir 54 in FIG. 1 . As in the case of the first hydraulic control valve 48 , the valve 50 is preferably a solenoid operated electromechanical unit, the solenoid being indicated as component 50 a of the valve 50 . This valve 50 preferably has a normally closed configuration, i.e., electrical power to the solenoid 50 a is only required during the brief times that the valve 50 is open at the end of testing the main shut-off valve 14 . This is a safety factor to assure that this hydraulic valve 50 will remain in its desired state in the event that electrical power is lost. However, it will be seen that this hydraulic valve 50 may be configured to require electrical power during its normally closed state and opening only when power is removed, if desired.
A third hydraulic control valve 52 is disposed in the actuating pressure hydraulic line 28 between the hydraulic pressure source 24 and the actuating pressure side or volume 22 of the actuator 16 . This third hydraulic valve 52 is also operated by a solenoid 52 a , and is also normally closed when no electrical power is supplied to its solenoid 52 a . However, electrical power is normally provided to this solenoid 52 a to hold this valve 52 in an open condition, to provide hydraulic pressure to the actuating pressure side or volume 22 of the actuator 16 . This third valve 52 only closes when the actuator 16 is being cycled to close the main shut-off valve 14 , either partially during testing or completely during a shutdown event. The preferred state of this valve 52 is to require electrical power to hold it open, i.e., for normal operations. Thus, it will close if electrical power is lost, resulting in cycling of the actuator 16 and closure of the main shut-off valve 14 . As in the cases of the pneumatic control valve 48 and the first hydraulic control valve 50 , the third valve 52 may be reconfigured to require electrical power for closure, but the preferred configuration wherein the valve 52 closes when electrical power is lost is a safer configuration.
A hydraulic fluid reservoir 54 is provided in the system and communicates hydraulically with the actuating pressure side or volume 22 of the actuator 16 . This reservoir 54 may comprise a hydraulic fluid supply tank for the hydraulic pressure source 24 , and would be connected conventionally to the pressure source 24 by a hydraulic line or passage (not shown). A fourth hydraulic control valve 56 is installed in the hydraulic line between the actuating pressure hydraulic line 28 and the hydraulic reservoir 54 , and an essentially identical fifth hydraulic control valve 58 is installed in the hydraulic line between the line connecting the actuating side or volume 22 of the actuator 16 and the actuator side or volume 40 of the control cylinder 34 . It will be seen that since there are no intervening components to affect the hydraulic pressure or flow between the fourth and fifth hydraulic control valves 56 and 58 and the components to which they attach, i.e., they both communicate hydraulically directly with the actuating pressure side or volume 22 of the actuator 16 , that either or both of these valves 56 and 58 may function to relieve pressure in the actuating pressure hydraulic line 28 and the actuating pressure side or volume 22 of the actuator 16 . This redundancy provides greater reliability for the emergency shutdown functions of the system.
The fourth and fifth hydraulic control valves 56 and 58 are also electromechanically actuated by their respective solenoids 56 a and 58 a , as in the cases of the other solenoid-operated valves 48 , 50 , and 52 . The fourth and fifth valves 56 and 58 are closed during all normal operations of the system, including partial stroke testing of the main shutoff valve 14 . The valves 56 and 58 are preferably configured to be normally open when no power is received, and are held in their closed states or conditions by power applied through their respective solenoids 56 a and 58 a . These two valves 56 and 58 are only opened to relieve hydraulic pressure to the actuating side or volume 22 of the actuator 16 when a “trip” or emergency shutdown of the system occurs. When this occurs, electrical power is terminated to the two solenoids 56 a and 58 a , allowing their valves 56 and 58 to open to release hydraulic pressure in the actuating portion of the system. It will be seen that these two valves 56 and 58 may be reconfigured to require electrical power to open, but it is preferred that they open when electrical power is terminated due to the additional safety factor provided by the likelihood that electrical power will be cut off in an emergency shutdown.
As the third, fourth, and fifth hydraulic control solenoid valves 52 , 56 , and 58 are cycled during any emergency shutdown of the system, i.e., the complete closure of the main shut-off valve 14 , additional means may be provided for the operation of these three valves 52 , 56 , and 58 to return the system to normal operation in the event that electrical power has not been restored by the operating system for the valves. Accordingly, each of the valves 52 , 56 , and 58 includes a manual reset “latch,” shown as components 52 b , 56 b , and 58 b , allowing an operator(s) to close the valves 56 and 58 and reopen the valve 52 manually to restart the system in order to reopen the main shut-off valve 14 .
A number of additional manual valves are also provided in the system to remove hydraulic pressure and flow to various components for maintenance. A first manual valve 60 is installed in the hydraulic line between the actuating pressure side 22 of the actuator 16 and the first hydraulic control valve 50 . This valve 60 allows the first hydraulic valve 50 to be removed from the system for maintenance or replacement as required without affecting the emergency shutdown capability of the system. A second manual valve 62 is installed in the hydraulic line between the hydraulic pressure source 24 and the return side or volume 42 of the hydraulic-hydraulic control cylinder 34 . This second manual valve 62 permits hydraulic pressure and flow to be cut off to the second hydraulic control valve 50 for maintenance or replacement. A third manual valve 64 is provided in the hydraulic line between the actuating pressure hydraulic line 28 and the fourth hydraulic control valve 56 , and a fourth manual valve 66 is installed in the hydraulic line extending from the line between the actuating pressure side or volume 22 of the actuator 16 and the first hydraulic valve 48 . Either the third or the fourth manual valve 64 or 66 may be closed to allow the respective hydraulic control valve 56 or 58 to be removed from the system for maintenance or replacement, as required. As the two control valves 56 and 58 are redundant to one another, the operational retention of a single one of the valves 56 or 58 in the system still allows the emergency shutdown function of the system to perform as required in the event that it is needed, even if one of the two valves 56 or 58 is inoperative or removed.
Additional components are provided in the mechanical linkage that connects the actuator 16 to the main shut-off valve 14 . These components serve to indicate the position of the shut-off valve 14 during its operation. Main shut-off valve opening and closure limit switches, respectively 68 and 70 , serve to detect the respective fully opened and fully closed positions or states of the main shut-off valve 14 and to transmit those states to the control system. A third limit switch 72 serves to detect a predetermined partially open position or state for the main shut-off valve 14 during shut-off valve testing, and to transmit that data to the control system in order that the control system will stop the actuator 16 at that point to avoid excessive closure of the main shut-off valve 14 and subsequent reduction in gas flow through the line 12 .
FIG. 5 provides a schematic view of the control system for the hydraulic-pneumatic valve testing system 10 of FIG. 1 . The area to the lower right in FIG. 5 indicates in a general manner some of the various components illustrated schematically in FIG. 1 and described further above, i.e., the main shut-off valve 14 , its actuator 16 , the differential pressure transmitter or transducer 38 of the hydraulic-pneumatic control cylinder (not shown in FIG. 5 ), and a single block representing the three limit switches 68 , 70 , and 72 of the connection between the main shut-off valve 14 and the actuator 16 . This system is controlled by a computerized control system 100 , comprising an emergency shutdown system (ESD) control center 102 that drives a series of transducers 102 . The transducers 102 interface with the differential pressure transmitter or transducer 38 across the two ends or volumes of the hydraulic-hydraulic cylinder 34 of FIG. 1 . The ESD control center 102 normally carries out the operation of the hydraulic-hydraulic valve system of FIG. 1 , particularly for emergency shutdown operations. However, a computer and monitor 104 are provided to enable the human operator to command the ESD control center 102 , as may be required from time to time. The computer 104 may be hardwired to the ESD controller 102 , but may bypass the ESD controller to control and receive information from the transducers 102 via a remote communication interface 106 , if desired.
FIG. 2 of the drawings is a flowchart describing the basic steps in the Partial Instrument Trip Testing (PITT) of the main shut-off valve 14 of FIG. 1 . Start position 200 represents the normal operational status of the system 10 , i.e., the main shut-off valve 14 is in its normal, fully opened state to allow gaseous fuel to flow therethrough. When the test is initiated, the third solenoid valve 52 installed in the actuating pressure hydraulic line 28 ( FIG. 1 ) is de-energized to allow the valve 52 to close, generally as indicated in the second step 202 of FIG. 2 . At this point the system pauses for a two second delay (more or less, depending upon programming) in order to confirm that the valve 52 is completely closed and will not allow any residual hydraulic fluid under pressure to continue to flow for a short period of time as the remainder of the sequence operates. This delay step is indicated as step 204 in FIG. 2 .
After the delay has been completed, the first hydraulic shut-off valve 48 installed in the hydraulic line between the actuator 16 and the actuator side or volume 40 of the hydraulic-hydraulic cylinder 34 is actuated, i.e., opened, as indicated by step 206 of the flow chart of FIG. 2 . This allows hydraulic pressure to flow from the actuating pressure side 22 of the actuator 16 to the actuator side 40 of the hydraulic-hydraulic cylinder 34 , where the increase in hydraulic pressure is limited by the return side of the cylinder 34 . The corresponding hydraulic flow from the actuating pressure side 22 of the actuator 16 allows its piston 18 to move, thereby mechanically moving the main shut-off valve 14 to a partially closed position. The Partial Instrument Trip Testing (PITT) timer of the control system of FIG. 5 may also be initiated at this point, if travel of the main shut-off valve 14 is to be determined by time rather than by position as determined by the partial stroke limit switch 70 of FIG. 1 .
The shut-off valve 48 remains energized (open) as indicated by step 208 in FIG. 5 until either the main shutdown valve 14 reaches a point close to its partial stroke limit as measured by the partial stroke limit switch 72 or until the timer expires, as indicated by step 210 of FIG. 5 . If neither of these conditions occurs, the shut-off valve 48 remains open. However, with normal main shut-off valve operation it will reach its predetermined partial closure limit before the time limit expires, and the system will then energize (open) the three-way hydraulic solenoid valve 50 , as indicated by step 212 of FIG. 5 .
The opening of the three-way solenoid valve 50 allows hydraulic fluid to flow under pressure from the source 24 ( FIG. 1 ) into the return side or volume 42 of the hydraulic-hydraulic cylinder 34 . This increase in hydraulic pressure drives the piston 46 toward the actuator side 40 of the cylinder, thereby pushing hydraulic fluid back into the actuating pressure side or volume 22 of the actuator 16 . This causes the actuator piston 18 to move in a direction to reopen the main shut-off valve 14 . This condition continues until the main shutdown or shut-off valve 14 ( FIG. 1 ) has completely reopened, as indicated by step 216 of FIG. 2 .
Once the main shut-off valve 14 has reopened completely, the first hydraulic shut-off valve 48 is closed, as indicated by step 218 of FIG. 2 . This prevents hydraulic pressure from flowing from the actuating pressure side or volume 22 of the actuator 16 to the actuator side or volume 40 of the hydraulic-hydraulic cylinder 34 , once the system has returned to normal. Another two-second delay (or other time period as determined) is initiated immediately after closure of the valve 48 before the operation of any other valves in order to be certain that the valve 48 is completely closed, as indicated by step 220 of FIG. 2 .
When the time delay has elapsed and solenoid valve 48 is completely closed, the third solenoid valve 52 is reopened to allow hydraulic pressure to the actuating pressure side 22 of the actuator 16 , to assure that the main shut-off valve 14 is held open. At the same time, the three-way hydraulic solenoid valve 50 is closed, with the closure of the hydraulic solenoid valve 48 and three-way solenoid valve 50 locking the hydraulic-pneumatic cylinder out of the system until the next operational check, as indicated by the final steps 222 and 224 of FIG. 2 .
FIGS. 3 and 4 are flowcharts that respectively describe the basic steps involved in the emergency shutdown procedure and in the restart procedure. In FIG. 3 , a signal indicating some other than nominal aspect of operation is sent to the control system 100 ( FIG. 5 ). The system 100 reacts by sending a shut-down signal to the third hydraulic solenoid valve 52 to close the actuating pressure hydraulic line 28 to the actuator 16 and to open the fourth and fifth hydraulic solenoid valves 56 and 58 to release hydraulic pressure in the actuating pressure side 22 of the actuator 16 . Although it is only necessary to open one of the two valves 56 or 58 to shut down the system due to the redundancy of these two valves, the operating system opens both valves to be absolutely certain that hydraulic pressure to the actuating pressure side 22 of the actuator is dumped in the event that one of the two valves 56 or 58 does not function. The regulated pressure through the loading pressure line 26 is of course greater than the essentially zero pressure in the actuating pressure side 22 of the actuator 16 . The spring 32 provides further pressure to drive the piston 18 to rapidly close the main shut-off valve 14 . The emergency shutdown process ends with the completion of the actuation of the three valves noted above, as indicated by the final step 304 of FIG. 3 .
FIG. 4 is a flowchart briefly describing the essential steps in the restart process. Once the system has been determined to be ready to return to normal operation, as indicated by the initial step 400 of FIG. 4 , the state or condition of the three hydraulic solenoid valves 52 , 56 , and 58 is reversed, as indicated by the second step 402 of FIG. 4 . However, the valves 52 , 56 , and 58 may be set to remain in their system shutdown condition until their respective manual latches 52 b , 56 b , and 58 b ( FIG. 1 ) are reset (manually latched) to allow the valves to function normally, as indicated by step 402 of FIG. 4 . This manual latch feature requires the operator(s) of the system to verify the proper state or condition of the system prior to restart of the system. Once this has been accomplished, the valves 52 , 56 , and 58 are returned to their respective states or conditions for normal operation of the system, i.e., valve 52 is reopened and valves 56 and 58 are closed, to assure that the main shut-off valve 14 is open to supply a full delivery of combustive gas to the operation.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The shut-off valve testing system provides for the testing of the main shut-off valve of a combustible gas supply line in such facilities as refineries, factories, or other plants utilizing such gaseous fuel. The system includes a double-ended hydraulic cylinder receiving hydraulic pressure from a suitable source, the cylinder communicating hydraulically with a hydraulic actuator for the main shut-off valve. The system provides for testing of the shut-off valve by actuating the valve through a portion of its full travel, thus confirming that the valve is free. This is accomplished by shutting off the pressure to one side of the double-ended hydraulic cylinder, and opening the hydraulic line between the cylinder and the actuator. Thus, hydraulic pressure from the actuator can bleed to the cylinder, allowing the actuator to move to the extent of the limiting spring and/or hydraulic pressure to the opposite side of the cylinder.
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[0001] The disclosure of Japanese Patent Application No. 2003-277919 filed on Jul. 22, 2003 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a combining method for combining a proton conducting material with a skeleton.
[0004] 2. Description of the Related Art
[0005] As general-use electrolyte membranes, fluorine-based membranes are known that have a basic skeleton of perfluoroalkylene group, with an ion exchange group like sulfone group or carbon group attached to the terminal of a perfluoro-vinylether side chain in one portion (for example, the Nafion R membrane of Du Pont (see U.S. Pat. No. 4,330,654)). However, when such fluorine membranes are utilized in an electrolyte membrane of a fuel cell or a sensor, the operation temperature is limited to 100° C. or less due to the heal resisting properties of the electrolyte membrane. In addition, it is necessary to make sure that sufficient humidity is present to maintain ion resistance at a low level. Accordingly, there is demand in the fuel cell field for improvement in electricity generation efficiency and effective utilization of heat reduction technologies and techniques, and the like. Moreover, in the sensor field, there are calls for an increase in the range of ambient temperatures in which sensors can be installed. Thus, an electrolyte membrane that can operate in a high temperature/low humidity atmosphere is desired.
[0006] In this regard, Japanese Patent Laid-Open Publication No. 2000-272932 discloses a P 2 O 5 —MOx (M═Si, Ti, Zr, Al) based glass electrolyte which can operate at high temperatures of 100° C. or more. An electrolyte membrane formed from this glass electrolyte is obtained by drying a glass electrolyte that is formed synthetically using a sol-gel process. However, this electrolyte membrane is liable to crack, or the like, when humidity changes rapidly, and thus concerns have been raised about its durability when used in fuel cells, and so on. In order to avoid such problems, a spark plasma sintering (SPS) method has been proposed that enables glass electrolyte that is formed synthetically using the sol-gel process to be sintered so as to form an electrolyte membrane (refer to Japanese Patent Laid-Open Publication No. 2003-75040). However, the obtained electrolyte membrane has spaces present within it, which leads to difficulties related to permeation of gas through the spaces. Accordingly, utilization of this electrolyte membrane in fuel cells in which a gas barrier must be maintained between an anode (an air electrode) and a cathode (a fuel electrode) is problematic.
[0007] Given the above described circumstances, various electrolyte membranes have been proposed (as disclosed in Japanese Patent Laid-Open Publication Nos. 2001-35509, 2001-307545, 2002-15742, 2002-198067, and 2002-309016). These electrolyte membranes are hybrid combinations of (i) a skeleton configured from a hydrocarbon-based polymer, and (ii) a proton conducting material which is configured from an inorganic solid acid and which conducts protons. These electrolyte membranes have both gas barrier properties and heat resisting properties, and can be operated in a low humidity atmosphere.
[0008] However, sometimes, phosphoric acid is used in the proton conducting material of the above disclosed conventional hybrid electrolyte membranes. In this case, when the electrolyte membranes are used for a long period in conditions in which water is present, the phosphoric acid is eluted into the water, whereby proton conductivity is impaired.
SUMMARY OF THE INVENTION
[0009] The present invention has been conceived of in the light of the above described problems, and aims to offer a solution by providing a combining method that enables an electrolyte membrane, an electrode, or the like, to maintain proton conductivity, even when used for a long period in conditions in which water is present.
[0010] The inventors have conducted high-level research concerning the cause of the above described deterioration in the proton conductivity of conventional hybrid electrolyte membranes. Further, they have discovered that the cause is related to elution of phosphorous that acts as the proton conducting material into the water from the skeleton. The inventors have found that it is possible to offer a solution by applying microwaves with a specific wavelength to the conventional hybrid electrolyte membrane so as to bond the skeleton and the proton conducting material (in particular, phosphorous or a phoshide). As a result of this research, the inventors have succeeded in realizing and perfecting the present invention.
[0011] More particularly, a combining method according to the present invention includes a step of combining a proton conducting material including a hydroxyl group with a skeleton formed from a hydrocarbon-based polymer. This combining step is achieved by performing irradiation with microwaves with a specific wavelength that selectively imparts energy to the hydroxyl group.
[0012] Accordingly, the combining method of the present invention enables an electrolyte membrane, an electrode, or the like, to be manufactured that can maintain proton conductivity even when used for a long period in conditions in which water is present.
[0013] The hydrocarbon-based polymer is used for the skeleton in order to (a) give the electrolyte membrane suitable flexibility, and (b) make handling and electrode formation easier. As the hydrocarbon-based polymer it is possible to utilize a polyether like poly-tetramethylene oxide, or a poly-methylene group.
[0014] For the proton conducting material, it is desirable to use phosphoric acid or a phoshide Moreover, phosphoric acid or phosphate are particularly suitable.
[0015] In the case that an intermediate product is manufactured from a skeleton formed from a hydrocarbon-based polymer, and a proton conducting material including a hydroxyl group, an example of the method used for obtaining the intermediate product is as follows. A substituent (like hydrolyzable silyl group or metal alkoxide that is capable of bonding with the proton conducting material) is introduced in advance to the hydrocarbon-based polymer. This substituent is used to covalently bond the skeleton and the proton conducting material. For example, it is possible to obtain a proton conducting material from phosphoric acid or phosphorus alkoxide using a sol-gel process. In this case, a hydrocarbon-based polymer with introduced alkoxide-silane is used as the skeleton, and phosphoric acid or phosphorous alkoxide is added to a solution thereof. Then, hydrolysis and intermediate product dehydration polymerization are performed, whereby it is possible to obtain an intermediate product in which the skeleton and the proton conducting material are covalently bonded.
[0016] The intermediate product obtained in this manner includes an unreacted portion where the intermediate product dehydration polymerization reaction has not taken place. Accordingly, if this intermediate product is used in this form for a long time in conditions in which water is present, the phosphorous elutes from the skeleton. As a result, proton conductivity is liable to reduce. Thus, according to the combining method of the present invention, in the process step that follows forming of the intermediate product, microwaves with a specific wavelength are applied. The wavelength of these microwaves selectively imparts energy to the hydroxyl group which is bonded with the phosphorous-oxygen bonds and which is included in the intermediate product. Accordingly, intermediate product dehydration polymerization takes place in the unreacted portion, and bonding of the phosphorous that is the proton conducting material and the skeleton takes places. As a result, it is possible to obtain an intermediate product which is not affected by phosphorous elution and which maintains proton conductivity even if used for a long time in conditions in which water is present.
[0017] By applying microwaves to the hydroxyl group included in the intermediate product, it is possible to polymerize the skeleton and the proton conducting material. In other words, bonding is facilitated since the microwaves apply energy to the hydroxyl group included in the intermediate product. Accordingly, microwaves are applied at one of the frequencies (namely, 915 MHz, 2,450 MHz, or several 10s of GHz) that are the H—O—H absorption bands associated with the intermediate product dehydration polymerization. As a result, it is possible to complete the reaction of the crosslinked structure. However, when a frequency of several 10s of GHz is used, efficiency is raised too much, and just the surface of the intermediate product is heated rapidly, whereby damage of the electrolyte membrane occurs. Accordingly, it is preferable if the microwaves are applied within a 900 MHz to 10 GHz band. By doing so, microwave irradiation can be used to locally irradiate energy at room temperature. This makes it possible to only promote the polymerization reaction of the proton conducting material, without causing damage to the hydrocarbon-based polymer that forms the skeleton.
[0018] The electrolyte membrane obtained as a result of the above process is able to maintain proton conductivity even if used for a long period in conditions in which water is present, since it is difficult for phosphorous to elute from the skeleton. Moreover, this electrolyte membrane simultaneously demonstrate (a) gas barrier properties and flexibility due to the hydrocarbon-based polymer, and also (b) proton conductivity in the low humidity range due to the proton conducting material. In addition, the hybrid combination of the crosslinked structure and the hydrocarbon-based polymer that forms the skeleton enables the electrolyte membrane to operate in a higher temperature range than conventional electrolyte membranes.
[0019] Moreover, the inventors have confirmed that the effects of the invention can also be obtained with an intermediate product that uses 3-isocyanate propyl-triethoxysilane and polyethylene oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a graph showing proton conductivity of intermediate products according to ar embodiment;
[0021] FIG. 2 is a graph showing respective retention rates of phosphorous of electrolyte membranes according to first and second examples of the embodiment, and a comparative example;
[0022] FIG. 3 is a comparison graph showing respective proton conductivities of the second example according to the embodiment and the comparative example; and
[0023] FIG. 4 is a thermogravimetry-differential thermal analysis (TG-DTA) graph showing heat resisting properties of the intermediate product according to the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Hereinafter, a specific embodiment of the present invention will be described with reference to the drawings.
[0025] First Process Step
[0026] Polyethylene glycol (average molecular weight, 200 to 1000) was adopted for the hydrocarbon-based polymer. As shown in Formula 1, the polyethylene glycol and 3-isocyanate propyl-triethoxysilane were reacted at 60 degrees C. in a tetrahydrofuran (THF) solvent for forty-eight hours under a nitrogen atmosphere. Ethoxysilane group was then introduced by urethane bonding. Then, as indicated by Formula 2, a skeleton was obtained by introducing substituent.
[heading-0027] Formula 1
H(OC 2 H 4 ) n OH+2(C 2 H 5 O) 3 Si(CH 2 ) 3 NCO
Formula 2
(C 2 H 5 O) 3 Si(CH 2 ) 3 NHOC(OC 2 H 4 ) n OCONH(CH 2 ) 3 Si(C 2 H 5 O) 3
[0029] Next, the skeleton with the attached substituent was dissolved in ethanol, and water and phosphoric acid were added. The obtained solution was poured into a PTFE made petri dish. Then, hydrolysis and intermediate product dehydration polymerization of the solution were performed at a temperature of 40 degrees C. in a hermetically sealed environment so as to obtain a gel. This gel was first dried for twenty-four hours at 40 degrees C., and then dried for twenty-four hours at 100 degrees C. (with a temperature increase rate of 10 degrees/minute). As a result, an intermediate product with thickness of around 0.3 mm was obtained. The added amount of phosphorous (P) with respect to silicon (Si) was 0.5 to 5 (molar ratio). In this way, it was possible to obtain the intermediate product without any dependency on the average molecular weight of the polyethylene glycol.
[0030] Second Process Step
[0031] The intermediate product obtained by the first process step was irradiated with microwaves of 500 Watts at a frequency of 2,450 MHz so as to insolubilize the phosphorous.
[0032] Evaluation of Proton Conductivity
[0033] Intermediate products with various phosphorous concentrations (in a range from P/Si 0.5/1 to 5/1) were obtained using the first process step described above. The respective intermediate products, which were formed to have a thickness of around 0.5 mm, were cut into squares of around 1.5 cm in a petri dish. Then, a sputter method was used to deposit gold electrodes on both sides of the cut intermediate product, and a lead line was attached to each electrode. The respective intermediate products were then placed into a variable temperature-humidity chamber under a nitrogen atmosphere, and impedance was measured using an LCR meter. In this way, the ion conductivity (S/cm) of each intermediate product was measured. Note that, the average molecular weight of the polyethylene glycol was 400. The measurement results that were obtained at a relative humidity of 5% are shown in FIG. 1 .
[0034] As is apparent from FIG. 1 , all of the intermediate products simultaneously demonstrate (i) gas barrier properties and flexibility due to the polyethylene glycol, and also (ii) proton conductivity in the low humidity range due to the phosphoric acid. Moreover, it is also clear that all of the intermediate products have an increased phosphorous content and improved proton conductivity.
[0035] Elution Test
[0036] First and second examples (described below) and a comparative example of the electrolyte membrane were immersed in pure water, and left for twenty-four hours at room temperature The examples were then removed and dried, and their phosphorous concentration was measured by performing elemental analysis using an X-ray microanalyser. The phosphorous retention rate (%) was then calculated by taking the respective pre-immersion phosphorous contents of the first, second and comparative examples of the electrolyte membrane as reference values. The results of this analysis are shown in FIG. 2 .
[0037] Among the intermediate products obtained from the first process step, the product with an average molecular weight of polyethylene glycol of 400 and a phosphorous to sulfur ratio of 2:1 was irradiated with microwaves at a frequency of 2,450 MHz for one minute. At this time, the microwave output was set at 250 or 500 Watts. The electrolyte membrane obtained with the 250 Watt microwave output was used as the first example, and that obtained with the 500 Watt microwave output was used as the second example. Note that, the comparative example is a electrolyte membrane (intermediate product) that was not subject to irradiation by microwaves.
[0038] As can be seen from FIG. 2 , the comparative example electrolyte membrane that was not irradiated by microwaves has a phosphorous retention rate of around 20%. However the first example electrolyte membrane irradiated with 250 Watt microwaves shows a phosphorous retention rate of around 40%, and that of the second example electrolyte membrane irradiated with 500 Watt microwaves is near to 80%. In light of the above proton conductivity evaluation it is apparent that proton conductivity is higher when phosphorous content is high. Accordingly, as compared to the electrolyte membrane of the comparative example, the electrolyte membranes of the first and second examples exhibit superior proton conductivity when used for a long period in conditions in which water is present.
[0039] It should be noted that it is also preferable if irradiation is performed with a microwave output of 500 Watts rather than 250 Watts. However, if the output level is too large, and irradiation is performed for a long time, there is a possibility that the electrolyte membrane will be damaged due to surface temperature increase. Accordingly, an optimal balance of microwave output and irradiation time is set. Of course, it is desirable if the optimal combination of these parameters is set based on a weight of the intermediate product, a surface area thereof and a thickness thereof.
[0040] Measurement of Proton Conductivity
[0041] The second example electrolyte membrane and the comparative example electrolyte membrane (respective intermediate products) were immersed in pure water, and left for twenty-four hours at room temperature. Following this, the electrolyte membranes were dried, and ion conductivity (S/cm) was measured in the same manner as described previously. The results are shown in FIG. 3 .
[0042] The electrolyte membrane of the second example that was irradiated by microwaves has a high phosphorous retention rate as discussed previously. Thus, as shown in FIG. 3 , the second example exhibits hardly any fall in proton conductivity. In comparison with this, however, the non-processed comparative example electrolyte membrane (intermediate product) shows a substantial fall in proton conductivity due to phosphorous elution. Given these results, it is clear that proton conductivity is made more stable as a result of phosphorous fixing caused by the microwave irradiation.
[0043] Evaluation of Heat Resisting Properties
[0044] Using the first process step described above, an intermediate product was obtained with an average molecular weight of polyethylene glycol of 400 and a phosphorous to sulfur ratio of 2:1. Moreover, the thermal stability of the intermediate product was confirmed using TG-DTA The results are shown in FIG. 4 .
[0045] As shown in FIG. 4 , weight reduction resulting from release of absorbed water, and an endothermic reaction were observed up until about 200 degree C. However, from around 250 degrees C. and upwards, weight reduction resulting from destruction of the electrolyte membrane, and an exothermic reaction were observed. Based on these results, it is apparent that the intermediate product has adequate heat resisting properties up until around 200 degrees C. In other words, the heat resisting properties of the intermediate product are improved by the hybrid combination of the phosphoric acid and the polyethylene glycol of the skeleton. As a result, an electrolyte membrane is obtained that can operate in a higher temperature range than conventional electrolyte membranes.
INDUSTRIAL APPLICABILITY
[0046] The combining method of the present invention can be desirably applied to manufacturing methods for fuel cell and sensors, and to the manufacture of electrodes for fuel cells, or similar. Further, it is preferable if the proton conducting material is phosphoric acid or a phoshide.
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In a first process step, intermediate product dehydration polymerization of a hydrocarbon-based polymer including a metal alkoxide and phosphoric acid is performed to obtain an intermediate product. Then, in a second process step, the intermediate product is irradiated by microwaves with a wavelength that selectively imparts energy to a hydroxyl group included in the intermediate product. As a result, an electrolyte membrane is obtained that is composed from a skeleton formed from a hydrocarbon-based polymer and phosphoric acid that is proton conductive.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 60/305,093, filed Jul. 16, 2001, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to design simulation and verification, and specifically to design verification based on symbolic model checking.
BACKGROUND OF THE INVENTION
Simulation-based testing is the most commonly-used method for verifying integrated circuit hardware designs. A software model of the design is prepared, typically using a hardware description language, such as VHDL or Verilog. Different input test patterns are then applied to the model, and the output of the model is inspected for errors. The test patterns may be generated either deterministically or at random. In either case, however, it is impossible to ascertain when enough tests have been performed to adequately cover the entire state space of the design. Therefore, even after lengthy simulation, it is still possible that a design bug may have gone undetected.
Because of the shortcomings of simulation, methods of formal verification, particularly model checking, have been gaining in popularity as tools for use in designing integrated circuits and other complex systems. Such methods are described generally by Clarke et al. in Model Checking (MIT Press, 1999), which is incorporated herein by reference. To perform model checking of the design of a device, a user reads the definition and functional specifications of the device and then, based on this information, writes a set of properties (also known as a specification) that the design is expected to fulfill. The properties are written in a suitable specification language for expressing temporal logic relationships between the inputs and outputs of the device. Such languages are commonly based on Computation Tree Logic (CTL). A hardware model (also known as an implementation) of the design is then tested to ascertain that the model satisfies all of the properties in the set.
After the specification and hardware model have been prepared, the actual model checking is typically carried out automatically using a symbolic model checking program, such as SMV, as described, for example, by McMillan in Symbolic Model Checking (Kluwer Academic Publishers, 1993), which is incorporated herein by reference. A number of practical model checking tools are available, among them RuleBase, developed by IBM Corporation. This tool is described by Beer et al. in RuleBase: an Industry-Oriented Formal Verification Tool, in Proceedings of the Design Automation Conference DAC 96 (Las Vegas, Nev., 1996), which is incorporated herein by reference.
Formal verification based on model checking is, in principle, superior to simulation-based testing methods, because model checking covers the entire state space of the target system exhaustively and systematically. Therefore, any violations of the specified properties are certain to be discovered. Existing model checking tools, such as RuleBase, also give the designer a clear exposition of the path through the state space of the model that led to the violation.
Formal verification suffers, however, from the well-known problem of state space explosion. As the modeled system grows larger, the computational resources needed to explore the entire state space grow exponentially. Techniques have been developed for reducing the severity of this problem. Such a technique is described, for example, by Beer et al., in On-the-fly Model Checking of RCTL Formulas, Proceedings of the Tenth International Conference on Computer Aided Verification (CAV 1998), which is incorporated here in by reference. Nevertheless, it appears that simulation testing will still remain part of the design verification tool chest for the foreseeable future.
Although formal verification and simulation are essentially different and separate techniques, some attempts have been made to combine elements of both techniques in a single testing environment. For example, Schlipf et al. describe a methodology and tool for combined formal verification and simulation in Formal Verification Made Easy, IBM Journal of Research and Development 41:4,5 (1997), which is incorporated herein by reference. A state machine formulation is used to represent the specification of the system being verified. If formal verification is not completed within a preset time period (due to state-space explosion), the verification tool switches automatically to random simulation testing.
SUMMARY OF THE INVENTION
Preferred embodiments of the present invention provide methods for automatic generation of on-line formal checkers from properties expressed as temporal logic formulas, for use in simulation-based verification. Each property is translated into a program in a hardware description language, which is then compiled together with the actual hardware model. The term formal checker, or simply checker, as used herein refers to this program, which may be generated either in a dedicated hardware description language, such as VHDL, or in a generic software language, such as C (depending on the language in which the hardware model is written).
The checker program represents one or more finite state machines that express the property to be checked. During simulation, the checker tracks the status of the simulated design and reaches an error state if the model violates the property. The checker causes the simulator to report the error to the hardware designer, who can then take the appropriate corrective steps. Such on-line checkers thus provide some of the benefits of formal verification in the simulation environment. They facilitate test result analysis and save debugging efforts by directly identifying property violations and their sources.
In some preferred embodiments of the present invention, a formal checking tool automatically generates checkers based on forall properties. A forall property depends on one or more specified variables, including at least one forall variable. The forall property states that a given formula will hold true in all states of the model for any selected values of the forall variables within a given range. Checkers based on forall properties are particularly difficult to implement, since in principle a separate state machine must be generated for each possible combination of values of the forall variables in the range. When the range is large, it becomes practically impossible to produce all these checkers by manual coding. Nave, automated generation of all the possible checkers that are needed will make the resulting simulation model grow to an unwieldy size, which may exceed memory limitations.
Therefore, the forall checker of the present invention tracks the actual values that the forall variables assume in the simulation, and checks the formula only for these values. The checker preferably spawns a state machine for each new combination of actual values of the forall variables that is assigned in the simulation, and subsequently deletes particular state machines when they are no longer needed. Thus, the checker generates and maintains only the number of state machines that it actually needs at any point in the simulation. If the hardware description language being used imposes a limit on memory allocation (as is the case for VHDL, for example), the user may determine in advance the maximum number of state machines to be generated. In this case, the checker will stop spawning new state machines when it reaches the limit.
Although preferred embodiments are described herein with particular reference to forall properties, the principles of the present invention may similarly be applied to on-line checking of properties of other types. Specifically, whenever multiple parallel state machines are called for to perform a given checking task, the present invention can be used to limit the number of states that must be evaluated, thus alleviating the need to use a complete product model in the checker program.
There is therefore provided, in accordance with a preferred embodiment of the present invention, a method for design verification, including:
receiving a software model of a design of a system under evaluation;
providing a property, which is dependent on a specified variable having a predefined range of values, the property applying to all states of the system for any selected value among the values of the variable within the predefined range;
processing the property so as to generate a checker program for detecting a violation of the property; and
running a simulation of the system using the software model together with the checker program.
Typically, receiving the software model includes receiving a simulation model of an electronic device, written in a hardware description language, wherein processing the property includes generating checker code in the hardware description language. Preferably, running the simulation includes compiling the checker code together with the simulation model, and running the compiled code in a hardware simulation environment.
Typically, the specified variable is one of a plurality of variables upon which the property depends, such that the property applies to all states of the system for any combination of respective values of the variables within respective ranges of the variables.
Preferably, providing the property includes defining a formula that is expected to hold for all of the states of the system, and running the simulation includes detecting a violation of the property using the checker program. Most preferably, the states' of the system include one or more initial states and one or more error states, in which the property is violated, and detecting the violation includes finding a trace through the states of the system from one of the initial states to one of the error states.
Further preferably, processing the property includes generating a finite state machine representing the property, and running the simulation includes stepping through the states of the state machine. Most preferably, stepping through the states includes generating multiple instances of the state machine, each corresponding to one of the values of the specified variable. Additionally or alternatively, generating the finite state machine includes generating a non-deterministic finite automaton, wherein generating the finite state machine further includes converting the non-deterministic finite automaton to a deterministic form.
Preferably, running the simulation includes creating multiple checker instances, each such instance corresponding to a respective one of the values of the specified variable, and running each of the checker instances to detect the violations of the property. Further preferably, creating the multiple checker instances includes creating each of the instances at a respective point in the simulation at which the respective one of the values is referenced to the specified variable. Most preferably, running each of the instances includes running a first one of the instances, and creating each of the instances includes spawning a second one of the instances from the first one of the instances at the respective point in the simulation at which the respective one of the values for the second one of the instances is referenced to the specified variable in running the first one of the instances. At the respective point in the simulation at which the second one of the instances is spawned, the states of the first one and the second one of the instances are identical, except for assignment of the respective one of the values to the specified variable in the second one of the instances.
Additionally or alternatively, creating the multiple checker instances includes creating a number of the checker instances that is substantially smaller than the number of the values that the specified variable can assume within the predefined range. Preferably, creating the number of the checker instances includes setting a limit on the number of the checker instances to be created, and creating each of the instances when the respective one of the values is referenced to the specified variable during the simulation only if the number of the checker instances running is less than the limit. Further additionally or alternatively, running each of the checker instances includes determining that one of the checker instances has reached a predefined terminal state, and deleting the one of the checker instances that has reached the predefined terminal state.
There is also provided, in accordance with a preferred embodiment of the present invention, a method for design verification, including:
receiving a software model of a design of a system under evaluation;
providing a property that is applicable to the system;
processing the property so as to generate a finite state machine representing the property, the state machine having a plurality of states including an error state that corresponds to a violation of the property;
initiating a simulation of the system using the software model and an initial instance of the state machine;
stepping through the states of the initial instance of the state machine while running the simulation;
spawning one or more further instances of the state machine during the simulation, responsive to the states of the initial instance;
stepping through the states of the one or more further instances of the state machine while running the simulation; and
detecting the violation of the property when one of the instances of the state machine reaches the error state.
Preferably, providing the property includes specifying a dependence of the property on a specified variable of the system having multiple possible values, and spawning the one or more further instances includes generating the further instances responsive to assignment of respective new values to the specified variable during the simulation. Further preferably, providing the property includes defining the property so as to apply to all states of the system for any selected value in a predefined range of the possible values that the specified variable can assume. Typically, generating the further instances includes creating a number of the instances that is substantially smaller than the number of the values that the specified variable can assume within the predefined range. Most preferably, creating the number of the instances includes setting a limit on the number of the instances to be created, and creating each of the instances when the respective new values are assigned to the specified variable during the simulation only if the number of the instances running is less than the limit.
Additionally or alternatively, generating the further instances includes initializing the further instances such that the states of the initial and further instances are identical, except for the assignment of the new values to the specified variable in the further instances.
Preferably, stepping through the states of the initial and further instances includes determining that one of the instances has reached a predefined terminal state of the state machine, and deleting the one of the instances that has reached the predefined terminal state.
Additionally or alternatively, stepping through the states of the one or more further instances includes spawning one or more additional instances of the state machine during the simulation, responsive to the states of at least one of the one or more further instances.
There is additionally provided, in accordance with a preferred embodiment of the present invention, apparatus for design verification, including:
a checker generator, which is coupled to receive a property, which is dependent on a specified variable having a predefined range of values, the property applying to all states of a system under evaluation for any selected value among the values of the variable within the predefined range, and which is arranged to process the property so as to generate a checker program for detecting a violation of the property; and
a simulator, which is coupled to receive a software model of a design of the system under evaluation and to receive the checker program, and which is arranged to run a simulation of the system using the software model together with the checker program.
There is further provided, in accordance with a preferred embodiment of the present invention, apparatus for design verification, including:
a checker generator, which is coupled to receive a property that is applicable to a system under evaluation and to process the property so as to generate a checker program corresponding to a finite state machine representing the property, the state machine having a plurality of states including an error state that corresponds to a violation of the property; and
a simulator, which is coupled to receive a software model of a design of the system under evaluation and to receive the checker program, and which is arranged to initiate a simulation of the system using the software model with an initial instance of the state machine,
wherein the checker program causes the simulator to step through the states of the initial instance of the state machine while running the simulation, to spawn one or more further instances of the state machine during, the simulation, responsive to the states of the initial instance, to step through the states of the one or more further instances of the state machine while running the simulation, and to detect the violation of the property when one of the instances of the state machine reaches the error state.
There is moreover provided, in accordance with a preferred embodiment of the present invention, a computer software product, including a computer-readable medium in which program instructions are stored, which instructions, when read by the computer, cause the computer to receive a property, which is dependent on a specified variable having a predefined range of values, the property applying to all states of a system under evaluation for any selected value among the values of the variable within the predefined range, and which is arranged to process the property so as to generate a checker program, to be run by a simulator together with a software model of a design of the system under evaluation in a simulation of the system so as to detect a violation of the property.
There is furthermore provided, in accordance with a preferred embodiment of the present invention, a computer software product, including a computer-readable medium in which program instructions are stored, which instructions, when read by the computer, cause the computer to receive a property that is applicable to a system under evaluation and to process the property so as to generate a checker program to be run by a simulator together with a software model of a design of the system under evaluation in a simulation of the system, the checker program corresponding to a finite state machine representing the property, the state machine having a plurality of states including an error state that corresponds to a violation of the property,
wherein the checker program causes the simulator to initiate the simulation of the system using an initial instance of the state machine, to step through the states of the initial instance of the state machine while running the simulation, to spawn one or more further instances of the state machine during the simulation, responsive to the states of the initial instance, to step through the states of the one or more further instances of the state machine while running the simulation, and to detect the violation of the property when one of the instances of the state machine reaches the error state.
The present invention will be more fully understood from the following detailed description of the preferred embodiments thereof, taken together with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram that schematically illustrates a system for design verification, in accordance with a preferred embodiment of the present invention;
FIG. 2 is a flow chart that schematically illustrates a method for design simulation using a formal checker, in accordance with a preferred embodiment of the present invention; and
FIG. 3 is a flow chart that schematically illustrates a method for updating finite state machines used in formal checking, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a block diagram that schematically illustrates a system 20 for design verification, combining design simulation with formal checking, in accordance with a preferred embodiment of the present invention. A verification engineer 24 inputs a formal specification 26 to a checker generator 22 . The checker generator typically comprises a general-purpose computer, which is equipped with software for translating formulas from specification 26 into formal checker programs 28 in a hardware description language. The software used by generator 22 in carrying out such operations may be supplied to the computer on tangible media, such as CD-ROM, or it may alternatively be downloaded to the computer in electronic form, over a network, for example. Typically, although not necessarily, the software is supplied as part of a suite of programs for formal verification.
Formal checkers 28 are linked to a design 30 of a hardware device in development, which is typically written in the same hardware description language as the checkers. The hardware description language may be a dedicated hardware description language, such as VHDL or Verilog, or it may alternatively be a generally-purpose software language, such as C, which is used for modeling the behavior of hardware designs in development. The checkers and design are compiled together and then run on a simulator 32 , using methods of simulation known in the art. The simulator exercises design 30 in accordance with test programs 34 , which may be generated automatically or written by engineer 24 or other personnel.
During simulation, checkers 28 detect violations of the properties in specification 26 and cause simulator 32 to output indications 36 of violations that have occurred. These indications are provided to engineer 24 and/or to other users. Depending on the information provided about any given violation, the user concerned may decide to fix design 30 , change the properties in specification 26 , or modify test programs 34 . The checkers and design are then recompiled, and simulator 32 is run again until the design is bug-free and no more property violations are encountered.
Typically, engineer 24 writes specification 26 in a suitable temporal logic language. For example, the specification may be written in RCTL, an extension to the conventional CTL language using regular expressions, which is described in the above-mentioned article by Beer et al. The article goes on to describe a technique for translating many CTL formulas conveniently into state machines having an error state. This technique may be used to generate state machines to serve as formal checkers 28 . Running such a state machine together with design 30 is equivalent to testing for violations of the CTL formula AG( error). (An AG(p) formula states that the property p is true in every reachable state of the model.) More recently, Beer et al. have extended RCTL to include further expressions and syntax, as described in The Temporal Logic Sugar, Proceedings of the Thirteenth International Conference on Computer Aided Verification (CAV 2001), which is incorporated here in by reference.
RCTL provides forall constructs, which can be used to express properties that are dependent on a specified variable or variables, and which are required to hold true in all states of the hardware model for any selected values of the variables within given ranges. Forall properties have the syntax:
forall variable: type:
formula{ }
The forall variable can take any of its allowed values as an initial value, and then keeps this value subsequently for the duration of the present verification run. The variable type implies a set of allowed values that the variable can take. The formula (or formulas) in the scope of the forall statement should be true for every possible value of the forall variable. The forall property may also include other variables that are not forall variables.
For example, consider the following forall property:
forall x(0 . . . 31): Boolean:
formula{
{[*], read & din(0 . . . 31)=x(0 . . . 31)} {!write, write & dout(0 . . . 31)=x(0 . . . 31)}
}
The formula states that if during any read operation, the value of the vector that is read in, din (a 32-bit vector), is equal to x (which can take any value between 0 and 2 32 −1), then in the next write operation, the vector read out, dout, must be equal to the same value of x. It must hold true for all of the possible values of x. Since the actual values that will be assumed by x during a simulation run are not known in advance, covering all the possibilities would require generating 2 32 state machines, running in parallel. The situation becomes even more extreme when (as is often the case) a forall property depends on a combination of two or more different forall variables. A method for limiting the number of state machines to those actually needed is described below.
FIG. 2 is a flow chart that schematically illustrates a method for simulation testing using formal checkers based on a forall property, in accordance with a preferred embodiment of the present invention. To begin with, checker generator 22 translates the property into a non-deterministic state machine, at a translation step 40 . The state machine is expresses as a non-deterministic finite automaton (NFA) and an AG(p) formula, wherein p is a Boolean expression. The NFA has a set of error states, in which the property p is false. The NFA is preferably generated automatically using the method described by Beer et al. in the above-mentioned article, On-the-fly Model Checking of RCTL Formulas. Other methods for construction of a NFA based on a temporal logic formula are known in the art.
Formally, the NFA constructed at step 40 has the following elements:
A set S of n states: s 0 , s 1 , , s n−1 . A set I ⊂ S of initial states. A set A ⊂ S of error states, in which AG(p) is false. A terminal state term ∈ S. Transition conditions T(i,j), 0≦i<n, 0≦j<n.
Each T(i,j) is a Boolean expression referring to a possible transition from state s i to state s j . Each T(i,j) references one or more identifiers, which may be forall variables. Identifiers that are not forall variables are referred to as port signals. The terminal state is characterized by having only one possible transition, to itself, i.e., if s≠t term, then T(term,s)=false.
There may be m different forall variables referenced by the NFA, f 0 , f 1 , f m−1 , each of a declared type.
The NFA constructed at step 40 is said to accept a finite trace t 0 , t 1 , t u−1 , through the states in S iff there is a sequence of states a 0 , a 1 , a u−1 in S and a value assignment of all the forall variables such that:
a 0 is an initial state of the NFA; a u−1 is an error state of the NFA; and For each i, 0≦i<u, T(a i , a i+1 ) is true for the value assignment obtained by combining t i and the value assignment of the forall variables.
Each state of the NFA combined with the forall variable assignment has the form (t i , a i ). In running checker 28 in simulator 32 , as described hereinbelow, this product model is evaluated in order to find any accepting traces of the NFA, i.e., traces that lead to violation of a specification property.
An integer constant K may also be defined by engineer 24 , providing a limit on the number of overlapping transactions that need to be monitored by checker 28 . In other words, K is the maximum number of different combinations of values of the forall variables for which the condition p is checked simultaneously. The choice of K depends on memory restrictions imposed by simulator 32 .
The NFA generated at step 40 is converted into a form suitable to be used as a checker in simulator 32 , in a preprocessing step 42 . Typically, simulators do not support non-determinism. Therefore, the NFA is preferably converted at this stage or at the next stage (step 44 , described below) into a deterministic finite automaton (DFA), or a set of DFAs. For each possible outcome of each non-deterministic transition in the NFA, checker generator 22 creates a different DFA transition. The number of states of the DFA may be exponential in the number of states of the NFA, but simulation is generally sensitive to the size of the representation (i.e., the number of lines of code used in the hardware description language), rather than the number of states. The number of code lines is at most quadratic in the size of the property in question, i.e., in the number of temporal operators in the formula. Practically speaking, for most common property types, the growth in the code is only linear.
For the purposes of the operation of the checker, it is useful to partition the states of the automaton (whether the NFA or DFA representation is used) with respect to each of the forall variables into latching states and checking states. A latching state is a state in which a value is assigned to the forall variable in question. The automaton should be able to enter a checking state only after having passed through a latching state, and it should not be able to enter any latching state twice. If checker generator 22 is unable partition the states into latching and checking states in this manner, it typically returns an error message and exits. Automatic generation of checker 28 in this case may lead to unreliable results in simulation, and engineer 24 should therefore either modify specification 26 or write the checker code manually.
In order to partition the states into latching and checking states, checker generator 22 detects, for each forall variable f i , all states of the automaton that reference it, i.e., states S j such that for some k, T(j,k) references f i . Transitions from a latching state that reference f i are referred to as latching transitions of f i . After partitioning the set of states that reference f i into latching states and checking states, generator 22 also verifies that the reference to f i in all these latching states is of the form f i =g(x 1 , , x n ), wherein g is a Boolean expression over a set of port signals x 1 , , x n (not a forall variable). If there is some latching state in which this condition is not fulfilled, generator 22 likewise returns an error message and exits. Here, too, automatic generation of checker 28 may give unreliable results.
As long as the partition into latching and checking states is successful, and the assignments to the forall variables are of the proper form, all references to the forall variables in all latching states (i.e., all expressions of the form f i =x) are replaced simply by the expression true. The latching states are marked to identify the forall variables that should be sampled in each such state.
Having preprocessed the automaton to put it in the desired form, checker generator 22 now converts the automaton into a hardware description language program, at a checker generation step 44 . Hardware description languages are generally designed, inter alia, for representing state machines in a clear, simple way. Translation of the automaton into a hardware description language process is therefore straightforward. The property AG(p) of the automaton becomes an Assert(p) statement in VHDL, for example. This statement causes the simulator to print a message when the checker process reaches an error state. The simulator may also be programmed to stop the simulation in such an event. A sample VHDL checker program, based on a simple forall property, is shown in an Appendix below.
In operation, the checker program generates multiple instances of its state machine, as described in detail hereinbelow. The checker keeps track of these instances using a vector L, made up of slots L[0], L[1], L[K−1], wherein K is the constant that was input above at step 40 . Each slot is used by the checker to monitor a different state machine instance, corresponding to a different combination of assigned values of the forall variables.
Each slot in L contains the following fields:
1. L[i].active: a Boolean flag specifying whether this slot is currently active. 2. L[i].v: a Boolean vector of n elements, which simulates the behavior of the state machine for the given combination of forall variable values. In each cycle of simulator 32 , L[i].v[j] is true iff the state machine could be in state s j in this cycle. L[i].v thus translates the original NFA into a set of DFAs. 3. For each forall variable f j :
a. L[i].have_value[j]: a Boolean flag specifying whether this slot has a latched value of f j . b. L[i].value[j]: a field used to store the latched value of f j must be large enough to hold any legal value of f j .
The checker is initialized by marking the first slot, L[0], as active, and all others as inactive. L[0].v holds the initial states of the automaton, i.e., L[0].v[j] is true iff s j ∈I. All forall variables are non-latched in L[0], so that L[0].have_value[j] is false for all j. Checker 28 and design model 30 are linked and compiled together, and are then ready to be run by simulator 32 .
Simulation now proceeds in the usual fashion, in successive steps of the simulator clock, at a simulation step 46 . At each step of the clock, the checker component of the compiled simulation model updates the state of the checker, at an update step 48 . Generally speaking, multiple instances of the checker state machine are created, each corresponding to a different combination of values of the forall variables. New state machines are spawned whenever the initial state machine or one of the subsequently-created state machine instances passes a latching transition. (Of course, if there is only a single forall variable, as in the example given above, each instance simply corresponds to a different value that is assigned to this variable. In this case, the state machines spawned by the initial state machine should have no more latching transitions, and only the initial state machine can spawn further new state machines.) Each new state machine instance occupies a different slot of L. Details of this step, including the manner in which the state machine instances are generated, are described below with reference to FIG. 3 . The checker program monitors all of the active slots. If any active slot reaches one of the error states s i ∈A, the simulator outputs violation indication 36 .
Cycling of the simulation clock at step 46 and updating of the checker state machines at step 48 continue until the simulation is finished, at a completion step 50 . Typically, the simulation is considered done after a certain number of cycles of the simulation clock have passed, or until certain error conditions are reached. Simulator 32 then reports the simulation results to engineer 24 , at a reporting step 52 , including any violations of the forall property under test.
FIG. 3 is a flow chart that schematically shows details of update step 48 , illustrating the operation of checker 28 in simulator 32 , in accordance with a preferred embodiment of the present invention. At each cycle of the simulation clock, the checker program reviews all of the active state machines to determine whether any of them have reached one of the error states, at an error checking step 60 . In other words, for each active slot L[i], the checker determines whether this slot accepts the trace through the simulation states traversed up to this point. Formally, a slot L[i] will be found to have accepted the trace if for any j, 0≦j<n, L[i].v[j] is true, and s j is an error state. If the trace is accepted, checker 28 causes simulator 32 to report the violation of the forall property, at a violation reporting step 62 . In some cases, as noted above, detection of such an error may trigger termination of the simulation.
Checker 28 next reviews the existing state machine instances to determine whether any of them have reached a terminal state (or sink state), at a sink checking step 64 . These state machines have no more useful information to provide with respect to the forall property being checked. Formally, a slot L[i] will be found to have reached the terminal state if L[i].v[term] is true, and L[i].v[j] is false for all j≠term. The continued existence of these dead state machines uses up memory of simulator 32 unnecessarily. Therefore, any state machines found to be in the terminal state term are deleted, at a machine deletion step 66 , thus freeing slots of L for state machine instances with new values of the forall variables.
For all remaining active state machines, checker 28 computes the next state transition, at a state computation step 67 . Each active state machine may spawn a new state machine instance, if it has reached a latching state of one of the forall variables, at a latching step 68 . Before spawning a new instance, however, the checker verifies that there is not a state machine instance already in existence with this assignment of forall variables, at an existence checking step 69 . If not, the new instance may be spawned.
To begin with, when the initial state machine (corresponding to L[0]) reaches a latching state, in which a given forall variable f j is referenced for the first time, a new copy of the state machine is spawned, at a spawning step 72 . The new state machine initially has the same state as the parent state machine that spawned it, except that f j in the new state machine is latched at the referenced value. The new state machine continues to run in parallel with its parent, but whenever the new machine encounters f j again, it uses the latched value.
Subsequently, the initial state machine and any spawned state machines may continue to spawn further new state machines at subsequent steps of the simulator clock. The new state machines spawned by the initial state machine may latch different values of f j , and may alternatively latch values of other forall variables. The spawned state machine, with the latched value of f j , may spawn a further state machine if it reaches a latching state of another forall variable f k . The spawning of such offspring can continue successively until descendant state machines are spawned in which all the forall variables have latched values.
Table I below is a pseudocode representation of the process of computing state transitions, identifying latching states and spawning new state machines for each existing L[i] in each simulation cycle. The operations represented by the pseudocode correspond to steps 67 , 68 , 69 and 72 in FIG. 3 .
TABLE I
NEXT-STATE COMPUTATION
temp: Boolean vector with n elements
set all elements of temp to false
for each j, 0 ≦ j < n:
if L[i].v[j] is true:
for each k, 0 ≦ k < n:
Compute T(j,k) (using latched values of forall
variables stored in L[i].value[j] if s j
is a checking state of one or more of the
forall variables);
if T(j,k) evaluated to true, and (j,k) is a
latching transition for a forall variable f y ,
attempt to spawn a new state machine instance as
follows:
(1) set val to the value of the port
signal to which f y , is referenced in
T(j,k);
(2) if an active slot x exists having the
same set of latched forall variables
as L[i] and having f y latched to value
val, set L[x].v[k] to true;
(3) if step (2) fails, find a currently-
inactive slot x and initialize it as
follows:
In L[x].v, set L[x].v[k] to true and
all other elements of L[x] to false;
Set L[x].have_value[y] to true;
Set L[x].value[y] to val;
Set L[x].active to true;
if T(j,k) evaluated to true, and (j,k) is not a
latching transition for any forall variable,
set temp[k] to true.
Set L[i].v to temp.
The process of checking for latching states at step 68 and spawning new state machine instances at step 72 continues until all the active slots of L have been checked. If engineer 24 has not specified a value of the parameter K, L may have an essentially unbounded number of slots, and spawning of new state machine instances can continue indefinitely. When simulator 32 is implemented in a language, such as C, that permits dynamic memory allocation, the depth and breadth of the hierarchy of state machines and their spawn is limited only by the available memory of the simulator. If the simulation language is more limiting, as is the case with VHDL, for example, the checker program keeps track of the number of state machine instances that are active. In this case, the checker blocks spawning of new offspring when there are already K instances running, so that all the slots available in L are filled, at a blocking step 70 .
Although preferred embodiments are described herein with particular reference to checkers 28 of forall formulas, the principles of the present invention may similarly be applied to on-line checking of formulas of other types. It frequently occurs in simulation checking, even when forall formulas are not used, that multiple state machines must be run in parallel. In methods of checking known in the art, this situation is handled by running a complete product model of all the state machines in question. In such situations, the present invention may be applied so as to limit the number of states that must be evaluated to those actually encountered in the simulation. Furthermore, although the description herein of system 20 refers to verification of a hardware design, the system, as well as the underlying principles of the present invention, may equally be adapted for simulation testing of software and other complex designs.
It will be appreciated that the preferred embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.
APPENDIX
Sample Checker
The list below contains VHDL code corresponding to the forall property:
forall data(0 . . 31): boolean;
formula {ag(write & data_in(0 . . 31)=data, !write[*], read(data_out(0 . . 31)=data)}
library ieee; use iii.std_logic — 1164.all; entity check is
port}
clock : std_logic; reset : std_logic; write : std_logic; read : std_logic; data_in : std_logic_vector(0 to 31); data_out : std_logic_vector(0 to 31);
)
end checker; architecture checker of checker is
type slot_type is record
is_active : std_logic; data_latched : std_logic; data_value : std_logic_vector(0 to 31); v : std_logic_vector(0 to 4);
end record; constant K : integer := 10; type slot_vector is array(0 to K-1) of slot_type;
begin
p: process
variable slot : slot_vector variable temp : std_logic_vector(0 to 4); variable fail : std_logic; variable i_arg : integer; variable data_value_arg : std_logic_vector(0 to 31); procedure spawn(
variable i : integer; variable data_value : std_logic_vector(0 to 31)) is variable target : integer;
begin
target := −1; for j in 0 to K-1 loop
if slot (j).is_active = ‘0’ then slot(j).is_active := ‘1’; slot(j).data_latched := ‘1’; slot(j).data_value := data_value; slot(j).v := “00000”; target := j; exit;
elsif (slot(j).data_latched = ‘1’) and
(slot(j).data_value = data_value) then target := j; exit;
end if;
if target = −1 then
assert false report “ran out of slots”
severiety note;
return;
end if; slot(target).v(3) := ‘1’; slot(target).v(4) := ‘1’;
end;
begin
wait until clock′event and clock = 1’; if reset = ‘1’ then
slot(0).is_active := ‘1’; slot(0).data_latched := ‘0’; slot(0).data_value := (others => ‘0’); slot(0).v := “11100”; for i in 1 to K-1 loop
slot(i).is_active := ‘0’; slot(i).data_latched := ‘0’; slot(i).data_value := (others => ‘0’); slot(i).v := “00000”;
end loop;
else
for i in 0 to K-1 loop
if slot(i).is_active = ‘1’ then
check for property violation
fail := (slot(i).v(4) = ‘1’) and
(read = ‘1’) and data_out(0 to 31) /= slot(i).data_value);
assert not fail report “property failed” severity error;
vacate dead slots
if slot(i).v = “00000” then slot(i).is_active := ‘0’; end if;
perform state transitions
temp := “00000”; if slot(i).v(1) = ‘1] then
temp(2) := ‘1’; temp(1) := ‘1’;
end if; if (slot(i).v(2) = ‘1’]) and
(write = ‘1]) and (true) then find a vacant slot, latch data_in and spawn a new state machine i_arg := i; data_value_arg := data_in(0 to 31); spawn(i_arg, data_value_arg);
end if; if (slot(i).v(3) = ‘1]) and
(not (write = ‘1])) then temp(4) := ‘1]; temp(3) := ‘1];
end if slot(i).v := temp
end if: end loop;
end if; end process;
end checker;
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A method for design verification includes receiving a software model of a design of a system under evaluation, and providing a property, which is dependent on a specified variable having a predefined range of values. The property applies to all states of the system for any selected value among the values of the variable within the predefined range. The property is processed so as to generate a checker program for detecting a violation of the property. A simulation of the system is then run using the software model together with the checker program.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of Korean Patent Application No. 10-2010-0133067, filed on Dec. 23, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to a flight dynamics subsystem (FDS) and an operation method thereof, and more particularly, to an FDS for propagating an orbit of a satellite through calculation of a velocity increment.
2. Description of the Related Art
When a maneuver is included during determination and prediction of a satellite orbit, accuracy of estimating an initial orbit value using a velocity increment may be varied according to data length. When observation data is short, accurate estimation of the velocity increment and a satellite position becomes difficult since the observation data is insufficient for estimating the velocity increment. When a noise is serious, a noise error may be greater than the velocity increment. Therefore, it is difficult to determine and predict the orbit without an accurate velocity increment. A conventional orbit estimation method related to a maneuver applies the velocity increment predicted for a station-keeping maneuver plan directly to propagation of the orbit. However, since the predicted velocity increment may cause a large error in an actual maneuver, when only the predicted velocity increment is applied to propagation of the orbit, the propagation result may be inaccurate.
SUMMARY
An aspect of the present invention provides a flight dynamics subsystem (FDS) for predicting an orbit more accurately by estimating a difference between a fuel quantity planned for a station-maintaining maneuver of a satellite and an actual fuel quantity actually used in the satellite, and compensating a velocity increment planned for the station-maintaining maneuver using the estimated error.
According to an aspect of the present invention, there is provided a calculation module for calculating a velocity increment for determining and predicting an orbit of a satellite, the calculation module including a fuel quantity calculation unit to calculate a used fuel quantity about fuel used in the satellite based on TM data; and an error calculation unit to calculate an error with respect to a predicted velocity increment predicted for a station-maintaining maneuver of the satellite, based on a velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to another aspect of the present invention, there is provided an FDS including a receiving unit to receive ranging data, angle observation data, and TM data related to a satellite; a velocity increment calculation unit to calculate an error with respect to a velocity increment for determining and predicting an orbit of a satellite; and an orbit determination and prediction unit to determine and predict the orbit of the satellite based on the velocity increment included in the ranging data, the angle observation data, and the TM data, and to propagate the orbit of the satellite based on an orbit determination value related to the satellite and the error.
According to another aspect of the present invention, there is provided an operational method for a velocity increment calculation module that calculates a velocity increment for determining and predicting an orbit of a satellite, the operation method including calculating a used fuel quantity about fuel used in the satellite based on TM data; calculating an error with respect to a predicted velocity increment predicted for a station-keeping maneuver of the satellite, based on a velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to another aspect of the present invention, there is provided an operational method for an FDS, the operational method including receiving ranging data, angle observation data, and TM data related to a satellite; calculating an error with respect to a velocity increment for determining and predicting an orbit of the satellite, based on the TM data; determining and predicting the orbit of the satellite based on the velocity increment included in the ranging data, the angle observation data, and the TM data; and propagating the orbit of the satellite based on an orbit determination value related to the satellite and the error.
EFFECT
According to embodiments of the present invention, an error of a velocity increment planned for next station-maintaining maneuver is obtained using fuel quantity information, that is, information on a used fuel quantity related to fuel actually used in a satellite. In addition, the velocity increment is calculated using a fuel quantity calculated using accurate velocity increment information. As a result, an orbit of the satellite may be predicted more accurately.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects, features, and advantages of the invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a diagram illustrating an inner structure of a satellite control system for a geostationary satellite, according to an embodiment of the present invention;
FIG. 2 is a diagram illustrating a structure of a flight dynamics subsystem (FDS) according to an embodiment of the present invention;
FIG. 3 is a diagram illustrating a velocity increment calculation module according to an embodiment of the present invention;
FIG. 4 is a flowchart illustrating an operational method for an FDS, according to an embodiment of the present invention; and
FIG. 5 is a flowchart illustrating an operational method for a velocity increment calculation module, according to an embodiment of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Exemplary embodiments are described below to explain the present invention by referring to the figures.
FIG. 1 is a diagram illustrating an inner structure of a satellite control system 100 for a geostationary satellite, according to an embodiment of the present invention.
Referring to FIG. 1 , the satellite control system 100 may include an antenna 101 , a tracking, telemetry and command (TTC) subsystem 110 , a real-time satellite operation subsystem 120 , a flight dynamics subsystem (FDS) 130 , and a mission planning subsystem (MPS) 140 .
The satellite control system 100 may determine and predict an orbit of a satellite 102 , using orbit observation data observed by ranging and tracking with respect to the satellite 102 . Additionally, the satellite control system 100 may perform a station-maintaining maneuver so that the satellite 102 , that is a geostationary satellite, stays within a section of a nominal orbit maintaining limit.
The TTC subsystem 110 may generate ranging data and angle observation data through ranging and tracking with respect to the satellite 102 , receive telemetry data from the satellite 102 via the antenna 101 , and transmit tele-command data to the satellite 102 .
The real-time satellite operation subsystem 120 may perform direct operation of the satellite 102 . The real-time satellite operation subsystem 120 may receive the telemetry data of the satellite 102 from the TTC subsystem 110 , and process the received telemetry data so that an operator may check the telemetry data. In addition, the real-time satellite operation subsystem 120 may generate the tele-command data of the satellite 102 and transmit the tele-command data to the satellite 102 through the TTC subsystem 110 . The real-time satellite operation subsystem 120 may transmit telemetry data related to flight dynamics, among the received telemetry data, to the FDS 130 .
The FDS 130 may process various elements of flight dynamics data required for operation of the satellite 102 , that is, the geostationary satellite. That is, the FDS 130 may process ranging data and angle observation data, thereby determining and predicting an operational orbit. Additionally, the FDS 130 may estimate or calculate a bias of observation data for accurate determination and prediction of the operational orbit.
The FDS 130 may perform determination and prediction of a real-time operational orbit using data received from the TTC subsystem 110 or determination and prediction of a post-processed operational orbit. Depending on embodiments, the FDS 130 may selectively perform determination and prediction of one of the real-time operational orbit and the post-processed operational orbit, based on a mission designed in regard to the satellite 102 .
The FDS 130 may generate a dynamics model with respect to the satellite 102 to perform the orbit determination and prediction. In addition, the FDS 130 may design a filter for estimating the observation data.
The FDS 130 may select an estimation parameter with respect to the dynamics model or the observation data, and estimate a value of the selected estimation parameter.
The FDS 130 may calculate a velocity increment for the station-maintaining maneuver with respect to the satellite 102 , and store the calculated velocity increment in a database (DB).
The FDS 130 may calculate a fuel quantity for performing a maneuver, by thruster modeling.
The MPS 140 may receive a request related a payload from operators of various payloads, and schedule a mission of the satellite 102 by connecting the received request with various events of the satellite 102 . The MPS 140 may plan a remote command using a mission scheduling result and transmit the planned remote command to the real-time satellite operation subsystem 120 .
FIG. 2 is a diagram illustrating a structure of an FDS 200 according to an embodiment of the present invention.
Referring to FIG. 2 , the FDS 200 may include a receiving unit 210 , a velocity increment calculation unit 220 , and an orbit determination and prediction unit 230 .
The receiving unit 210 may receive ranging data and angle observation data related to a satellite from a TTC subsystem 201 . In addition, the receiving unit 210 may receive TM data from a real-time satellite operation subsystem 202 . Depending on embodiments, the receiving unit 210 may receive the TM data after the station-maintaining maneuver of the satellite is performed.
The velocity increment calculation unit 220 may calculate an error with respect to a velocity increment for determination and prediction of an orbit of the satellite, based on the TM data.
According to an aspect of the present invention, the velocity increment calculation unit 220 may calculate a used fuel quantity related to fuel used in the satellite, based on the TM data. Also, the velocity increment calculation unit 220 may calculate the error with respect to the velocity increment for determination and prediction of the orbit of the satellite, based on a velocity increment related to the used fuel quantity and a predicted velocity increment predicted for the station-keeping maneuver of the satellite.
The orbit determination and prediction unit 230 may determine and predict the orbit of the satellite based on the velocity increment included in the ranging data, the angle observation data, and the TM data. Also, the orbit determination and prediction unit 230 may propagate the orbit of the satellite based on an orbit determination value with respect to the satellite and the error.
According to another aspect of the present invention, the velocity increment calculation unit 220 may collect information on the velocity increment with respect to the used fuel quantity related to fuel used for a predetermined time, and on the predicted velocity increment predicted for station-keeping maneuver.
In addition, the velocity increment calculation unit 220 may generate pattern information related to the error, based on the collected information. Here, the orbit determination and prediction unit 230 may propagate the orbit of the satellite based on the pattern information. In addition, the orbit determination and prediction unit 230 may determine and predict the orbit based on the pattern information, by compensating the pattern information using the error of the velocity increment for station-maintaining maneuver.
The FDS 200 may further include a transmission unit 240 .
The transmission unit 240 may transmit information on the orbit of the satellite to an external observation site.
Hereinafter, a velocity increment calculation unit of an FDS according to an embodiment of the present invention will be described in further detail with reference to FIG. 3 .
FIG. 3 is a diagram illustrating a velocity increment calculation module 300 according to an embodiment of the present invention.
Referring to FIG. 3 , the velocity increment calculation module 300 may include a fuel quantity calculation unit 310 and an error calculation unit 320 .
The velocity increment calculation module 300 may calculate a velocity increment for determination and prediction of an orbit of a satellite. The velocity increment calculation module 300 may be included in an FDS in the form of a module. In this case, the velocity increment calculation module 300 may be the velocity increment calculation unit illustrated in FIG. 2 .
The error calculation unit 310 may calculate a used fuel quantity related to fuel used in the satellite, based on TM data.
The error calculation unit 320 may calculate an error with respect to a predicted velocity increment predicted for the station-maintaining maneuver of the satellite, based on a velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to an aspect of the present invention, the error calculation unit 320 may calculate the error by performing polynomial fitting that applies a least square method with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to another aspect of the present invention, the error calculation unit 320 may calculate an error in a radial direction, an error in an in-track direction, and an error in a cross-track direction with respect to the predicted velocity increment, based on the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
The error calculation unit 320 may calculate the error in the radial direction with respect to the predicted velocity increment, using Equation 1 below. In detail, the error calculation unit 320 may calculate the error in the radial direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
[
Δ
V
r
1
Δ
V
r
2
⋮
Δ
V
ri
]
=
[
⋱
x
2
x
1
x
2
x
1
⋮
⋮
⋮
]
[
ar
br
⋮
]
↵
[
Equation
1
]
In addition, the error calculation unit 320 may calculate the error in the in-track direction with respect to the predicted velocity increment, using Equation 2 below. In more detail, the error calculation unit 320 may calculate the error in the in-track direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
[
Δ
V
I
1
Δ
V
I
2
⋮
Δ
V
Ii
]
=
[
⋱
x
2
x
1
x
2
x
1
⋮
⋮
⋮
]
[
aI
bI
⋮
]
↵
[
Equation
2
]
In addition, the error calculation unit 320 may calculate the error in the cross-track direction with respect to the predicted velocity increment, using Equation 3 below. In detail, the error calculation unit 320 may calculate the error in the cross-track direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
[
Δ
V
C
1
Δ
V
C
2
⋮
Δ
V
Ci
]
=
[
⋱
x
2
x
1
x
2
x
1
⋮
⋮
⋮
]
[
a
c
bc
⋮
]
↵
[
Equation
3
]
In Equations 1, 2, and 3, ΔV r =V FA — r −V SK — r , ΔV I =V FA — I −V SK — I , and ΔV C =V FA — C −V SK — C . Also, FA denotes a fuel account and SK denotes station-maintaining.
According to another aspect of the present invention, the error calculation unit 320 may include a collector 321 and a pattern information generator 322 .
The collector 321 may collect information on the velocity increment with respect to the used fuel quantity related to fuel used for a predetermined time, and on the predicted velocity increment.
The pattern information generator 322 may generate pattern information related to the error, based on the collected information.
FIG. 4 is a flowchart illustrating an operational method for an FDS, according to an embodiment of the present invention.
Referring to FIG. 4 , the operational method receives ranging data and angle observation data related to a satellite from a TTC subsystem. Also, the operational method receives TM data from a real-time satellite operation subsystem in operation 410 . Depending on embodiments, the operation method may receive the TM data after the station-maintaining maneuver of the satellite is performed.
In operation 420 , the operational method may calculate an error with respect to a velocity increment for determining and predicting an orbit of the satellite, based on the TM data.
According to an aspect of the present invention, the operational method may calculate a used fuel quantity related to fuel used in the satellite, based on the TM data. Also, the operational method may calculate an error with respect to a predicted velocity increment predicted for the station-maintaining maneuver of the satellite, based on a velocity increment with respect to the used fuel quantity and the predicted velocity increment.
In operation 430 , the operational method may determine and predict the orbit of the satellite based on the velocity increment included in the ranging data, the angle observation data, and the TM data. In addition, the operational method may propagate the orbit of the satellite based on an orbit determination value with respect to the satellite and the error.
According to another aspect of the present invention, the operational method may collect information on the velocity increment with respect to the used fuel quantity for a predetermined time and the predicted velocity increment.
In addition, the operational method may generate pattern information related to the error, based on the collected information. Here, the operational method may propagate the orbit of the satellite based on the pattern information. Furthermore, the operational method may determine and predict the orbit based on the pattern information, by balancing the pattern information using the error of the velocity increment for station-maintaining maneuver.
According to an aspect of the present invention, the operational method may transmit information on the orbit of the satellite to an external observation site.
FIG. 5 is a flowchart illustrating an operational method for a velocity increment calculation module, according to an embodiment of the present invention.
Referring to FIG. 5 , in operation 510 , the operational method calculates a fuel quantity used in the satellite based on TM data.
In operation 520 , the operational method calculates an error with respect to a velocity increment predicted for a station-maintaining maneuver of the satellite, based on a velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to an aspect of the present invention, the operational method may calculate the error by performing the polynomial fitting that applies the least square method, with respect to the velocity increment, with respect to the used fuel quantity and the predicted velocity increment.
According to another aspect of the present invention, the operational method may calculate an error in a radial direction, an error in an in-track direction, and an error in a cross-track direction with respect to the predicted velocity increment, based on the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
The operational method may calculate the error in the radial direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
The operational method may calculate the error in the in-track direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
The operational method may calculate the error in the cross-track direction by performing the polynomial fitting that applies the least square method, with respect to the velocity increment with respect to the used fuel quantity and the predicted velocity increment.
According to still another aspect of the present invention, the operational method may collect information on the velocity increment with respect to the used fuel quantity for a predetermined time and the predicted velocity increment. In addition, the operational method may generate pattern information related to the error based on the collected information.
The above-described embodiments of the present invention may be recorded in non-transitory computer-readable media including program instructions to implement various operations embodied by a computer. The media may also include, alone or in combination with the program instructions, data files, data structures, and the like. The program instructions recorded on the media may be those specially designed and constructed for the purposes of the embodiments, or they may be of the kind well-known and available to those having skill in the computer software arts. Examples of non-transitory computer-readable media include magnetic media such as hard disks, floppy disks, and magnetic tape; optical media such as CD ROM discs and DVDs; magneto-optical media such as optical discs; and hardware devices that are specially configured to store and perform program instructions, such as read-only memory (ROM), random access memory (RAM), flash memory, and the like. Examples of program instructions include both machine code, such as produced by a compiler, and files containing higher level code that may be executed by the computer using an interpreter. The described hardware devices may be configured to act as one or more software modules in order to perform the operations of the above-described embodiments of the present invention, or vice versa.
Although a few exemplary embodiments of the present invention have been shown and described, the present invention is not limited to the described exemplary embodiments. Instead, it would be appreciated by those skilled in the art that changes may be made to these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
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A flight dynamics subsystem (FDS), a velocity increment calculation module, and operational methods of the same are provided. A used fuel quantity actually used in a satellite is calculated, and a velocity increment is calculated using the calculated fuel quantity. Therefore, an orbit of the satellite may be estimated more accurately.
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FIELD OF THE INVENTION
[0001] The present invention relates to fluorous tagging compounds and to methods of increasing the fluorous nature of compounds.
BACKGROUND OF THE INVENTION
[0002] Organic chemists are typically trained that organic compounds have to be synthesized as pure substances through well-planned reactions and scrupulous separation. In fields such as drug discovery, catalyst design and new material development, however, tens of thousands of organic compounds must be synthesized and tested to discover a few active ones. In the pharmaceutical industry, for example, synthesizing such a large number of compounds in the traditional way is too slow compared to the rapid emergence of new biological targets. A major factor limiting the productivity of orthodox solution (liquid) phase organic synthesis is the tedious separation process for the purification of products. High throughput organic synthesis, therefore, preferably integrates organic reactions with rapid purification/separation procedures.
[0003] Recently, fluorous synthetic and separation techniques have attracted the interest of organic chemists. In fluorous synthetic techniques, reaction components are typically attached to fluorous groups such as perfluoroalkyl groups to facilitate the separation of products. In general, fluorous-tagged molecules partition preferentially into a fluorous phase while non-tagged ones partition into an organic phase. Although fluorous synthetic and/or separation techniques are promising, such techniques are currently limited by a lack of availability of suitable fluorous tags.
[0004] It is thus very desirable to develop fluorous tagging compounds and methods of increasing the fluorous nature of compounds.
SUMMARY OF THE INVENTION
[0005] In one aspect, the present invention provides a method of increasing the fluorous nature of a compound. The method includes the step of reacting the compound with at least one second compound having the formula:
wherein Rf is a fluorous group (for example, a fluoroalkyl group, a fluorinated ether or another highly fluorinated group), Rs is a spacer group, d is 1 or 0 (that is, Rs may be present or absent), m is 1, 2 or 3, Ra is an alkyl group and X is a suitable leaving group. Suitable leaving groups include, but are not limited to, a halide (F, Cl, Br or I), —N 3 , CN, RO—, NH 2 O—, NHRO—, NR 2 O—, RCO 2 —, ROCO 2 —, RNCO 2 —, RS—, RC(S)O—, RCS 2 —, RSC(O)S—, RSCS 2 —RSCO 2 —, ROC(S)O—, ROCS 2 —, RSO 2 —, RSO 3 —, ROSO 2 —, ROSO 3 —, RPO 3 —, ROPO 3 —, an N-imidazolyl group, an N-triazolyl group, an N-benzotriazolyl group, a benzotriazolyloxy group, an imidazolyloxy group, an N-imidazolinone group, an N-imidazolone group, an N-imidazolinethione group, an N-imidazolinthione group, an N-succinimidyl group, an N-phthalimidyl group, an N-succinimidyloxy group, an N-phthalimidyloxy group, —ON═C(CN)R, or a 2-pyridyloxy group. R is preferably an alkyl group or an aryl group.
[0006] The terms “alkyl”, “aryl” and other groups refer generally to both unsubstituted and substituted groups unless specified to the contrary. Unless otherwise specified, alkyl groups are hydrocarbon groups and are preferably C 1 -C 15 (that is, having 1 to 15 carbon atoms) alkyl groups, and more preferably C 1 -C 10 alkyl groups, and can be branched or unbranched, acyclic or cyclic. The above definition of an alkyl group and other definitions apply also when the group is a substituent on another group. The term “aryl” refers to phenyl (Ph) or napthyl, substituted or unsubstituted. The terms “alkylene” refers to bivalent forms of alkyl.
[0007] The groups set forth above, can be substituted with a wide variety of substituents. For example, alkyl groups may preferably be substituted with a group or groups including, but not limited to, halide(s). Preferably, halide constituents are F and/or Cl. Aryl groups may preferably be substituted with a group or groups including, but not limited to, halide(s), alkyl group(s), a cyano group(s) and nitro group(s). As used herein, the terms “halide” or “halo” refer to fluoro, chloro, bromo and iodo. Preferred halide substituents are F and Cl.
[0008] The resulting fluorous “tagged” compound can be used in a variety of fluorous reaction and/or separation techniques. Such fluorous reaction and separation techniques are disclosed, for example, in U.S. Pat. Nos. 5,859,247 and 5,777,121 and U.S. patent application Ser. No. 09/506,779, assigned to the assignee of the present invention, the disclosures of which are incorporated herein by reference.
[0009] Preferably, the molecular weight of the fluorous tag of the present invention does not exceed about 2,500. More preferably, the molecular weight does not exceed about 2,000. Even more preferably the molecular weight does not exceed about 1,750. Compounds may bear more than one fluorous tag of the present invention.
[0010] In another aspect, the present invention provides a compound (a fluorous tagging compound) having the formula:
wherein Rf is a fluorous group (for example, a fluoroalkyl group, a fluorinated ether or another highly fluorinated group), n is an integer between 0 and 6, m is 1, 2 or 3, Ra is an alkyl group and X is a leaving group. Ra is preferably C 1 -C 6 alkyl group.
[0011] As used herein, the term “fluorous”, when used in connection with an organic (carbon-containing) molecule, moiety or group, refers generally to an organic molecule, moiety or group having a domain or a portion thereof rich in carbon-fluorine bonds (for example, fluorocarbons or perfluorocarbons, fluorohydrocarbons, fluorinated ethers and fluorinated amines). The term “fluorous compound,” thus refers generally to a compound comprising a portion rich in carbon-fluorine bonds. As used herein, the term “perfluorocarbons” refers generally to organic compounds in which all hydrogen atoms bonded to carbon atoms have been replaced by fluorine atoms. The terms “fluorohydrocarbons” and “hydrofluorocarbons” include organic compounds in which at least one hydrogen atom bonded to a carbon atom has been replaced by a fluorine atom. A few examples of suitable fluorous groups Rf for use in the present invention include, but are not limited to, —C 4 F 9 , —C 6 F 13 , —C 8 F 17 , —C 10 F 21 , —C(CF 3 ) 2 C 3 F 7 , —C 4 F 8 CF(CF 3 ) 2 , and —CF 2 CF 2 OCF 2 CF 2 OCF 3 .
[0012] As used herein, the term “tagging” refers generally to attaching a fluorous moiety or group (referred to as a “fluorous tagging moiety” or “tagging group”) to a compound to create a “fluorous tagged compound”. Separation of the tagged compounds of the present invention is achieved by using fluorous separation techniques that are based upon differences between/among the fluorous nature of a mixture of compounds. As used herein, the term “fluorous separation technique” refers generally to a method that is used to separate mixtures containing fluorous molecules or organic molecules bearing fluorous domains or tags from each other and/or from non-fluorous compounds based predominantly on differences in the fluorous nature of molecules (for example, size and/or structure of a fluorous molecule or domain or the absence thereof). Fluorous separation techniques include but are not limited chromatography over solid fluorous phases such as fluorocarbon bonded phases or fluorinated polymers. See, for example, Danielson, N. D. et al., “Fluoropolymers and Fluorocarbon Bonded Phases as Column Packings for Liquid Chromatography,” J. Chromat., 544, 187-199 (1991). Examples of suitable fluorocarbon bonded phases include commercial Fluofix® and Fluophase™ columns available from Keystone Scientific, Inc. (Bellefonte, Pa.), and FluoroSep™-RP-octyl from ES Industries (Berlin, N.J.). Other fluorous separation techniques include liquid-liquid based separation methods such as liquid-liquid extraction or countercurrent distribution with a fluorous solvent and an organic solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates synthesis and introduction of fluorous BOC groups.
[0014] FIG. 2 illustrates synthesis of a fluorous BOC reagent of the present invention and its attachment to an amine and detachment from the resulting amide.
[0015] FIG. 3 illustrates recovery of a fluorous BOC compound of the present invention.
[0016] FIG. 4 illustrates the utility of fluorous BOC compounds of the present invention in separating a library of compounds.
[0017] FIG. 5 illustrates the structure of several amides generated from fluorous BOC tagging compounds of the present invention.
[0018] FIG. 6 illustrates several products generated by deprotection of fluorous BOC protected amines.
[0019] FIG. 7 illustrates fluorous BOC groups with different fluorine content and spacer groups.
[0020] FIG. 8 illustrates the synthesis of the 96-compound library that is described in Example 15.
[0021] FIG. 9 illustrates the isolated yields of the 96-compound library of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] Carbamates are an important class of protecting group for nitrogen. For example, virtually all peptide synthesis schemes rely on carbamate protecting groups of some sort, and carbamates are commonly used in alkaloid synthesis and other areas. One of the most useful carbamates is the tert-butyloxycarbonyl group (commonly referred to as the “BOC” group) illustrated below:
In the present invention, a new class of fluorous carbamates referred to herein as fluorous BOC compounds or groups were synthesized after the BOC group. The fluorous tagging groups of the present invention can, for example, be reacted with nitrogen-bearing groups such as amine groups (—NR 1 R 2 ) of compounds to create a fluorous-tagged (or protected) compound.
[0023] The fluorous BOC ( F BOC) groups of the present invention generally act like traditional BOC and other carbamate groups to protect nitrogen-based functional groups during organic reactions. Protecting groups are discussed generally in Greene, T. W.; Wuts, P. G. M. Protective Groups in Organic Synthesis; 3rd ed.; Wiley-Interscience: New York, (1999) and Kocienski, P. “Protecting groups”, Thieme : Stuttgart (1994). However, the fluorous BOC groups of the present invention have advantages over other traditional carbamate and other protecting groups in that they facilitate separation of the F BOC-protected (fluorous-tagged) products from each other and from non-tagged reaction components. Additionally, the fluorous domain of the fluorous BOC groups are useful not only for attachment to nitrogen, but also to oxygen, sulfur and other heteroatoms. The resulting F BOC carbonates, thiocarbamates, etc. serve substantially the same purpose and are used analogously to the F BOC carbamates described in greater detail herein.
[0024] The reagents used for the protection of amines with fluorous BOC groups are generally prepared as shown in FIG. 1 . Fluorous alcohols 1a-c bearing one, two or three fluorous chains are readily synthesized, for example, by nucleophilic addition reactions. Addition of an organometallic reagent Rf(CH 2 ) n M (wherein, M is, for example, lithium, magnesium halide, etc. and Rf is a fluorous group) to an appropriate ketone generates an alcohol 1a with one fluorous chain and two alkyl groups. Similarly, alcohols with two fluorous chains 1b can be generated by organometallic addition to esters, acids chlorides or related molecules, and alcohols with three fluorous chains 1c can be generated by nucleophilic additions to carbonate esters, phosgene, or related molecules. The alcohols with two and three fluorous chains prepared by these routes usually contain the same fluorous group, but alcohols, with different fluorous groups can be prepared by several routes. For example, addition of Rf 1 (CH 2 ) n1 M to an aldehyde followed by oxidation of the resulting secondary alcohol and addition of Rf 2 (CH 2 ) n2 M results in an alcohol with two different fluorous chains (Rf 1 and Rf 2 ) spaced by alkylene spacers that can be the same or different. A series of fluorous alcohols with different numbers of fluorines is useful, for example, in fluorous mixture synthesis techniques. See, U.S. patent application Ser. No. 09/506,779.
[0025] Fluorous BOC reagents 3 can be prepared by one of many schemes known to those skilled in the art for the conversion of standard alcohols to activated carbamoylating agents. For example, alcohols bearing one fluorous chain and two alkyl groups can react with one of many reagents 2, which can be considered as doubly activated derivatives of carbonic acids. In FIG. 1 , the leaving group (X) is a part of the molecule that is cleaved in the substitution reaction. Many different leaving groups suitable for use in the present invention are known to those skilled in the art. For the purposes of this invention, leaving groups whose conjugate acids have a pKa of less than about 18 are preferred. Leaving groups whose conjugate acids have a pKa of less than about 10 are more preferred. Even more preferred are leaving groups whose conjugate acids have a pKa of less than about 5. In a preferred method, the fluorous alcohol 1a is first reacted with the reagent 2 to displace the first leaving group to give 3. The intermediate BOC reagent 3 may be isolated prior to reaction with an amine under standard conditions, or it may be reacted directly with the amine in situ without isolation. Either or both of the acylation reactions may be catalyzed by standard catalysts known to those skilled in the art. An example on one such acylation catalyst is 4-dimethylaminopyridine (DMAP). Fluorous BOC reagents with two or three fluorous chains are prepared and reacted analogously to those with one chain.
[0000] Reactions and Compounds in the Examples:
[0026] The synthesis of a representative fluorous BOC ( F BOC) reagent 7 of the present invention and its attachment to a typical amine 8 and detachment from the resulting amide 9 are shown in FIG. 2 . Reaction of perfluorooctylethyl iodide with t-BuLi followed by addition of acetone and workup and chromatographic purification provided the alcohol 5 in 60% yield. Activated reagent 6 was generated according to the literature methods set forth in M. Itoh, et. al, Bull. Chem. Soc. Jpn., 50, 718 (1977), and then reacted with alcohol 5. Workup and chromatography provided the representative F BOC reagent 7 as a solid. Protection of amino amide 8 with the F BOC reagent 7 was accomplished under standard conditions and gave F BOC derivative 9 in quantitative yield. F BOC-protected 9 could be deprotected to regenerate 8 by treatment with neat TFA for 40 min followed by evaporation and vacuum drying to remove the fluorous BOC remnants and other volatile compounds. The fluorous BOC remnants can also be removed by solid phase extraction over fluorous reverse phase silica gel.
[0027] The ability to recover the fluorous BOC component for reuse is demonstrated by the results of FIG. 3 . Coupling of 7 with dimethyl amine provided 10 in 95% yield. Cleavage of 10 with 30/70 CH 2 Cl 2 /TFA followed by evaporation provided the trifluoroacetate 11 in 100% yield. Trifluoroacetate 11 was hydrolyzed by treatment with lithium hydroxide in methanol to provide the starting alcohol 5 in 87% yield.
[0028] To demonstrate the utility of the fluorous BOC group in facilitating reaction separation, a 16 compound library of amides was made by parallel synthesis as shown in FIG. 4 . Amines 12a-d were reacted with the F BOC reagent 7 as in FIG. 2 to give F BOC protected acids 13a-d. Each of the four acids was coupled with amines 14a′-d′ under standard amide formation conditions using 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDI), N-hydroxybenzotriazole (HOBt), and triethylamine (Et 3 N). These reaction mixtures were purified by solid phase extraction using a commercially available semi-preparative Fluofix column. The fluorous tagged products are readily separated from all non-tagged reaction components. Yields and structures for the coupled products 15aa′-dd′ are illustrated in FIG. 5 .
[0029] To demonstrate the removal of the fluorous BOC group, four of the products were heated in 3N HCl/MeOH at 60° C. for 16 h. All the volatile products (including the residual fluorous products) were removed by exposure to high vacuum, and hen the yields of the final amine hydrochlorides were determined by NMR analysis as described in the Examples. These products are shown in FIG. 6 . A second library of eight amines involving the steps of F BOC protection, amide formation with rapid purification by fluorous solid phase extraction, and removal of the F BOC group with TFA, is also described in Example 15. The resulting secondary amines were used to make 96 tertiary amines.
[0030] The amides shown in FIG. 7 were prepared to demonstrate that other fluorous BOC groups with different numbers of fluorous chains and different spacer elements could also be used. The syntheses of the respective F BOC precursors and the amides themselves are described in the Examples. The retention times of amides 16a-c were then measured on an analytical Fluofix column, eluting with the gradient shown in FIG. 7 . The retention times of these amides are all longer than that of amide 9. This is expected because they have more fluorines. Under these conditions, most non-fluorous tagged organic compounds have retention times at or near the solvent front (approximately 2-3 minutes). Since 9 can be separated by fluorous solid phase extraction, it follows that the more strongly retained amides 16a-c will also be separable from non-tagged compounds by solid phase extraction.
EXPERIMENTAL EXAMPLES
Example 1
[0031] Authentic Sample of (3,4-Dihydro-1H-isoquinolin-2-yl)piperidin-4-yl-methanone (8). N-Trifluoroacetyl isonipecotic acid (2.56 g, 11.4 mmol), tetrahydroisoquinoline (1.82 g, 13.7 mmol), EDCI (2.63 g, 13.7 mmol), HOBT (1.85 g, 13.7 mmol) and triethylamine (1.38 g, 13.7 mmol) were stirred in dry dichloromethane (30 mL) at 25° C. for 6 h. The reaction was quenched with water and the aqueous phase was extracted with dichloromethane. The combined organic phase was dried over MgSO 4 and purified by column chromatography (40/60 EtOAc/hexanes). The solid obtained was stirred with excess K 2 CO 3 in MeOH at 25° C. overnight (16 h). After evaporation of MeOH, the residue was partitioned between dichloromethane and basic water. Evaporation of the organic phase gave pure product as a colorless solid (2.12 g, 76% for two steps). 1 H NMR (CDCl 3 ) (mixture of two rotamers) δ 7.23-7.16 (m, 4H), 4.73 (s, 1H), 0.4.67 (s, 1H), 3.83 (t, J=5.9 Hz, 1H), 3.74 (t, J=5.8 Hz, 1H), 3.21-3.16 (m, 2H), 2.92 (t, J=5.7 Hz, 1H), 2.85 (t, J=5.7 Hz, 1H), 2.76-2.67 (m, 3H), 2.29 (s, 1H), 1.80-1.73 (m, 4H); 13 C NMR (CD 3 OD-CDCl 3 ) δ 175.5, 175.3, 135.8, 135.1, 134.0, 133.8, 129.6, 129.3, 127.9, 127.6, 127.4, 127.3, 127.0, 48.2, 45.8, 45.4, 0.44.2, 41.4, 40.2, 39.6, 39.5, 30.5, 29.5, 29.4, 29.1; LRMS: m/z (relative intensity), 244 (M + , 37%), 188 (100%), 132 (74%); HRMS: calcd. for C 15 H 19 N 2 O 244.1576, found 244.1574. MP: 75-76° C.
Example 2
[0032] 1,5-Bis(perfluorohexyl)-3-methylpentan-3-ol. A portion of 2-perfluorohexylethyl iodide (1.0 mL) was added to a suspension of Mg powder (0.85 g, 35.0 mmol) in dry diethyl ether (5 mL) under argon. The mixture was sonicated for 30 min. To the resulting suspension, a solution of 2-perfluorohexylethyl iodide (total 7.8 ml, 31.8 mmol) in dry diethyl ether (40 mL) was added over 40-60 min. Upon completion of addition, the dark mixture was stirred at reflux for 1 h. After cooling down to room temperature, a solution of ethyl acetate (0.9 mL, 11.1 mmol) in diethyl ether (4.0 mL) was added slowly. The mixture was stirred at room temperature overnight before quenching with saturated aqueous NH 4 Cl. The aqueous phase was extracted with diethyl ether (3×20 mL). The ether phase was combined and dried over MgSO 4 . After evaporation of solvent, the residue was purified by column chromatography with 5:95 ethyl acetate-hexane. The title compound obtained was further recrystallized twice from chloroform to give colorless needles (5.18 g, 79%). 1 H NMR (CDCl 3 ) δ 2.34-2.10 (m, 4H), 1.89-1.68 (m, 4H), 1.28 (s, 3H), 1.17 (s, 1H); 13 C NMR (CDCl 3 ) δ 70.5, 32.0, 26.2, 25.7 (t); IR (Nujol) 3467, 2923, 1461, 1369, 1244, 1140, 1051, 701, 521 cm −1 ; LRMS m/z: 1491 (50%), 1145 (5%), 723 (42%), 375 (100%); HRMS found: C, 29.04%, H, 1.62%. Calcd.: C, 29.28%, 1.64%. MP: 57-58° C.
Example 3
[0033] O-Bis(perfluorohexylethyl)ethyloxycarbonyloxyiminophenylacetonitrile. To a sample tube sealed under argon was charged with a solution of phosgene in toluene (0.27 mL, 0.55 mmol) and the solution was cooled to 0° C. A solution of 2-hydroxyimino-2-phenylacetonitrile (75 mg, 0.51 mmol) and dimethylaniline (70 uL, 0.55 mmol) in THF (0.2 mL) and benzene (0.2 mL) was added dropwise to the ice-cooled solution. The mixture was stirred at 0° C. for 6 h. The mixture was placed in a freezer (−20° C.) overnight before returning to the ice bath. A solution of the alcohol from Example 2 (0.39 g, 0.55 mmol) and pyridine (45 uL, 0.55 mmol) in THF (3.0 mL) was added dropwise. The orange mixture was stirred at 0° C. for 6 h and allowed to warm to room temperature over night. The suspension was quenched with water and extracted with diethyl ether. The organic phase was dried over MgSO 4 . After removal of solvent, the residue was purified by column chromatography with 5:95 ethyl acetate-hexanes to give pure product as a white gum (223 mg, 49%). 1 H NMR (CDCl 3 ) δ 7.95 (d, J=7.5 Hz, 2H), 7.61 (t, J=7.3 Hz, 1H), 7.51 (t, J=7.7 Hz, 2H), 2.42-2.08 (m, 8H), 1.66 (s, 3H); 13 C NMR (CDCl 3 ) δ 149.7, 138.7, 133.3, 129.4, 127.6, 108.2, 86.1, 28.8, 25.6 (t), 22.8; IR (thin film): 1795, 1450, 1240, 1023, 940, 729 cm −1 ; FABMS m/z: 910 (M + , absent), 867 (M + −CO 2 , 21%), 721 (100%), 681 (16%).
Example 4
[0034] 1,7-Bis(perfluorobutyl)-4-methylheptan-4-ol. To a solution of 3-perfluorobutylpropyl iodide (688 mg, 1.77 mmol) in a mixture of dry diethyl ether and dry hexane (25 mL, 1:1 v/v) was added t BuLi (2.2 mL, 1.7 M in pentane, 3.74 mmol) at −78° C. The mixture was stirred for 1 h during which time the temperature increased to −35° C. After cooling to −78° C., acetyl chloride (57 uL, 0.80 mmol) was added dropwise. The cooling bath was removed and the reaction mixture was stirred for 1 h. Water was added to quench the reaction. After extraction with ether, the organic phase was dried over MgSO 4 and evaporated to dryness. The crude product was purified by column chromatography with 5:95 ethyl acetate-hexane to give the alcohol as a yellow oil (103 mg, 23%). 1 H NMR (CDCl 3 ) δ 2.19-2.01 (m, 4H), 1.76-1.68 (m, 4H), 1.67-1.53 (m, 4H), 1.24 (s, 3H); 13 C NMR (CDCl 3 ) δ 121.8-110.8 (m), 72.4, 41.4, 31.3, 26.7, 15.1; LRMS m/z (relative intensity) 551 (M + −Me, 15%), 305 (100%); HRMS found: 551.0676, calcd. for C 15 H 13 F 18 O: 551.0679; IR (thin film): 3147, 2975, 1468, 1356, 1206, 880, 720 cm −1 .
Example 5
[0035] 1,7-Bis(perfluorohexyl)-4-methylheptan-4-ol. This compound was prepared by the same procedure as Example 4 but ethyl acetate was used instead of acetyl chloride. Yield: 68% (white solid). 1 H NMR (CDCl 3 ) δ 2.13-2.04 (m, 4H), 1.76-1.66 (m, 4H), 1.64-1.53 (m, 4H), 1.24 (s, 3H); 13 C NMR (CDCl 3 ) δ 122.0-107.0 (m), 72.4, 41.4, 31.4 (t), 26.5, 15.1; 19 F NMR (CDCl 3 ) δ −81.2 (3F), −114.8 (2F), −122.4 (2F), −123.4 (2F), −124.1 (2F), −126.6 (2F); LRMS: m/z (relative intensity) 751 (M + −Me, 77%), 709 (24%), 405 (100%); HRMS found: 751.0570, calcd. for Cl 19 H 13 OF 26 : 751.0566; MP: 46-47° C.
Example 6
[0036] 4-Perfluorooctyl-2-methylbutan-2-ol (5). This compound was prepared by the same procedure as Example 4 but acetone was used instead of acetyl chloride. Yield: 60% (white solid). 1 H NMR (CDCl 3 ) δ 2.32-2.14 (m, 2H), 1.78-1.73 (m, 2H), 1.29 (s, 6H); 13 C NMR (CDCl 3 ) δ 122.4-107.4 (m), 69.9, 33.5, 29.4, 26.2 (t); LRMS m/z (relative intensity) 505 (M + −H, 12%), 491 (M + −Me, 100%); HRMS found: 491.0306; calcd. for C 12 H 8 F 17 O: 491.0304. MP: 50-51° C.
Example 7
[0037] O-Bis(perfluorobutylpropyl)ethoxycarbonyloxyiminophenylacetontrile. This compound was prepared by the same procedure as Example 3. Yield: 27% (gum). 1 H NMR (CDCl 3 ) δ 7.95 (d, J=8.1 Hz, 2H), 7.60 (t, J=7.2 Hz, 1H), 7.51 (t, J=7.5 Hz, 2H), 2.20-1.91 (m, 8H), 1.79-1.71 (m, 4H), 1.62 (s, 3H); 13 C NMR (CDCl 3 ) δ 150.0, 138.3, 133.2, 129.4, 127.6, 121.5-114.8 (m), 108.4, 88.7, 37.5, 30.8 (t), 23.1, 14.8; LRMS m/z (relative intensity) 761 (M + +Na), 548 (45%), 305 (100%), 287 (90%). IR (thin film): 2982, 1795, 1234, 1132, 1022, 878 cm −1 .
Example 8a
[0038] O-(Perfluorooctylethyl)isopropanoxycarbonyloxyiminophenylacetonitrile (7). This compound was prepared by the same procedure as Example 3. Yield: 61% (orange solid). 1 H NMR (CDCl 3 ) δ 7.95 (d, J=8.1 Hz, 2H), 7.60 (t, J=6.9 Hz, 1H), 7.51 (t, J=7.8 Hz, 2H), 2.29-2.15 (m, 4H), 1.66 (s, 6H); 13 C NMR (CDCl 3 ) δ 150.0, 138.3, 133.3, 129.5, 127.9, 127.7, 111.0, 85.9, 31.5, 25.7; 19 F NMR (CDCl 3 ) δ −79.6 (3F), −113.2 (2F), −120.7 (6F), −121.5 (2F), −121.9 (2F), −124.9 (2F); LRMS: 634 (16%), 615 (10%), 489 (100%); MP: 76-78° C.
Example 8b
4-(3,4-Dihydro-1H-isoquinoline-2-carbonyl)-piperidine-1-carboxylic Acid 4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-heptadecafluoro-1,1,-dimethyl-undecyl Ester
[0039] A solution of compound 7 (89 mg, 0.13 mmol) and compound 8 (29 mg, 0.12 mmol) in dichloromethane (4 ml) was stirred at room temperature for 2 h. The mixture was evaporated to dryness. The residue was purified by column chromatography (3:1 EtOAc/hexanes) to give compound 9 (93 mg, 100%) as a white solid. 1 H NMR (CDCl 3 ) δ 7.22-7.14 (m, 4H), 4.74 (s, 1H), 4.68 (s, 1H), 4.23-4.07 (br, 2H), 3.8 (br, 1H), 3.74 (t, J=2.9 Hz, 1H), 2.96-2.74 (m, 5H), 2.22-2.01 (m, 4H), 1.74 (br, 4H), 1.51 (s, 6H); 13 C NMR (CDCl 3 ) δ 173.4, 173.2, 154.2, 135.3, 133.9, 133.6, 132.6, 129.3, 128.5, 127.3, 126.9, 126.8, 126.6, 126.1, 47.5, 44.7, 43.8, 43.3, 40.2, 39.1, 38.9, 32.1, 30.0, 28.5, 26.2; LRMS: 776 (M + , 15%) 757 (27%), 739 (22%), 243 (100%), 188 (60%), 132 (45%); HRMS: calcd. for C 29 H 29 N 2 O 3 F 17 : 776.1907, found 776.1894. MP: 114-116° C.
Example 9
[0040] 4-(3,4-Dihydro-1H-isoquinoline-2-carbonyl)piperidine-1-carboxylic acid 1-perfluorooctylethylisopropyl ester (16a). The fluorous Boc reagent from Example 3 (89 mg, 0.13 mmol), the compound in Example 1 (29 mg, 0.12 mmol) and triethylamine (20 mg, 20.0 mmol) were mixed in dry dichloromethane (4.0 mL) and stirred at room temperature for 2 h. After evaporation of solvent, the residue was purified by column chromatography with 30:70 ethyl acetate-hexane to give pure product as a white solid. Yield: 93 mg (96%); Rf=0.22 (30:70 ethyl acetate-hexane); 1 H NMR (mixture of two rotamers) (CDCl 3 ) δ 7.22-7.14 (m, 4H), 4.74 (s, 1H), 4.68 (s, 1H), 4.23-4.07 (br, 2H), 3.85 (br, 1H), 3.74 (t, J=5.8 Hz, 1H), 2.95-2.74 (m, 5H), 2.22-2.05 (m, 4H), 1.74 (br, 4H), 1.52 (s, 6H); 13 C NMR (CDCl 3 ) δ 173.4, 173.2, 154.2, 135.3, 134.0, 133.6, 132.6, 129.3, 128.5, 127.3, 126.9, 126.8, 126.6, 126.1, 122.8-107.3 (m), 79.9, 47.5, 44.7, 43.8, 43.3, 40.2, 39.1, 38.9, 32.1, 30.0, 28.5, 26.2; LRMS: m/z (relative intensity) 776 (M + , 14%), 757 (M + −F, 25%), 739 (M + −2F, 20%), 489 (11%), 287 (20%), 271 (24%), 243 (100%), 188 (60%), 132 (45%); HRMS calcd. for C 29 H 29 N 2 O 3 F 17 : 776.1907, found: 776.1894; MP: 115° C.
Example 10
[0041] Compound 16b. This compound was prepared by the same procedure as Example 9 with the fluorous Boc reagent from Example 8. Yield: 79% (yellowish oil); 1 H NMR (CDCl 3 ) δ 7.22-7.14 (m, 4H), 4.74 (s, 1H), 4.68 (s, 1H), 4.16 (br, 2H), 3.85 (br, 1H), 3.74 (t, J=5.8 Hz, 1H), 2.95-2.74 (m, 5H), 2.18-2.00 (m, 6H), 1.75-1.60 (m, 10H), 1.46 (s, 3H); 13 C NMR (CDCl 3 ) δ 173.4, 173.2, 154.2, 135.3, 134.0, 133.7, 132.7, 129.5, 129.0, 128.7, 128.2, 127.5, 127.0, 126.7, 126.3, 125.0, 123.3-108.7 (m), 82.7, 47.6, 44.7, 43.3, 40.2, 39.0, 38.7, 38.3, 37.9, 31.4, 30.8, 30.3, 30.0, 28.5 (t), 24.6, 23.7, 14.9 (t); LRMS: m/z (relative intensity) 835 (M + −H, 35%), 817 (M + −F, 23%), 548 (17%), 287 (77%), 243 (100%), 188 (72%), 132 (71%).
Example 11
[0042] Compound 16c. This compound was prepared by the same procedure as Example 9 with the fluorous Boc reagent from Example 7. Yield: 100% (white solid); 1 H NMR (CDCl 3 ) δ 7.22-7.14 (m, 4H), 4.74 (s, 1H), 4.68 (s, 1H), 4.23-4.07 (br, 2H), 3.8 (br, 1H), 3.74 (t, J=2.9 Hz, 1H), 2.96-2.74 (m, 5H), 2.22-2.01 (m, 4H), 1.74 (br, 4H), 1.51 (s, 6H); 13 C NMR (CDCl 3 ) δ 173.4, 173.2, 154.2, 135.3, 133.9, 133.6, 132.6, 129.3, 128.5, 127.3, 126.9, 126.8, 126.6, 126.1, 47.5, 44.7, 43.8, 43.3, 40.2, 39.1, 38.9, 32.1, 30.0, 28.5, 26.2; LRMS: 776 (M + , 15%) 757 (27%), 739 (22%), 243 (100%), 188 (60%), 132 (45%); HRMS: calcd. for C 29 H 29 N 2 O 3 F 17 : 776.1907, found 776.1894. MP: 114-116° C.
Example 12
[0043] Dimethyl-carbamic acid 4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-heptadecafluoro-1,1-dimethylundecyl ester (10). Dimethylamine (300 uL, 2.0 M in THF, 0.60 mmol) was added to a solution of fluorous Boc reagent 7 (101 mg, 0.15 mmol) in THF. The mixture was stirred at room temperature for 1.5 h. After evaporation of solvent, the residue was purified by column chromatography with 10:90 ethyl acetate/hexane (Rf=0.18) to give pure product (82 mg, 95%); 1 H NMR (CDCl 3 ) δ2.87 (s, 6H), 2.24-1.99 (m, 4H), 1.51 (S, 6H); 13 C NMR (CDCl 3 ) δ 155.5, 122.0-105.2 (m), 79.4, 35.9, 32.1, 26.0; LRMS: 577 (M+, 9%), 558 (M + −F, 12%), 489 (45%), 90 (70%), 72 (100%); IR (thin film): 2942, 1707, 1454, 1389, 1236, 656 cm −1 .
Example 13
[0044] Trifluoro-acetic acid 4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-heptadecafluoro-1,1-dimethylundecyl ester (11). Dimethylamine (2-perfluorooctylethyl)isopropyl carbamate 10 (251 mg, 0.44 mmol) was stirred with 1:1 CH 2 Cl 2 /TFA at room temperature overnight. After evaporation of solvent, the residue was partitioned between dichloromethane and aqueous K 2 CO 3 . The organic phase was dried over MgSO 4 and evaporated to give pure product (262 mg, 100%); 1 H NMR (CDCl 3 )δ 2.22-2.08 (m, 4H), 1.63 (s, 6H); 19 F NMR (CDCl 3 ) δ −74.6 (3F), −79.6 (2F), −113.3 (2F), −120.8 (6F), −121.6 (2F), −122.1 (2F), −125.0 (2F). 13 C NMR (CDCl 3 ) δ 156.4 (t), 121.5-105.1 (m), 86:7, 31.5, 25.7 (t), 25.0; LRMS: m/z (relative intensity) 587 (M + −Me, 70%), 489 (M + −CF 3 CO 2 , 68%), 155 (82%); HRMS calcd. for C 13 H 10 F 17 : 489.0511, found: 489.0504; IR (thin film): 2992, 1784, 1371, 1214 cm −1 .
Example 14
Synthesis of the Library in FIGS. 4 and 5
[0045] 1. Piperidine-1,4-dicarboxylic acid mono-(4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-heptadecafluoro-1,1-dimethylundecyl)ester (13a). To a solution of fluorous Boc reagent 7 (6.2 g, 9.1 mmol) and triethylamine (1.01 g, 10.0 mmol) in THF was added a solution of isonipecotic acid (1.29 g, 10.0 mmol) in water. The mixture was stirred at room temperature overnight. After removal of solvent, the solid residue as stirred with chloroform (300 mL) and the white solid was filtered off. The organic solvent was evaporated and the residue was recrystallized from chloroform/hexane to give product (2.3 g). The mother liquid was concentrated and purified by column chromatography. The product (total: 5.24 g, 87%) was obtained as a colorless solid. 1 H NMR (CDCl 3 ) δ 3.97 (br, 2H), 2.99 (t, J=10.9 Hz, 2H), 2.56-2.48 (m, 1H), 2.18-1.91 (m, 6H), 1.72-1.59 (m, 2H), 1.51 (s, 6H); 13 C NMR (CDCl 3 ) δ 180.1, 154.2, 126.1-106.8 (m), 80.1, 43.5, 42.8, 40.8, 31.8, 27.8, 26.2, 25.8; LRMS m/z (relative intensity) 661 (M + , 13%), 642 (M + −F, 41%); HRMS calcd. for C 20 H 20 NO 4 F 17 : 661.1148, found: 661.1146; MP: 140-142° C.
[0046] 2. 3-(4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-Heptadecafluoro-1,1-dimethyl-undecyloxycarbonylamino)propionic acid (13b). This compound was prepared by the same procedure as Example 14.1. Yield: 51%. 1 H NMR (CDCl 3 ) δ 5.08 (br, 1H), 3.42 (q, J=5.7 Hz, 2H), 2.61 (t, J=5.6 Hz, 2H), 2.17-2.04 (m, 4H), 1.49 (s, 6H); LRMS m/z (relative intensity) 622 (M + +H, 6%), 584 (M + −2F, 32%), 562(74%), 489(51%), 133(47%), 116(100%); HRMS: found 622.0874; calcd. for C 17 H 17 NO 4 F 17 : 622.0886. MP: 94-95° C.
[0047] 3. 4-[(4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-Heptadecafluoro-1,1-dimethyl-undecyloxycarbonylamino)-methyl]benzoic acid (13c). This compound was prepared by the same procedure as Example 14.1. Yield: 52%. 1 H NMR (MeOH-d4) δ 7.96 (d, J=8.2 Hz, 2H), 7.36 (d, J=8.2 Hz, 2H), 4.30 (s, 2H), 2.20-2.01 (m, 4H), 1.50 (s, 6H); LRMS m/z (relative intensity) 667(M + −F, 59%), 547(63%), 489(54%), 196(100%), 151(55%). MP: 137-140° C.; HRMS: found: 66.0929; calcd. for C 22 H 17 NO 3 F 17 : 666.0937.
[0048] 4. (2S)-Pyrrolidine-1,2-dicarboxylic acid 1-(4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-Heptadecafluoro-1,1-dimethylundecyl)ester (13d). This compound was prepared by the same procedure as Example 14.1. Yield: 47%.
[0049] 1 H NMR (CDCl 3 ) δ 4.37-4.22 (m, 1H), 3.55-3.35 (m, 2H), 2.26-1.93 (m, 8H), 1.52-1.47 (s, 6H); 13 C NMR (MeOH-d4) δ176.6, 155.5, 120.4-109.2 (m), 81.6, 60.6, 47.8, 32.8, 32.0, 31.1, 27.0, 26.5, 25.3, 24.6; LRMS m/z (relative intensity) 646 (M + −H, 10%), 628 (M + −F, 16%), 489 (56%), 114 (100%), 70 (70%); HRMS calcd. for C 18 H 17 NO 2 F 17 : 602.0974, found: 602.0988; MP: 75-76° C.
[0050] 5. General Procedure for the Synthesis of 15. To sixteen vials were added acids 13a-d (0.06 mmol), amines 14a′-d′ (0.24 mmol), EDCI (0.09 mmol), HOBT (0.09 mmol) and Et 3 N (0.09 mmol). Chloroform (0.5 mL) and DMF (0.5 mL) was added to each vial. These sixteen reaction mixtures were stirred at room temperature for 16 h. After concentration with a vacuum centrifuge, each reaction mixture was injected onto a preparative Fluofix™ 1EW 125 column. The column was eluted with 9:1 MeOH—H 2 O for 25 min and followed by pure MeOH for 20 min. The fractions of products were collected and evaporated with a vacuum centrifuge to give the sixteen compound library 15aa-15dd′, which was analyzed by 1 H NMR spectroscopy. The isolated yields of the amides are listed in FIG. 5 .
[0051] 15aa′ 1 H NMR (CDCl 3 ) δ 7.22-7.17 (m, 4H), 4.74 (s, 1H), 4.68 (s, 1H), 4.14-4.10 (m, 2H), 3.84 (s, 1H), 3.74 (t, J=5.7 Hz, 1H), 2.95-2.74 (m, 4H), 2.24-2.05 (m, 4H), 1.74 (br, 4H), 1.51 (s, 6H).
[0052] 15ab′ 1 H NMR (CDCl 3 ) δ 8.54 (d, J=6.0 Hz, 2H), 7.16 (d, J=5.8 Hz, 2H), 5.95 (s, 1H), 4.46 (d, J=6.0 Hz, 2H), 4.11 (br, 2H), 2.80 (t, J=11.8 Hz, 2H), 2.34-2.28 (m, 5H), 1.71 (br, 4H), 1.51 (s, 6H).
[0053] 15ac′ 1 H NMR (CDCl 3 ) δ 6.08 (s, 1H), 4.08 (br, 2H), 3.53-3.49 (m, 1H), 3.16-3.11 (m, 2H), 2.81-2.74 (m, 3H), 2.52 (br, 1H), 2.26-2.03 (m, 8H), 1.85-1.53 (m, 7H), 1.51 (s, 6H), 1.10 (t, J=7.2 Hz, 3H).
[0054] 15ad′ 1 H NMR (CDCl 3 ) δ 7.56-7.43 (m, 4H), 5.85 (t, J=5.4 Hz, 1H), 4.51 (d, J=6.0 Hz, 2H), 4.10 (br, 2H), 2.79 (br, 2H), 2.36-2.06 (m, 5H), 1.87-1.60 (m, 4H), 1.51 (s, 6H).
[0055] 15ba′ 1 H NMR (CDCl 3 ) δ 7.24-7.09 (m, 4H), 5.45 (t, J=5.8 Hz, 1H), 4.74 (s, 1H), 4.59 (s, 1H), 3.83 (t, J=6.0 Hz, 1H), 3.65 (t, J=5.9 Hz, 1H), 3.50-3.45 (m, 2H), 2.92-2.85 (m, 2H), 2.61-2.58 (m, 2H), 2.22-1.98 (m, 4H), 1.56 (s, 6H).
[0056] 15bb′ 1 H NMR (CDCl 3 ) δ 8.55 (d, J=5.9 Hz, 2H), 7.17 (d, J=5.8 Hz, 2H), 6.35 (s, 1H), 5.29 (s, 1H), 4.46 (d, J=6.0 Hz, 2H), 3.45 (q, J=6.0 Hz, 2H), 2.51 (t, J=5.8 Hz, 2H), 2.11-1.98 (m, 4H), 1.46 (s, 6H).
[0057] 15bc′ 1 H NMR (CDCl 3 ) δ 6.16 (br, 1H), 5.38 (s, 1H), 4.14 (br, 2H), 3.67-3.41 (m, 2H), 3.16-3.12 (m, 2H), 2.79-2.75 (m, 2H), 2.55 (br, 1H), 2.42 (br, 1H), 2.24-2.02 (m, 4H), 1.85-1.68 (m, 5H), 1.48 (s, 6H), 1.08 (m, 3H).
[0058] 15bd′ 1 H NMR (CDCl 3 ) δ 7.56-7.42 (m, 4H), 6.11 (s, 1H), 5.23 (s, 1H), 4.50 (d, J=5.9 Hz, 2H), 3.48-3.42 (q, J=6.0 Hz, 2H), 2.48 (t, J=5.9 Hz, 2H), 2.22-1.99 (m, 4H), 1.46 (s, 6H).
[0059] 15ca′ 1 H NMR (CDCl 3 ) 7.43 (d, J=7.8 Hz, 2H), 7.33 (d, J=7.6 Hz, 2H), 7.18-7.01 (m, 4H), 5.0 (br, 1H), 4.94 (br, 1H), 4.59 (br, 1H), 4.37 (m, 2H), 3.99 (br, 1H), 3.64 (br, 1H), 2.97-2.87 (br, 2H), 2.20-2.06 (m, 4H), 1.53 (s, 6H).
[0060] 15cb′ 1 H NMR (CD 3 OD) δ 8.47 (s, 2H), 7.85 (d, J=8.2 Hz, 2H), 7.39 (d, J=8.0 Hz, 4H), 4.62 (s, 2H), 4.30 (s, 2H), 2.31-2.09 (m, 4H), 1.46 (s, 6H).
[0061] 15cc′ 1 H NMR (CDCl 3 ) δ 7.74 (d, J=8.1 Hz, 2H), 7.33 (d, J=7.9 Hz, 2H), 4.36 (s, 2H), 3.71-3.67 (m, 1H), 3.31-3.25 (m, 2H), 2.82-2.79 (m, 2H), 2.28-1.99 (m, 8H), 1.74-1.63 (m, 2H), 1.51 (s, 6H), 1.11 (t, J=7.2 Hz, 3H).
[0062] 15cd′ 1 H NMR (CDCl 3 ) δ 7.77 (d, J=8.2 Hz, 2H), 7.60-7.41 (m, 4H), 7.34 (d, J=7.75 Hz, 2H), 6.48 (s, 1H), 4.98 (s, 1H), 4.71 (d, J=5.8 Hz, 2H), 4.36 (m, 2H), 2.36-1.91 (m, 4H), 1.51 (s, 6H).
[0063] 15da′ 1 H NMR (CDCl 3 ) δ 7.26-7.11 (m, 4H), 4.83-4.58 (m, 0.3H), 4.10 (m, 1H), 3.70-3.56 (m, 3H), 2.91-2.84 (m, 2H), 2.24-1.84 (m, 8H), 1.52 (s, 6H).
[0064] 15db′ 1 H NMR (CDCl 3 ), δ 8.53 (d, J=4.3 Hz, 2H), 7.43 (s, 1H), 7.17 (d, J=5.7 Hz, 2H), 4.51-4.34 (m, 3H), 3.43-3.36 (m, 2H), 2.40-1.94 (m, 8H), 1.40 (s, 6H).
[0065] 15dc′ 1 H NMR (CDCl 3 ) δ 6.91 (s, 1H), 6.42 (s, 1H), 4.29-4.18 (m, 1H), 3.51-3.40 (m, 3H), 3.13-2.05 (m, 2H), 2.75 (m, 1H), 2.52 (m, 1H), 2.26-1.68 (m, 13H), 1.52 (s, 6H), 1.08 (t, J=7.2 Hz, 3H).
[0066] 15dd′ 1 H NMR (CDCl 3 ) δ 7.50-7.36 (m, 4H), 4.49-4.23 (m, 4H), 3.49-3.32 (m, 2H), 2.41-1.82 (m, 7H), 1.51 (s, 6H).
[0067] 6. General Procedure for the Deprotection of 15. Amide 15 (0.05 mmol) was heated with 3N HCl/MeOH (1.0 mL) at 65° C. for 16 h. The mixture was evaporated and dried under high vacuum (˜1 mmHg) for 16 h. The yields of products were determined by 1 H NMR spectroscopy with p-dimethoxybenzene as an internal standard and are shown in FIG. 6 .
[0068] Amine from compound 15aa′. 1 H NMR (CDCl 3 ) δ 7.21-7.13 (m, 4H), 4.73 (s, 1H), 4.67 (s, 1H), 3.84 (t, J=5.9 Hz, 1H), 3.75-3.69 (m, 1H), 3.24 (br, 2H), 2.95-2.78 (m, 5H), 1.79 (br, 4H).
[0069] Amine from compound 15bb′. 1 H NMR (CD 3 OD) δ 8.98 (d, J=5.9 Hz, 2H), 8.21 (d, J=6.0 Hz, 2H), 4.56 (s, 2H), 3.21 (m, 2H), 2.77-2.73 (m, 2H).
[0070] Amine from compound 15cc′. 1 H NMR (CD 3 OD) δ 8.01 (d, J=8.1 Hz, 2H), 7.60 (d, J=8.1 Hz, 2H), 4.20 (s, 2H), 3.92-3.58 (m, 5H), 3.30-3.15 (m, 2H), 2.29-2.02 (m, 4H), 1.41 (t, J=6.9 Hz, 3H).
[0071] Amine from compound 15dd′. 1 H NMR (CD 3 OD) δ 9.00 (s, 1H), 7.83-7.54 (m, 4H), 4.52 (m, 2H), 4.34-4.29 (m, 1H), 3.73 (s, 2H), 3.43-3.31 (m, 1H), 2.48-2.42 (m, 1H), 2.11-1.98 (m, 2H).
Example 15
[0072] General Procedure for the Synthesis of the Library in FIGS. 8 and 9 . Eight vials were charged with a mixture of acid 13a (330 mg, 0.50 mmol), an amine 17{1-8} (2.0 mmol), EDCI (0.70 mmol), HOBT (0.70 mmol) and triethylamine (0.70 mmol) in chloroform/DMF. The reaction mixtures were stirred at room temperature overnight (16 h) and quenched with water. The organic phase was collected and evaporated with a vacuum centrifuge. These residues were charged onto eight short columns packed with fluorous reverse phase silica gel (5 g, bonded phase —Si(Me) 2 CH 2 CH 2 C 6 F 13 ). Each column was eluted with 80:20 MeOH—H 2 O (15 mL) followed by MeOH (5 mL) and diethyl ether (20 mL). The combined MeOH and ether fractions were evaporated to dryness with a vacuum centrifuge to give library 18{1-8}. A mixture of dichloromethane and TFA (1:1, 5 mL) was added to each of these amides 18. The reaction mixtures were stirred at room temperature for 2.5 h. After removal of dichloromethane and TFA, stock solutions of the residues 19{1-8} were prepared. Each of these eight solutions in DMF was added to an array of twelve halides 20{1-12} in the presence of diisopropylethylamine (0.5 mmol). These 96 reaction mixtures were heated at 50° C. for 48 h. After concentration, the mixtures were purified with a PrepLCMS system. In 89 out of 96 reactions, the desired products were detected by LC-MS and isolated in yields from 5 to 100% ( FIG. 9 ). Spectroscopic data for twelve members of library 21{1-8, 1-12} are listed below.
[0073] Compound 21{2,2}. 1 H NMR (DMSO-d6) δ 9.3 (br, 2H), 8.04 (t, J=3.3 Hz, 1H), 7.28 (m, 2H), 7.20 (m, 2H), 6.76 (m, 2H), 6.01 (m, 2H), 3.94 (t, J=4.1 Hz, 2H), 3.47 (d, J=7.1 Hz, 2H), 3.28 (q, J=4.0 Hz, 2H), 2.97-2.84 (m, 4H), 2.70 (t, J=4.3 Hz, 2H), 2.32-2.29 (m, 1H), 2.11-2.05 (m, 2H), 1.84-1.71 (m, 4H); 13 C NMR (DMSO-d 6 ) δ 172.5, 139.4, 128.6, 128.2, 126.1, 120.5, 107.9, 53.6, 51.2, 45.8, 35.0, 25.9, 25.5.
[0074] Compound 21{3,7}. 1 H NMR (DMSO-d6) δ 9.21 (br, 1H), 8.50 (t, J=5 Hz, 2H), 7.32 (t, J=4.5 Hz, 2H), 7.24 (t, J=4.5 Hz, 2H), 5.82-5.77 (m, 1H), 5.03 (d, J=10.5 Hz, 1H), 4.98 (d, J=6.1 Hz, 1H), 4.26 (d, J=3.5 Hz, 2H), 3.51 (d, J=7.1 Hz, 2H), 3.05-3.01 (m, 2H), 2.89 (q, J=6.6 Hz, 2H), 2.47-2.44 (m, 1H), 2.05 (q, J=4.3 Hz, 2H) 1.93 (d, J=8.1 Hz, 2H), 1.84-1.79 (m, 2H), 1.67-1.60 (m, 2H), 1.37 (q, J=4.5 Hz, 2H); 13 C NMR (DMSO-d 6 ) δ 172.7, 139.4, 138.0, 128.3, 127.1, 126.8, 115.3, 55.8, 51.1, 41.9, 32.5, 25.9, 25.2, 22.7.
[0075] Compound 21{2,9} 1 H NMR (DMSO-d6) δ 8.03 (s, 1H), 7.30-7.27 (m, 2H), 7.21-7.18 (m, 2H), 6.94-6.89 (m, 5H), 4.7 (s, 1H), 4.29 (dd, J=7.0, 1.1 Hz, 1H), 3.05 (s, 2H), 2.71 (t, J=4.4 Hz, 2H), 2,35 (s, 1H), 1.89 (m, 4H); 13 C NMR (DMSO-d 6 ) δ172.5, 139.4, 128.7, 128.3, 126.1, 121.8, 117.4, 117.2, 68.0, 65.0, 55.8, 52.4, 51.7, 35.0, 25.9.
[0076] Compound 21{4,4} 1 H NMR (DMSO-d6) δ 9.47 (s, 1H), 8.01 (t, J=3.3 Hz, 1H), 7.37-7.34 (m, 2H), 7.30-7.25 (m, 2H), 7.10 (d, J=5.0 Hz, 2H), 0.6.84 (d, J=5.0 Hz, 2H), 3.72 (s, 3H), 3.57 (m, 2H), 3.34-3.31 (m, 5H), 3.00-2.84 (m, 4H), 2.64 (t, J=4.4 Hz, 2H), 2.37-2.32 (m, 1H), 1.89-1.73 (m, 3H); 13 C NMR (DMSO-d 6 ) δ 172.5, 157.7, 136.9, 131.2, 129.7, 128.8, 126.9, 114.1, 113.7, 56.6, 55.1, 51.2, 34.2, 29.5, 25.9.
[0077] Compound 21{1,1}. 1 H NMR (DMSO-d6) δ 8.41 (t, J=3.5 Hz, 1H), 7.15 (d, J=5.1 Hz, 2H), 6.88 (d, J=5.1 Hz, 2H), 4.25-4.19 (m, 6H), 3.72 (s, 3H), 3.01 (s, 2H), 1.92 (br, 4H), 1.24 (t, J=4.2 Hz, 3H); 13 C NMR (DMSO-d 6 ) δ 172.5, 165.9, 158.2, 131.3, 128.5, 113.7, 61.9, 55.1, 41.4, 25.6, 13.9.
[0078] Compound 21{6,10}. 1 H NMR (DMSO-d6) δ 8.54 (t, J=3.5 Hz, 1H), 0.7.78-7.72 (m, 2H), 7.69-7.57 (m, 4H), 7.50-7.44 (m, 3H), 7.37-7.31 (m, 3H), 4.31-4.25 (m, 4H), 3.41 (d, J=7.1 Hz, 2H), 2.99-2.95 (m, 2H), 2.50-2.47 (m, 1H), 1.97-1.80 (m, 4H); 13 C NMR (DMSO-d 6 ) δ 172.7, 139.9, 138.8, 138.6, 133.3, 132.5, 129.0, 127.8, 126.9, 126.6, 57.7, 50.9, 41.7, 25.8.
[0079] Compound 21{5,3}. 1 H NMR (DMSO-d6) δ 11.0 (s, 1H), 10.2 (s, 1H), 7.62-7.57 (m, 3H), 7.51 (d, J=4.5 Hz, 2H), 7.38 (d, J=4.8 Hz, 2H), 7.25 (s, 1H), 7.12-7.09 (m, 1H), 7.04-7.01 (m, 1H), 3.72 (d, J=7.1 Hz, 2H), 3.14-3.11 (m, 2H), 3.03 (q, J=6.7 Hz, 2H), 2.66-2.60 (m, 1H), 2.09-186 (m, 4H); 13 C NMR (DMSO-d6) δ 171.9, 138.4, 136.3, 131.5, 126.6, 123.2, 121.3, 121.1, 118.5, 118.2, 114.9, 111.6, 108.9, 56.1, 51.0, 25.8, 19.8.
[0080] Compound 21{8,12}. 1 H NMR (DMSO-d6) δ 8.05 (s, 1H), 7.87 (d, J=4.5 Hz, 2H), 7.63 (d, J=4.5 Hz, 2H), 7.57 (d, J=4.2 Hz, 2H), 7.47-7.42 (m, 3H), 7.36-7.33 (m, 1H), 7.27 (d, J=4.7 Hz, 2H), 4.98 (s, 4H), 3.52-3.49 (m, 2H), 3.02-3.00 (m, 2H), 2.76 (t, J=4.3 Hz, 2H), 2.39 (s, 3H), 1.90 (br, 4H).
[0081] Compound 21{5, 11}. 1 H NMR (DMSO-d6) δ 9.2 (s, 1H), 8.04 (d, J=4.5 Hz, 1H), 7.30 (s, 1H), 7.26 (d, J=5.7 Hz, 1H), 7.02 (d, J=5.0 Hz, 1H), 3.93 (s, 1H), 3.51 (d, J=7.2 Hz, 2H), 3.06-3.02 (m, 2H), 2.93-2.78 (m, 4H), 2.56-2.53 (m, 2H), 2.38-2.35 (m, 1H), 1.88-1.76 (m, 5H), 1.64-1.50 (m, 3H), 0.90 (d, J=4.6 Hz, 6H); 13 C NMR (DMSO-d6) δ 172.3, 138.4, 134.1, 131.2, 130.9, 128.4, 118.6, 54.5, 51.1, 44.3, 34.3, 31.9, 27.9, 26.9, 26.0, 25.9, 25.7, 22.1.
[0082] Compound 21{5,5}. 1 H NMR (DMSO-d6) δ 8.04 (d, J=4.5 Hz, 1H), 7.35-7.26 (m, 4H), 7.04-6.99 (m, 4H), 4.33 (t, J=2.8 Hz, 2H), 3.94-3.92 (m, 1H), 3.61 (d, J=7.2 Hz, 2H), 3.57 (s, 2H), 3.04-3.02 (m, 2H), 2.94-2.89 (m, 1H), 2.87-2.78 (m, 2H), 2.56-2.53 (m, 1H), 2.40-2.37 (m, 1H), 1.90-1.84 (m, 4H), 1.64-1.62 (m, 1H); 13 C NMR (DMSO-d 6 ) δ 172.3, 157.5, 138.4, 134.1, 131.2, 130.9, 129.6, 128.4, 121.4, 118.6, 114.7, 62.0, 55.0, 51.8, 44.3, 34.3, 27.9, 26.9, 25.9.
[0083] Compound 21{1,8}. 1 H NMR (DMSO-d6) δ 8.42 (t, J=3.4 Hz, 1H), 7.15 (d, J=5.1 Hz, 2H), 6.87 (d, J=5.2 Hz, 2H), 4.19 (d, J=3.3 Hz, 2H), 3.72 (s, 3H), 2.94 (t, J=6.9 Hz, 2.84 (t, J=4.5 Hz, 1H), 2.74 (t, J=4.5 Hz, 1H), 2.4 (m, 1H), 1.93-1.77 (m, 4H); 13 C NMR (DMSO-d6) δ 171.6, 170.6, 169.5, 130.3, 127.5, 112.7, 54.1, 50.9, 50.4, 40.4, 27.7, 27.4, 25.0.
[0084] Although the present invention has been described in detail in connection with the above examples, it is to be understood that such detail is solely for that purpose and that variations can be made by those skilled in the art without departing from the spirit of the invention except as it may be limited by the following claims.
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A method of increasing the fluorous nature of a compound includes the step of reacting the compound with at least one second compound having the formula:
wherein Rf is a fluorous group, Rs is a spacer group, d is 1 or 0, m is 1, 2 or 3, Ra is an alkyl group and X is a suitable leaving group. A compound has the formula:
wherein Rf is a fluorous group, n is an integer between 0 and 6, m is 1, 2 or 3, Ra is an alkyl group and X is a leaving group.
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[0001] (This application claims the benefit of Provisional Patent Application Ser. No. 60/339016 filed Nov. 13, 2001)
FEDERAL SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OF PROGRAM
[0003] Not Applicable
BACKGROUND—FIELD OF INVENTION
[0004] This invention relates to a novel and useful visual guide, for the benifit of a driver, in the postioing and parking of a recreational type vehicle in a campsite or any other confined parking space.
BACKGROUND—DESCRIPTION OF PRIOR ART
[0005] Background
[0006] In the mid 1990's, manufacturers of Recreational Vehicles (RVs), such as motor homes, fifth wheel and other pull type trailers, introduced a new optional feature, called “slide out rooms”. Slide out rooms are not actually separate rooms, but are an extension of the interior space within the RV created when a portion of the outside wall is mechanically extended outward. The slide out rooms usually extend two to four feet and result in the space inside the RV being increased.
[0007] Over 500,000 recreation vehicles were sold in 2002. Slide out rooms became so popular that over 80% of such RVs included one, or more on either, or both sides of the unit. In the future, it is estimated that virtually all RV units will have a minimum of at least one slide out room.
[0008] The Problem
[0009] When the RV is being driven or pulled along the highway, the slide out rooms are retracted and the unit is of normal road width. Slide out rooms are only extended when the RV is stationary, for example, while parked in a campsite. Herein lies the problem! With the addition of slide out rooms, once extended, the RV requires a larger space, while most campsites and other parking spaces have remained the same size. Some private campgrounds have enlarged their sites, however most public state and federal campgrounds have not. Many are located in parks or other heavily wooded areas, which often makes accommodating RV's with slide out rooms quite difficult.
[0010] Positioning and parking a RV with slide out rooms requires the owner/operator to have a greater degree of skill, time and patience. To accommodate the extra width of a RV unit with slide out rooms, the additional space, which the extended room will occupy, must be measured, or calculated. After arriving at the parking site, the driver must position and reposition the unit, requiring repeated and frequent trips outside the RV and/or the help of an assistant to give maneuvering directions. A high degree of caution must be taken to insure that no fixed obstruction(s) are present, which would interfere or cause damage to the room when it is extended.
[0011] The Solution
[0012] This invention provides the driver of a RV unit, that is equipped with slide out rooms, a visual device to assist in positioning and parking, without ever getting out of the unit. Much less skill, time and patience is required and parking the RV becomes less difficult.
[0013] The Slide Out Guide involves the use of a pair of power-driven telescoping antennas, capable of being extended and retracted. Activation is by either a switch located within easy reach of the driver's seat, or by a remote control device. Installation and use of this invention is fully described and supported, in the following Drawings, Detailed Specifications and Claims contained in this application and represents the use and modification of Prior Art in a new and novel way.
PRIOR ART
[0014] Parking Guides
[0015] There have been many devices created and patented as aides in the parking and operation of automobiles, but none were found for specific use with RVs. U.S. Pat. No. 6,345,587, Toscano (2002) involves the use of manually operated telescoping antennas attached to the license plate holder of an automobile. This is used as a visual guide to locate the front end of the vehicle, which is not the use or objective of this invention. U.S. Pat. No. 3,998,285, Cooper (1976) and U.S. Pat. No. 3,563,200, Grossman (1971) refer to a parking guide mechanism attached to the rear bumper of an automobile, to assist in judging the relative position of the bumper to any fixed object, while backing. Again, this type of device would not solve the problem of visually measuring a pre-determined distance from the side of a vehicle and could not be permanently installed on the side of a RV, as it would interfere with traffic while being driven or towed. U.S. Pat. No. 5,894,673, Pretsch (1999), U.S. Pat. No. 5,655,306, Pretsch (1997) and U.S. Pat. No. 3,137267, Hurt (1964) all relate to devices and objects permanently attached to trucks or trailer-tractors for judging distance by contact, or touching another object, such as a loading dock or overhead obstruction.
[0016] The object of this invention is to visually measure a clear space for subsequent extension of the slide out room(s) and to avoid contact with another object. Many items of prior art found under the general classification of “parking guides” relate to positioning and parking a vehicle in a garage or other enclosed structure, including U.S. Pat. No. 6,199,287, Rankila (2001), U.S. Pat. No. 5,832,865, Harmel (1998), U.S. Pat. No. 4,036,165, Wood (1977), U.S. Pat. No. 5,507,245, Kennedy (1996), U.S. Pat. No. 5,230,296, Giltz, etal.(1993), U.S. Pat. No. 4,813,758, Sanders (1989), U.S. Pat. No. 4,101,868, Bubnich, etal. (1978), U.S. Pat. No. 3,793,981, Sparks (1974), U.S. Pat. No. 2,731,934, Hausmann,etal. (1956) and U.S. Pat. No. 1,981,188, Pavitt (1934). Each is a visual aide, however all require that a device or object be fixed to a garage or other structure to work in conjunction with the automobile. Parking a recreational vehicle within a campsite, or other open parking space can not depend on a fixed object attached to a structure. The aide must be totally self-contained within the RV. This invention meets that requirement and is available whenever and wherever use is desired.
[0017] Finally, U.S. Pat. No. 2,871,814, Stahl (1959), U.S. Pat. No. 2,753,439, Greenfield (1956) and U.S. Pat. No. 2,672,841, Nitzberg (1954) all cover fender guides for attachment to automobile headlight housings to assist drivers in the visual location of such fenders in parking situations. They have no relationship, nor offer any assistance, in visually measuring a horizontal and vertical reference point for clearance purposes, as does the subject invention in this application.
[0018] In summary of prior art in the area of parking guides, we could find no device or method, nor solution to the problem of positioning and parking a recreational vehicle, with or without slide out rooms, in a campsite or other open confined space.
[0019] Power-Driven Telescoping Antenna Units and Antennas
[0020] The other prior art utilized with this invention is an electrically powered telescoping antenna device, capable of extending and retracting an antenna (hereinafter referred to as a telescoping “rod”), as used in this application. While all referenced prior art we cite herein is designed for the specific purpose of receiving radio reception while installed in a vertical position, it can, with modification, work in a horizontal position, as a measuring device. This, however, would be considered unobvious, when installed and used for the purpose of this invention. Also, the construction of all prior art in the area of power-driven telescoping rods and antennas for use therewith, contemplates the use of conductive materials capable of radio wave reception. This invention can utilize any non-conductive material in construction of the telescoping rod, as long as it is of sufficient strength to maintain a reasonably straight horizontal line, when fully extended. In addition, this invention does not require a cable connection from the rod to a radio.
[0021] U.S. Pat. No. 6,107,969, Gulino etal. (2000), U.S. Pat. No. 5,929,826, Shinkawa etal. (1999), U.S. Pat. No. 5,201,391, Arai etal. (1993), U.S. Pat. No. 4,875,053, Harada (1989), U.S. Pat. No. 4,829,317, Shinkawa (1989), U.S. Pat. No. 4,742,360, Carolus etal. (1988), U.S. Pat. No. 4,542,383, Cusey etal. (1985) and U.S. Pat. No. 4,303,872, Alf etal. (1981) represent several of the most recent automobile power antennas fully equipped with a motor, clutch, drive and telescoping antenna. All are designed for use in a vertical position and for radio wave reception.
[0022] U.S. Pat. No. 6,046,706, Vargas (2000), U.S. Pat. No. 6,002,378, Harada, etal. (1999), U.S. Pat. No. 5,959,593, Hoshi (1999), U.S. Pat. No. 5,900,846, Phelps (1999), U.S. Pat. No. 5,835,070, Scaraglino (1998), U.S. Pat. No. 4,717,923, Kimura (1988) and U.S. Pat. No. 4,633,266, Alf etal. (1986) represent only a few recently developed telescoping antenna rods and only differ in design, components and construction. Again, each is intended for vertical use, with radio wave reception capabilities and not as horizontal measuring device.
[0023] In summary, while many prior art devices have been introduced to the public, a few of which have been listed above, there have been no previous indication that such art could also be used as suggested by this invention. By modification of prior art, as explained in detail herein, this invention becomes a novel and useful device and unobvious before this time.
[0024] Objects and Advantages
[0025] Accordingly, the objects and advantages of this power-driven telescoping rod measuring device, described above as my invention, would include the following:
[0026] (a) With only minor modifications as outlined herein, any standard power-driven telescoping rod could be used, thus drastically reducing the cost of this invention. When compared to the cost of repairing a slide out room, damaged during extension if it comes in contact with a solid object, this invention becomes very financially attractive.
[0027] (b) Provides a simple, yet important, means for visually measuring the space necessary to fully extend slide out room(s), in positioning and parking a RV unit in a confined campsite, or other parking space.
[0028] (c) Offers a manual switch or remote control activation from the driver's seat of a motor home or towing vehicle.
[0029] (d) Provides the ability to view telescoping rod tips in the driver's rearview mirrors while positing the RV unit, thus eliminating the need for frequent trips outside the vehicle, or use of an assistant.
[0030] (e) Bright colored telescoping sections and rod help separate the rod from background clutter, such as gravel, rocks, brush, etc.
[0031] (f) Built-in neon light automatically illuminates the extended rods for better nighttime use.
SUMMARY
[0032] This invention is the first product to be offered as a visual measuring device to RV owners to assist in positioning and parking their units in either tight and cramped campsites, or other confined parking spaces. It can be supplied at a reasonable cost. It is easily installed. Installation can be performed by a manufacturer, or by owners of RV's already in use, as an after-market product. It will be a great help for both first time RV buyers, or those less skilled in backing, positioning and parking of their units, making their RV experience much more enjoyable.
DRAWINGS
[0033] The best method and mode presently contemplated for utilizing this invention in actual practice is shown in the accompanying drawings, in which:
[0034] [0034]FIG. 1 is a perspective view of the preferable location(s) of the telescoping antennas, hereinafter referred to as telescoping rods, in their extended positions, for a recreational vehicle application, with said vehicle having, in a phantom view, one or more slide out rooms, as illustrated.
[0035] [0035]FIG. 2 is a view of a typical auto power-telescoping rod, disclosed as Prior Art elsewhere in this application, with preferred modifications.
[0036] [0036]FIG. 3 depicts a telescoping rod, disclosed as Prior Art elsewhere in this application, with preferable modifications.
[0037] [0037]FIG. 4 denotes the manner in which the end of the main power unit body is secured to the RV for stability during travel and operation.
[0038] [0038]FIG. 5 illustrates the various components at the base of the telescoping rod, which secures it to the outer body wall of the recreational vehicle.
[0039] [0039]FIG. 6 indicates the driver's projected sight lines, to form a visual frame of reference for proper clearance.
REFERENCE NUMBER IN DRAWINGS
[0040] [0040] 10 two types of recreational vehicles
[0041] [0041] 11 position of extended slide out rooms
[0042] [0042] 11 telescoping rods
[0043] [0043] 14 tip of telescoping rod
[0044] [0044] 15 hollow neck holding rod when retracted
[0045] [0045] 16 electrical wires
[0046] [0046] 17 rear mounting insert
[0047] [0047] 18 main body of unit
[0048] [0048] 19 end section of telescoping rod
[0049] [0049] 20 mounting assembly
[0050] [0050] 21 spacing sleeve
[0051] [0051] 22 ground washer
[0052] [0052] 23 outside wall of recreational vehicle
[0053] [0053] 24 mounting retainer and seal
[0054] [0054] 25 neon light insert
[0055] [0055] 26 neon light electrodes
[0056] [0056] 27 light seal
[0057] [0057] 28 mounting nut
[0058] [0058] 30 metal strap
[0059] [0059] 31 machine screw and lock washer
[0060] [0060] 32 rearview mirrors
[0061] [0061] 33 sight lines
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0062] Referring to FIG. 1 indicates where the telescoping rods 12 , should be mounted on the RV Preferably they should be located within an interior space of the vehicle body 10 , under the interior flooring, either within a storage compartment, or between the outside wall of said RV and its main longitudinal steel frame.
[0063] Proper and preferable location of the invention on the vehicle 10 is very important to achieve maximum benefit in its use as a visual device. One must determine optimum positioning to assure proper clearance for slide out room(s) 11 from any obstructions when it, or they, are extended. The preferred location of said telescoping rods 12 would be on each side of the slide out room(s) 11 , just to the side thereof and slightly below the bottom of said slide out room(s) 11 . When fully extended, said telescoping rods 12 , will provide a visual sight line horizontally between the outer most point, or tip, of each rod. Also, said telescoping rods 12 will provide a vertical view from said rod 12 tips to the top of said slide out room(s) 11 , to assure that no obstructions fall within the visual frame thus achieved. Such visual frame, when clear of any obstructions, will assure that the slide out room(s) 11 will not be damaged when extended.
[0064] Use of Prior Art
[0065] Referring now to FIG. 2, as shown, the main embodiment of this invention is the novel, unobvious and new use of Prior Art, as referred to and outlined elsewhere in this application. It is the use of a 12 V DC power-driven telescoping antenna 12 , hereinafter referred to as a telescoping “rod” 12 , encased in a base unit 18 and utilized in a horizontal position, in lieu of a vertical position as originally designed. Said power-driven telescoping base unit device 18 of any make, or model may be used, with preferred modifications as herein outlined. The rear drain hole and attachable drain tube may be eliminated. Rain or moisture collecting in the base unit is not a problem when said unit is installed within the vehicle ( 10 ) in a horizontal position, as opposed to a typical vertical position.
[0066] Another modification is made to the motor and clutch drive assembly, in that the duration of time said motor is running, can be adjusted. This will allow for extension or retraction of various lengths of said telescoping rods 12 , as may be desired, to accomplish the preferred use of the invention.
[0067] Additionally, the radio wave receptor cable, normally attached to the hollow neck housing tube 15 , will preferably be removed from said neck 15 , thus providing for greater ease of installation. Further, the material used in the construction of the telescoping rods 12 need not be of a conductive material, as radio wave reception is not required. Said telescoping rod 12 construction may be of any material, such as steel or a polyethylene plastic, which is sufficient to maintain a reasonable straight line, when extended horizontally to the desired length.
[0068] A rear-mounting insert 17 is provided to secure said base unit 18 to an inside support of the vehicle 10 as further explained in FIG. 4. Color-coded power and ground wires 16 are provided for connection of the base unit 18 to any DC power source, such as an onboard 12V battery. Installation can provide for activation of the telescoping rods 12 , by use of either a switch, located on the outside of the vehicle 10 , or inside thereof, within easy reach of the driver's seat of said vehicle 10 . Further, activation can be by use of a remote control device, similar to those used as garage and auto door openers, with simple modifications.
[0069] The Measuring Device
[0070] Regarding and referring to FIG. 3, the telescoping rod 12 is the heart of this invention, as it provides the means for measurement to determine proper clearance for extension of the vehicle's 10 slide out room(s) 12 , without expensive damage thereto. The telescoping rod 12 preferably is modified to better perform as a measuring device, as outlined in this application. Said telescoping rod 12 can be made to any desired length by deletion or addition of telescoping sections, or by lengthening or shortening one or more sections. Likewise the hollow housing tube 15 , can be made shorter or longer, as necessary to accommodate the length of the base section of the telescoping rod 12 , when in a retracted position, in order that the tip of said rod 12 is flush with the outside mounting base 20 .
[0071] Also, it is most preferable that the last, most extended section 19 of the telescoping rod 12 be painted a bright color, such as red, orange or yellow, to enhance visual observation from the driver's rear view mirrors, while said vehicle 10 is being positioned. Said colored section 19 will help distinguish said telescoping rods 12 from background clutter, such as gravel, grass, leaves, etc.
[0072] The Neon Light
[0073] Additionally, the outside mounting bracket assembly 20 is designed to provide for insertion of a recessed neon light, which is illuminated automatically when the telescoping rod 12 is extended. This will provide better visualization during nighttime use.
[0074] Mounting Unit to Vehicle
[0075] Referring now to FIG. 4, we describe and illustrate how the main body unit 18 is to be mounted inside of said vehicle 10 to provide stability during travel and subsequent operation of said telescoping rod 12 . An inside threaded brass support insert 17 is molded to the rear of the main body unit 18 . To this is attached a metal strap 30 having a plurality of holes, by use of a standard machine screw 31 using whichever hole is most convenient for proper installation. Metal strap 30 is then attached to any available wood or metal vehicle support member, brace, floor or underside of said vehicle's 10 upper flooring, by bending said metal strap 30 to any desired position as shown in FIG. 4 a . Holes in said metal strap 30 are provided to accommodate various installation applications.
[0076] Mounting the Telescoping Rods
[0077] [0077]FIG. 5 provides, in exploded detail, the various mounting pieces to secure the telescoping rod 12 to the outside body 23 of the vehicle 10 . A spacing sleeve 21 , length of which is determined by each installation, is slipped onto the end of said telescoping rod 12 and butts up against the housing neck 15 . A ground washer 22 is then slipped on the telescoping rod 12 next to said spacing sleeve 21 . Thus arranged, the main body unit 18 is placed inside the vehicle 10 so that the outward tip of said rod 12 protrudes through a pre-cut hole in said vehicle's 10 outside wall 23 . Then a mounting retainer 24 of rubber, plastic, or similar material, is slipped onto the telescoping rod 12 to form a weather seal. Next, a neon light ring 25 , with electrodes 26 , is installed, followed by a rubber insert 27 and then the mounting nut 19 . Thus installed, a stable and aesthetic attachment to the vehicle is achieved.
[0078] Visual Frame of Reference
[0079] Finally, referring to FIG. 6, we illustrate the visual sight lines 33 achieved by use of said telescoping rods 12 and the driver's rearview mirrors 32 attached to said vehicle 10 . Each pair of telescoping rods provide projected sight lines 33 . They form a horizontal line between the tips of said telescoping rods 12 and also form a vertical line from the tips of said telescoping rods 12 to the top line of the slide out room(s) 11 . In combination, this creates a visual estimation of the space the extended side out rooms will occupy. This space must be clear of any obstructions to prevent interference with the subsequent extension of the slide out room(s) 11 .
[0080] Further, this visualization will assure that the extended slide out room(s) 11 will not extend beyond any boundary or line imposed by a private or public body. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that it's application is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A positioning and parking guide for a recreational vehicle ( 10 ), consisting of two, or more power-driven telescoping rods ( 12 ), extended to provide a visual horizontal and vertical frame of reference ( 33 ), in determining the distance required to avoid any fixed object, or to not exceed any boundary, when parking such unit within a campsite or other parking space, after slide out rooms are extended.
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FIELD OF THE INVENTION
[0001] The present invention relates to the treatment or prevention of osteoarthritis.
BACKGROUND TO THE INVENTION
[0002] Osteoarthritis is the commonest form of arthritis and is detectable radiologically in 80% of individuals over the age of 55 in Western populations. Symptomatic osteoarthritis of the knee, that is pain with radiographic abnormalities, is present in about 6% of individuals over the age of 30 in both the USA and the UK. In the USA approximately 21 million people have physician diagnosed osteoarthritis, most of whom have significant pain and disability. Indeed, in some 12% of all subjects with limitation of activity, the cause is osteoarthritis, and it accounts for more dependency in walking and stair climbing than any other disease. The estimated annual cost of osteoarthritis in the USA is $15.5 billion in 1994 dollars, which approaches 1% of the GNP, with more than 50% of the costs due to work loss. The problem is inevitably becoming more severe with an ageing population and the clear age related incidence of osteoarthritis (1).
[0003] The pathology of osteoarthritis comprises loss of articular cartilage and complex processes of repair with fibrocartilage and reactive bone formation, leading to disruption of normal joint and peri-articular architecture. This is associated with pain, synovial effusions and loss of function.
[0004] Traditional treatments are: weight loss, exercise and psychosocial support; simple analgesics; non-steroidal anti-inflammatory drugs; intra-articular corticosteroids; hyaluronic acid; joint lavage; physical aids and appliances. However these conservative approaches are inadequate in a significant proportion of patients for whom surgery then becomes appropriate, including synovectomy, repair of meniscal tears, realignment osteotomy, and eventually total joint replacement. Only the latter is a cure for osteoarthritis, and obviously it is only applicable to some joints and some individuals.
[0005] Other experimental and less well validated therapeutic approaches include administration of glucosamine and chrondroitin sulphate, ostensibly to promote survival or even repair of damaged cartilage, and tetracycline, interleukin-1 antagonists and inhibitors of collagenase and other matrix proteinases.
[0006] There is thus clearly an enormous need for new medications that can modify progression of osteoarthritis, and, importantly, alleviate its distressing and incapacitating symptoms of pain, joint deformity and effusions, limitation of activity and disability.
[0007] Serum amyloid P component (SAP) is a member of the conserved and evolutionarily ancient pentraxin family (2) of plasma proteins, the other member of which is C-reactive protein (CRP) the classical acute phase protein (3). Homologous proteins that share the same 3D fold (4,5), oligomeric assembly and capacity for calcium-dependent ligand binding, are present in all vertebrates (6) and even in the horseshoe crab, Limulus polyphemus (7), that is separated in evolution from primates by about 600 million years. No deficiency or protein polymorphism of SAP have been described yet in humans, and its carbohydrate component is the most invariant of any known glycoprotein (8). This is all compelling evidence that SAP has beneficial functions that contribute to survival.
[0008] However, SAP derives its name from the fact that it is universally present in the pathological tissue deposits of amyloid in the disease state of amyloidosis (9). The bulk of these deposits consists of amyloid fibrils composed of autologous protein misfolded and aggregated with a pathognomonic cross-β fold (10), together with tightly bound glycosaminoglycans of heparan sulphate and dermatan sulphate types (11). SAP undergoes specific calcium-dependent binding to these fibrils, both in vitro (12) and in vivo (13,14), and this property has been exploited to develop radiolabelled SAP as a highly specific, sensitive and quantitative in vivo scintigraphic tracer for diagnosis and monitoring of the deposits in systemic and local extra-cerebral amyloidosis (15).
[0009] One of the forms of local extra-cerebral amyloidosis that is of the greatest clinical importance is dialysis associated amyloidosis, a very serious, painful and crippling complication of long term dialysis for end stage renal failure. This type of amyloid is largely confined to joints and peri-articular structures, producing nerve compression, and bone cysts leading to disruption of joints and pathological fractures. Dialysis amyloidosis has been studied extensively using radiolabelled SAP, showing that uptake in and around joints is specific for histologically proven amyloid deposits in these locations (16,17).
[0010] Drugs which are bound by SAP have been developed for the purpose of treating amyloidosis, including Alzheimer's disease. WO95/05394 describes therapeutic and diagnostic agents for amyloidosis which comprise molecules that inhibit the binding of SAP to amyloid fibrils. EP-A-0915088 describes D-prolines and derivatives thereof for use in the treatment or prevention of central and systemic amyloidosis including Alzheimer's disease, and maturity onset diabetes mellitus. WO03/013508 describes therapeutic agents for depletion of unwanted protein populations from plasma in which bifunctional agents form a complex with a plurality of proteins to deplete them from the plasma of a subject. It is disclosed that R-1-[6-R-2-carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid specifically targets SAP in vivo to cause aggregation of native pentameric SAP molecules into decameric SAP-drug complexes that are then swiftly cleared by the liver.
SUMMARY OF THE INVENTION
[0011] The present invention relates to the use of an agent for the production of a medicament for treatment or prevention of osteoarthritis in a subject. The agent is capable of inhibiting SAP ligand binding activity or capable of depleting SAP from the plasma of the subject.
[0012] It has surprisingly been found that the use of such agents to treat patients with osteoarthritis has a dramatic effect in relieving symptoms of the disease in patients.
[0013] In a first aspect, the agent is capable of inhibiting SAP ligand binding activity. Agents capable of inhibiting SAP ligand binding activity include those which are capable of being bound by a ligand binding site present on SAP and those which may be bound elsewhere and yet block or inhibit SAP ligand binding activity. Accordingly, inhibition of SAP ligand binding activity may arise by direct inhibition or by allosteric inhibition. The inhibition may be competitive or non-competitive and may be reversible or irreversible.
[0014] A general method for selecting an agent capable of inhibiting SAP ligand binding activity for use in the treatment or prevention of osteoarthritis comprises contacting serum amyloid P component (SAP) with a target ligand thereof under conditions to permit SAP ligand binding, in the presence of a test compound; testing for SAP ligand binding; and selecting the test compound as an SAP inhibitor if the test compound inhibits binding of SAP to the target ligand.
[0015] The present invention further provides a process for the production of an anti-osteoarthritis agent, which process comprises (i) identifying an SAP inhibitor by selecting the compound according to the above method; and (ii) producing an anti-osteoarthritis agent by providing the SAP inhibitor or a pharmaceutically-acceptable derivative thereof.
[0016] The present invention is therefore concerned in one embodiment with a method for selecting an SAP inhibitor which includes testing for SAP ligand binding in the presence of a test compound. Any test compound which inhibits binding of SAP to the ligand may be selected as an inhibitor. For example, the test compound may be selected in the sense that it is identified and can then be produced on a larger scale by chemical or biochemical synthesis or may be physically selected for direct formulation as an anti-osteoarthritis agent. In accordance with the process for production of the agent, the test compound may be formulated for pharmaceutical use or may be derivatised or chemically modified to produce a pharmaceutically-acceptable derivative thereof. Such derivatisation may simply be required to incorporate new functional groups or alter existing functional groups to make the agent easier to formulate, for example by altering the solubility of the compound. Derivatisation of this nature may be used to decrease the toxicity of the compound, to alter the stability of the compound or even to modify the pharmacological activity thereof. Any such derivatised or modified compound may need to be retested according to the method of the present invention.
[0017] In the step of contacting SAP with the ligand, the conditions must be sufficient to permit SAP ligand binding in the absence of the test compound. In this way, where SAP ligand binding does not occur in the presence of the test compound, or occurs to a smaller extent than expected, this effect can be attributed to the test compound. It should be noted here that inhibition of binding should be broadly construed and is not limited to any particular mechanism; any reduction of the extent of binding constitutes inhibition of binding according to the present invention. Inhibition of binding is generally measured with reference to a control value (maximum binding in absence of test compound) and it is preferred that the IC 50 be low micromolar or less, more preferably nanomolar or less. Contacting takes place under conditions which include sufficient free calcium ions to permit the specific calcium dependent binding of SAP. In addition, it is necessary to ensure a sufficient amount of serum albumin to prevent the calcium-dependent autoaggregation that is characteristic of isolated SAP (18,19). A preferred buffer for the contacting is physiological buffered saline. SAP may be provided in isolated pure form or incorporated in whole serum.
[0018] Suitable ligands to which SAP binds include materials of human or other mammalian origin, materials originating from lower animals or of microbial origin, and synthetic materials. Macromolecular ligands include DNA, chromatin, amyloid fibrils, glycosaminoglycans (specifically heparin, heparan and dermatan sulphates) and agarose and other carbohydrates bearing the carboxyethylidene ring that is specifically recognised by SAP. Synthetic ligands include phosphoethanolamine groups immobilised by covalent carbodiimide coupling to carboxyl groups attached to a solid phase. With appropriate solid materials that bear ligands, such as some micro-organisms, whole organisms such as bacteria can be used, thereby conveniently avoiding the need for purification of the actual ligand molecule(s). Suitable bacteria to which SAP avidly binds include Streptococcus pyogenes (20) and Neisseria meningitidis (21). The most suitable virus bearing ligands for SAP is the human influenza virus (22).
[0019] The order in which the SAP, target ligand and test compound are contacted together is not critical. All three components can be mixed at essentially the same time or two of the three components can be mixed and perhaps pre-incubated before addition of the third component. Contacting generally takes place under conditions in which at least one of the components is in the liquid phase. It is convenient, however, for either the SAP or the ligand to form part of a solid phase so that, in the testing procedure, phase separation can be used as a technique to separate bound species from unbound species to facilitate testing for the extent of SAP ligand binding.
[0020] Accordingly, it is preferred that a first component comprising one of SAP or the ligand is present as part of a solid phase, which is contacted with a second component comprising the other as part of a liquid phase. The step of testing for SAP ligand binding may then comprise detecting binding of the second component to the solid phase. Detecting binding of the second component to the solid phase may be effected either by detecting the presence of the second component on the solid phase or by determining the amount of second component unbound to the solid phase and deducing from the amount of second component originally applied to the solid phase the amount actually binding to the solid phase.
[0021] According to this embodiment, the solid phase preferably comprises the first component attached to a solid support, which solid support may comprise a particulate support or a solid surface. In a convenient embodiment, the solid surface comprises an interior surface of the container such as a microtitre plate well.
[0022] Conveniently, the step of testing for SAP ligand binding further comprises washing the solid phase to remove unbound material.
[0023] The second component may be labelled with a detectable label such as a radiolabel, a fluorochrome or an enzyme, as discussed herein. Alternatively, the binding of the second component to the solid phase may be detected immunologically either by antibody binding to the second component as bound to the solid phase or by quantitative immunological determination of the amount of second component not bound to the solid phase.
[0024] The present invention provides in vitro spot tests, low throughput, and high throughput screening procedures for detecting compounds with the capacity to inhibit binding of SAP, from man or other animals, to target ligands. These methods are suitable for screening test compound libraries of natural compounds of organic, inorganic and biological origin, as well as chemical libraries created by conventional synthesis or any form of combinatorial chemistry. They are also suitable for analysis of the mechanism of inhibition of SAP binding, and for evaluation of potency of inhibition during chemical and medicinal chemistry development of potential or actual pharmaceutical products from lead compounds identified by screening or spot testing. The present invention also provides in vivo methods for testing effects and potency of SAP-inhibitory compounds on SAP binding, plasma turnover and catabolism in man and experimental animals.
[0025] In a further embodiment, the present invention provides a method for selecting an anti-osteoarthritis compound from a plurality of test compounds, which comprises providing an array of reaction zones and a plurality of test compounds, contacting in each reaction zone SAP with a ligand thereof under conditions to permit SAP ligand binding, in the presence of one of the test compounds; testing for SAP ligand binding in each reaction zone; and selecting as an anti-osteoarthritis compound any test compound which inhibits binding of SAP to the ligand.
[0026] This method is suitable for a high throughput screening procedure in which the plurality of test compounds comprises a library of test compounds for screening. By providing an array of reaction zones and a plurality of test compounds, the anti-osteoarthritis compound may be selected by performing the method of the present invention in each reaction zone. This enables the method of the present invention to be scaled up for high throughput and can be performed by automated or semi-automated apparatus such as that based on an array of containers such as a microtitre plate well array.
[0027] Suitable compounds may be bound by SAP and thereby block the site of interaction between SAP and the ligand, or they may bind to SAP to alter its structure thereby to inhibit or prevent binding to the ligand. It is known that the SAP molecule has a specific calcium-dependent ligand binding site through which it binds to ligand. A major class of compounds that can be identified using the present invention comprises substances that are bound by the calcium-dependent ligand binding site of SAP so as to interfere with binding of SAP to the ligand. However the present invention also provides for detection and study of compounds that inhibit SAP binding by the other mechanisms listed above.
[0028] Test compounds useful according to the present invention include those candidate compounds described in WO95/05394. This PCT application describes the complete resolution of the three-dimensional structure of SAP by X-ray crystallography. The binding of SAP in vitro to amyloid fibrils is also demonstrated, whereby proteolytic degradation of those fibrils in the presence of proteinases is prevented. This protection by SAP may be abrogated by compounds capable of inhibiting SAP ligand binding activity. Such compounds may therefore be detected by an assay as described in WO95/05394. Candidate test compounds for that assay or for the screening methods described herein may be provided by knowledge of the structure of the ligand binding site identified in WO95/05394. The PCT application also provides a method for the production of a molecule that inhibits the binding of SAP to amyloid fibrils. The method comprises carrying out computer-aided molecular design using the three-dimensional structure of SAP, synthesising the molecules thus designed and testing the molecules for the ability to inhibit binding of SAP to amyloid fibrils and/or the ability to bind to amyloid fibrils. Molecules according to WO95/05394 may therefore be molecules which interact with SAP at and/or around the calcium binding site illustrated therein. Such a molecule may, for example, interact with one or more of the residues Asp58, Asn59, Glu136 Asp138 and Gln37 of human SAP or with the equivalent residues in SAP from another species and/or with one or more basic residues in the region of those residues. Molecules of WO95/05394 may form hydrogen bonds to the hydroxyl groups of Tyr64 and Tyr75 of human SAP or the equivalent residues in SAP of another species.
[0029] In a preferred aspect, the agent comprises a substituted or unsubstituted D-proline or stereoanalogue thereof. Such agents may or may not be capable of inhibiting SAP ligand binding activity or depleting SAP from the plasma of a subject provided that they are effective for treatment or prevention of osteoarthritis in a subject. It is preferred, however, that such agents are capable of inhibiting SAP ligand binding activity or depleting SAP from the plasma of a subject. Such agents may therefore be obtainable by any one of the screening methods described herein.
[0030] A preferred group of D-proline compounds according to the invention has previously been described in EP-A-0915088. This European patent application describes a class of D-prolines which have the formula
[0000]
[0000] wherein
R is
[0031]
[0000] the group;
R 1 is hydrogen or halogen; X is —(CH 2 ) n —; —CH(R 2 )(CH 2 ) n —; —CH 2 O(CH 2 ) n —; —CH 2 NH—; benzyl, —C(R 2 )═CH—; —CH 2 CH(OH)—; or thiazol-2,5-diyl; Y is —S—S—; —(CH 2 ) n —; —O—; —NH—; —N(R 2 )—; —CH═CH—; —NHC(O)NH—; —N(R 2 )C(O)N(R 2 )—; —N[CH 2 C 6 H 3 (OCH 3 ) 2 ]—; —N(CH 2 C 6 H 5 )—; —N(CH 2 C 6 H 5 )C(O)N(CH 2 C 6 H 5 )—; —N(alkoxyalkyl)-; N(cycloalkyl-methyl)-; 2,6-pyridyl; 2,5-furanyl; 2,5-thienyl; 1,2-cyclohexyl; 1,3-cyclohexyl; 1,4-cyclohexyl; 1,2-naphthyl; 1,4-naphthyl; 1,5-naphthyl; 1,6-naphthyl; biphenylen; or 1,2-phenylen, 1,3-phenylen and 1,4-phenylen, wherein the phenylen groups are optionally substituted by 1-4 substituents, selected from halogen, lower alkyl, lower alkoxy, hydroxy, carboxy, —COO-lower alkyl, nitrilo, 5-tetrazol, (2-carboxylic acid pyrrolidin-1-yl)-2-oxo-ethoxy, N-hydroxycarbamimidoyl, 5-oxo[1,2,4]oxadiazolyl, 2-oxo-[1,2,3,5]oxathiadiazolyl, 5-thioxo[1,2,4]oxadiazolyl and 5-tert-butylsulfanyl-[1,2,4]oxadiazolyl; X′ is —(CH 2 ) n —; —(CH 2 ) n CH(R 2 )—; —(CH 2 ) n OCH 2 —; —NHCH 2 —; benzyl, —CH═C(R 2 )—; —CH(OH)CH 2 ; or thiazol-2,5-diyl; R 2 is lower alkyl, lower alkoxy or benzyl and n is 0-3,
or a pharmaceutically acceptable salt or mono- or diester thereof.
[0038] Stereoanalogues of the D-prolines of this class are also included in the present invention.
[0039] According to the above formula, the term “lower alkyl” denotes straight-chain or branched-chain saturated hydrocarbon residues, preferably with 1 to 4 carbon atoms, such as methyl, ethyl, propyl, isopropyl, n-butyl, 2-butyl, isobutyl and t-butyl. Halogen denotes chlorine, iodine, fluorine and bromine. Compounds of formula 1-A and 1-B can form salts with metals, for example alkali metal salts such as sodium or potassium salts, or alkaline earth metal salts such as calcium or magnesium salts, with organic bases, for example salts with amines, such as n-ethylpiperidine, procaine or dibenzylamine, or salts with basic amine acids such as salts with arginine or lysine. The compounds can also be used in an ester form, such esters being aliphatic or aromatic. These esters include, for example, alkyl and phenolic esters. The most preferred esters are alkyl esters derived from C 1-4 alkanols, especially methyl and ethyl esters.
[0040] These compounds can also be used in the form of their prodrugs at either one or both carbonyl functions.
[0041] Details of examples of these compounds and their syntheses are described in EP-A-0915088.
[0042] Particularly preferred agents according to the present invention include those which comprise a plurality of ligands covalently co-linked so as to form a complex with SAP and a second protein, preferably SAP. At least two of the ligands are the same or different and one of which is capable of being bound by a ligand binding site present on SAP and another is capable of being bound by a ligand binding site present on the second protein. Agents of this type may be capable of inhibiting SAP ligand binding activity and/or may be capable of depleting SAP from the plasma in a subject. As described in WO03/013508 and by Pepys et al (23), such agents were found to be dramatically potent in vivo at depleting the target protein from the circulation by causing it to be rapidly cleared. It is thought that where at least one of the ligands is capable of being bound by a ligand site present on SAP and the other capable of being bound by a ligand site present on SAP or a second different protein, a complex is formed which is identified by the body's own physiological mechanisms as requiring prompt clearance and destruction. Accordingly, SAP is removed from the subject so as to effect treatment or prevention of osteoarthritis. In the compound (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid (WO03/013508 and reference (23)), the carboxylate-containing pyrrolidine ring at each end is bound by the calcium dependent ligand binding site of SAP, resulting in the face-to-face cross-linking of pairs of SAP molecules, as shown by gel filtration, and by atomic resolution X-ray crystallography of the complexes. This cross-linking evidently causes SAP to be cleared from the plasma in vivo and rapidly catabolised, and this is the desired effect of compounds according to this embodiment of the present invention.
[0043] The affinity of each individual ligand-protein binding site interaction does not need to be particularly high provided that the ligand is specific for each target protein. It is possible that a dissociation constant of up to 10 millimolar would suffice. However, it is preferred that the dissociation constant is no more than 1 millimolar, more preferably less than 100 micromolar, most preferably less than 10 micromolar. The affinity is preferably about micromolar or higher. Micromolar affinity has been found to be sufficient in the case of SAP, although the highest possible affinity is clearly desirable.
[0044] In the agents of the present invention, although the ligands may be directly linked together by a covalent bond, the ligands are preferably covalently co-linked by a linker. This enables the ligands to be sufficiently spatially separated whereby a plurality of target proteins may be bound to the agent without one protein hindering the binding of the other protein or proteins. The exact structure of the linker is not critical although it is typically preferred not to include reactive groups. The linker may comprise a linear or branched hydrocarbylene which may have one or more of its carbon atoms optionally substituted by a heteroatom. The linker may have a chain length in the range 2 to 20 atoms. Useful chain length and chemical composition may be determined empirically depending on the proteins with which the agent is to be complexed. Where the agent has two ligands, the linker is typically linear; a preferred general structure is ligand-linker-ligand. This is conveniently denoted a “palindrome” for the purposes of the present application. Although other structures involving three, four or more ligands with an appropriate branched chain linker are also contemplated where three, four or more target proteins could form a complex.
[0045] Pharmaceutical compositions may be formulated comprising an agent according to the present invention optionally incorporating a pharmaceutically-acceptable excipient, diluent or carrier. The pharmaceutical compositions may be in the form of a prodrug comprising the agent or a derivative thereof which becomes active only when metabolised by the recipient. The exact nature and quantities of the components of such pharmaceutical compositions may be determined empirically and will depend in part upon the route of administration of the composition. Routes of administration to recipients include oral, buccal, sublingual, by inhalation, topical (including ophthalmic), rectal, vaginal, nasal and parenteral (including intravenous, intra-arterial, intramuscular, subcutaneous and intra-articular) For convenience of use, dosages according to the present invention are preferably administered orally but this will depend on the actual drug and its bioavailability.
[0046] According to this aspect of the invention it is preferred that the ligand capable of being bound by the ligand binding sites on SAP comprises a substituted or unsubstituted D-proline or stereoanalogue thereof. A particularly preferred D-proline is (R)-1-[6-(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid or a pharmaceutically acceptable salt or mono- or diester thereof.
[0047] Another approach to the inhibition of SAP binding, and depletion of SAP that are desirable according to the present invention is the use of macromolecules that either are bound by, or bind to, SAP. In the first category are peptides of various sizes containing one, or preferably more that one, carboxy terminal D-proline residues and preferably composed of D-amino acids in order to resist proteolytic degradation in vivo. The ligands for SAP function in the same way as the low molecular weight compounds containing D-proline described here, in being bound by SAP, inhibiting the binding of SAP to other ligands in vivo, and promoting the accelerated clearance of SAP from the circulation with beneficial effects on osteoarthritis. SAP also recognises and binds other peptide motifs, including β-bends with aspartic acid and other residues in the apical position, and these types of peptide sequences are also therefore desirable. In the second category, macromolecules that bind to SAP and deplete it may comprise antibodies specific for human SAP, and for the presently desired therapeutic purpose these preferably are monoclonal antibodies that are preferably either humanised or are entirely human, or are lower molecular weight fragments of antibody molecules, such as Fv fragments, that retain their specific binding capacity for SAP. These moieties recognise and bind to SAP in vivo after administration by parenteral injection, and promote the accelerated clearance and depletion of SAP from the circulation. Generally, antibodies to SAP useful according to the present invention should not activate complement, in order to avoid potentially harmful pro-inflammatory effects when they bind to SAP in vivo. They also should preferably not recognise, bind to and damage the normal tissue structures in the body that bear SAP molecules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The present invention will now be described in further detail by way of example only, with reference to the following Examples and to the accompanying drawings, in which:
[0049] FIGS. 1 to 3 show traces from surface plasmon resonance experiments assessing the effect of 1-[(S)-3-Mercapto-2-methylpropionyl]-D-proline (designated Ro-3479 on these figures) on binding of SAP to amyloid fibrils in the presence and absence of calcium;
[0050] FIG. 4 shows a scintigraphic image of the hands of a patient with osteoarthritis 24 hours after intravenous injection of 123 I-labelled SAP; and
[0051] FIG. 5 shows the ratio of the concentration of the various proteins in the synovial fluid and serum from patients with various forms of arthritis-causing effusions.
DETAILED DESCRIPTION OF THE INVENTION
Examples
Methods for Showing Binding of SAP to Ligands
[0052] In order to identify compounds that inhibit ligand binding of SAP it is first necessary to have methods for showing such binding.
1] Binding of SAP to Solid Phase Ligands.
[0053] For the purposes of this invention, the binding of SAP to test ligands can be demonstrated directly by allowing SAP, provided either by whole human or animal serum, or in isolated purified form, to contact the solid phase ligand. Contact takes place in physiological buffered saline containing sufficient free calcium ions (about 2 mmol/l), which are essential for ligand binding by SAP. In the case of isolated human SAP, the buffer must also contain 40 g/l of human or bovine serum albumin, in order to keep the SAP in solution; at lower albumin concentrations isolated human SAP rapidly autoaggregates and precipitates in the presence of calcium (18,19). Suitable ligands to which SAP shows its typical calcium dependent binding include agarose (24), phosphoethanolamine (25), DNA (26), chromatin (27), and amyloid fibrils (12,28). They are immobilized on particles, such as agarose, acrylamide, polystyrene, latex, cellulose, or other beads, or on membranes, filters, or plastic or other solid surfaces such as microtitre plates or individual tubes, or may be integral components of solid particles, such as bacteria or agarose gel, that can be used directly. Immobilization of soluble ligands, or secondary immobilization of particulate ligands for purposes of convenience, may be by direct non-specific adherence of the ligand, or by covalent attachment via amino, hydroxyl, or other chemical groups on the ligand molecules being coupled directly or via spacer linkers to the solid phase material. After contacting the solid or immobilised ligands, SAP that has not bound is washed away with the same buffer in which binding took place, and the presence of SAP bound to the ligands is detected and quantified. Washing involves phase separation, such as centrifugation of solid particles, or immersion, flow through or flow over of solid surfaces such as membranes, filters, and plastic surfaces. Bound SAP may be detected directly if the source of SAP contains SAP that has been labelled with a detectable marker. Such markers include gamma-emitting isotopes such as 125 I or 131 I for detection in a gamma counter; beta-emitting isotopes such as 14 C or 3 H for detection in a beta or scintillation counter; fluorochromes for detection in a fluorimeter, flow cytometer, or fluorescence activated cell sorter; enzymes such as peroxidase or alkaline phosphatase for detection by their specific catalytic activity. In all of these cases it is essential to demonstrate that the process of directly labelling the SAP does not alter its physiological binding properties. This is done by comparing the binding of labelled and unlabelled SAP to an immobilised solid phase ligand, such as phosphoethanolamine attached using a carbodiimide to carboxyhexyl-Sepharose™. Binding of SAP can also be demonstrated directly by immunochemical assay showing depletion of SAP from the offered source of SAP, and recovery of the bound SAP when, after first washing with calcium containing buffer, the ligand material is eluted with buffer containing EDTA to chelate calcium ions. Alternatively, bound SAP may be detected indirectly, using antibodies raised in rabbits, sheep, goats, rats, mice, guinea pigs or other animals, specific for the SAP of the species being tested. For this purpose the anti-SAP antibodies may themselves be directly labelled with a radioactive isotope, enzyme, fluorochrome or other detectable marker, or the binding of anti-SAP antibodies to bound SAP may be detected using a second antibody directed against the immunoglobulin of the species of the primary anti-SAP reagent. In addition to detection and counting in instruments appropriate for the marker used, binding of SAP to micro-organisms or their components may be visualised directly or indirectly using light, fluorescence or electron microscopy. Enzyme labelled SAP or anti-SAP antibodies can be used for light or electron microscopy, fluorochrome labelled reagents for fluorescence microscopy, and gold (or other electron dense particle) labelling for electron microscopy.
2] Binding of Ligands by Immobilized SAP.
[0054] An alternative approach to demonstration of ligand binding by SAP is to immobilize the SAP on a solid phase and then allow it to bind ligands that are either directly labelled or that can be detected, for example using specific antibodies directed against these ligands. Thus isolated purified SAP from man or other animals can be immobilized on beads, particles, membranes, filters, or plastic or other solid surfaces, by direct non-specific adherence or by covalent coupling, or by trapping with specific anti-SAP antibodies immobilized on the solid phase (29). Using the conditions specified in 1] above, suitable ligands, can then be contacted to the immobilized SAP and allowed to be bound by it.
Inhibition of SAP Binding to Ligands
[0055] Any of the methods set out in 1] and 2] above for showing ligand binding by SAP can be used to test the capacity of compounds to inhibit such binding. However the speed and ease of use of the different techniques vary greatly, as well as their suitability for different purposes. Thus for screening large numbers of compounds, high throughput methods, such as those based on microtitre plates, are essential. A typical method of this type involves having ligand immobilized on the plates, and offering to each well an amount of radiolabelled SAP under conditions such that about 40% of it is bound. Compounds to be tested are added to the wells and preincubated in them before addition of the labelled SAP, and the effect of their presence on subsequent binding of SAP is monitored. In another configuration, the compounds to be tested are preincubated with the labelled SAP before the mixture is added to the plates. The reverse configuration, in which the SAP is immobilized, is also informative. Here the test compounds are preincubated with the immobilized SAP before the detectable ligand is added. These different approaches enable detection of compounds that block ligand binding by SAP by different mechanisms, and help to distinguish between those that are themselves specific ligands for SAP, those that affect the SAP molecule in other ways, and those that interact with the ligand to prevent its recognition by SAP.
Direct Detection of Ligand Binding by SAP and its Inhibition
[0056] Surface plasmon resonance (SPR) is a low throughput but powerfully informative method to identify compounds that are bound by, or themselves bind to SAP, either in a calcium dependent fashion or independently of calcium, for the purposes of the present invention. For example, low molecular weight compounds that inhibit binding of SAP to its macromolecular ligands, including target ligands relevant to the present invention, can be detected by their effect on the signal generated by fluid phase SAP binding to ligand immobilised on the solid phase (Example A). Furthermore, when SAP itself is immobilised on the solid phase in an SPR instrument, the interaction with it of test molecules provided in the fluid phase generates a signal that can be detected and quantified. Purified SAP immobilized within an SPR instrument gives a quantifiable signal when it is exposed to another molecule that forms a complex with the SAP, and this is distinct from the absence of such a signal if no complex is formed. This technique allows compounds to be screened for their capacity to interact with SAP, and does not depend on any specific mode of interaction with SAP, in particular involving the calcium dependent ligand binding site of SAP, so it detects molecules that might not be found in test systems that require calcium dependent SAP binding. Another low throughput but powerful direct method is isothermal calorimetry that measures the heat of interaction in solution between SAP and test compounds according to the present invention. The binding affinity can be measured precisely as a guide to potential efficacy. Typical results by this method for the dissociation constants, K d , between SAP and various compounds are as follows:
[0000]
K d in micromoles per litre (replicate
Compound
measurements)
Phosphoethanolamine
36, 27, 48
Phosphocholine
No binding
N-acetyl-D-proline
16, 23, 17
Ro-63-8695
0.0139, 0.0059, 0.0065, 0.0088
Ro-64-2856
0.019, 0.02
[0057] The latter two compounds are from EP-A-915088, in which Ro-63-8695 is (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid, and Ro-64-2856 is (R)-1-[[4-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-phenoxy]-acetyl]-pyrrolidine-2-carboxylic acid.
[0000] Effects on SAP In Vivo of Compounds that Block SAP-Ligand Binding In Vitro.
[0058] For the purpose of the present invention, compounds that block binding of SAP to target ligands are tested in vivo in transgenic mice expressing human SAP, as described elsewhere (23) for their effects on plasma SAP concentrations and the turnover and catabolism of SAP. Having established by the administration of graded doses that the compounds are not intrinsically toxic, various doses are administered to the human SAP transgenic mice. Serum is taken at regular intervals for immunochemical assay of SAP. In addition, trace radiolabelled human SAP may be injected intravenously at different times in relation to the drug dosage, and both whole body counting and blood sampling are performed to monitor the plasma half life and whole body clearance of SAP (14,30). In addition the tracer SAP is preincubated with different amounts of the compounds being tested, and then injected into mice not receiving any drug, in order to test the effect drug binding has on SAP clearance. According to the present invention, compounds that accelerate SAP clearance in vivo and/or lower plasma SAP concentration, thereby reducing in vivo availability of SAP, are likely to be of therapeutic value.
[0059] Compounds that have undergone formal toxicity testing and found to be acceptable for administration in man, are evaluated for their effects on plasma SAP concentration, half life, turnover and catabolism. Isolated human SAP is trace radiolabelled with 125 I and/or 123 I and injected intravenously, followed by plasma turnover studies and whole body scintigraphic imaging, as described elsewhere (15,23,31).
Example A
Use of Surface Plasmon Resonance to Detect Inhibition of Calcium Dependent Ligand Binding by SAP
[0060] Synthetic Aβ-42 amyloid fibrils (28) were covalently immobilised on the reactant surface of the Fisons IAsys surface plasmon resonance instrument, and then exposed to isolated SAP (32) in solution in Tris-buffered physiological saline in the absence of calcium (shown as TN/N in the Figures). No binding of SAP occurred and thus no signal was generated. Introduction of calcium allowed the SAP to bind specifically to the immobilised amyloid fibrils, generating a readily detectable signal ( FIG. 1 ). 1-[(S)-3-Mercapto-2-methylpropionyl]-D-proline (designated on the Figures as Ro-3479) is a specific inhibitor of calcium dependent ligand binding by SAP. Addition of 1-[(S)-3-Mercapto-2-methylpropionyl]-D-proline (Ro-3479) at 500 μmol/l in Tris-buffered physiological saline containing calcium (TC in the Figures), completely reversed the binding of SAP and the corresponding signal ( FIG. 1 ). After addition of SAP in the absence of calcium, followed by Ro-3479 at 100 μmol/l, and then allowing equilibration of the system, subsequent addition of calcium to enable specific calcium dependent ligand binding by SAP was followed by no signal ( FIG. 2 ), indicating that Ro-3479 not only dissociates SAP binding but also inhibits it. The solid phase ligand was regenerated for further calcium dependent ligand binding, by washing it with EDTA in Tris-buffered physiological saline (TE in the Figures), and then re-exposed to SAP in TN buffer followed by calcium. The typical signal reflecting ligand binding by SAP was observed again, and then completely reversed by addition of Ro-3479 at 50 μmol/l ( FIG. 3 ).
Example B
Screening for Inhibitors of Binding of 125 I Radiolabelled SAP to Neisseria meningitidis Organisms Immobilized in Microtitre Plates
Materials and Methods
[0061] A suspension of heat killed Neisseria meningitidis at 1×10 8 organisms per ml in PBS was dispensed to polystyrene microtitre plates at 50 μl volumes per well, and left overnight at 4° C. All wells were then washed three times with 200 μl volumes of PBS containing 0.05% v/v Tween 20, prior to equilibration for 2 min with 0.01M Tris buffered 0.14M NaCl/0.002M CaCl 2 at pH 8.0 (TC buffer), containing 4% w/v BSA and 0.05%/v Tween 20 (TCBT buffer). The wells were then emptied before adding to each one the following reagents. For control uninhibited maximal binding: 35 μl TCBT buffer (containing 2.3 mM CaCl 2 , 5.72% w/v BSA, 0.072% v/v Tween 20), 10 μl TC and 5 μl SAP radiolabelled with 125 I in 0.01M Tris buffered 0.14M NaCl at pH 8.0 (TN buffer), to provide final concentrations of BSA, 4%; Ca 2+ , 2 mM; Tween 20, 0.05%. For background, non-specific, non calcium dependent, binding in the presence of EDTA: 5 μl radiolabelled SAP in TN and 45 μl 0.01M Tris buffered 0.14M NaCl at pH 8.0 containing 11.1 mM EDTA, 4.4% w/v BSA and 0.06% w/v Tween 20 (TEBT buffer) to provide final concentrations of EDTA, 10 mM; BSA, 4%; Tween 20, 0.05%. For testing of inhibitors: 35 μl of TCBT (containing 2.3 mM Ca 2+ , 5.72% BSA and 0.072% Tween 20), 10 μl TC containing test compounds at 10 mM, 1 mM, 100 μM, 10 μM or 1 μM, and 5 μl of radiolabelled SAP in TN. All wells were then incubated at room temperature for 2 h before being washed three times with 200 μl volumes of TCBT, allowed to dry for 1 h at room temperature, and bound radiolabelled SAP was then counted.
[0062] The compounds tested in the experiment shown here were a family of molecules developed as inhibitors of SAP binding to amyloid fibrils, following identification of an initial lead molecule during high throughput screening of a large compound library according to U.S. Pat. No. 6,126,918. The original hit was 1-[(S)-3-Mercapto-2-methylpropionyl]-D-proline, (Ro-15-3479), and a dimer of one of its diastereoisomers, (R)-1-[(S)-3-[(S)-3-[(R)-2-carboxy-pyrrolidin-1-yl]-2-methyl-3-oxo-propyldisulfanyl]-2-methyl-propionyl]-pyrrolidine-2-carboxylic acid (Ro-63-3300) was found to be much more potent. The other two diastereoisomers did not inhibit ligand binding by SAP. A chemistry programme then produced, (R)-1-[6-(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid (Ro-63-8695) (Example 8b of EP-A-915088) and a family of related molecules, that were tested here. Their chemical names and coded designations are listed below:
Ro-64-4383: (R)-1-[[2,5-Dihydroxy-4-[2-[(R)-2-carboxy-pyrrolidin-1-yl]-2-oxo-ethyl]-phenyl]-acetyl]-pyrrolidine-2-carboxylic acid Ro-642856: (R)-1-[[4-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-phenoxy]-acetyl]-pyrrolidine-2-carboxylic acid Ro-63-3300: (R)-1-[(S)-3-[(S)-3-[(R)-2-carboxy-pyrrolidin-1-yl]-2-methyl-3-oxo-propyldisulfanyl]-2-methyl-propionyl]-pyrrolidine-2-carboxylic acid Ro-15-3479: 1-[(S)-3-Mercapto-2-methylpropionyl]-D-proline Ro-64-2848: (R)-1-[[3-[2-[(R)-1-Carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-2-methyl-phenoxy]-acetyl]-pyrrolidine-2-carboxylic acid Ro-64-2668: (R)-1-[[3-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethyl]-phenyl]-acetyl]-pyrrolidine-2-carboxylic acid Ro-64-2845: (R)-1-[[2-[2-[(R)-2-carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-3-methoxy-phenoxy]-acetyl]-pyrrolidine-2-carboxylic acid Ro-64-2600: (R)-1-[cis-4-[(R)-2-Carboxy-pyrrolidine-1-carbonyl]-cyclohexanecarbonyl]-pyrrolidine-2-carboxylic acid Ro-64-5607: (R)-1-[[4-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethyl]-naphthalen-1-yl]-acetyl]-pyrrolidine-2-carboxylic acid Ro-64-5445: (R)-1-[[5-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-naphthalen-1-yloxy]-acetyl]-pyrrolidine-2-carboxylic acid Ro-63-8593: (R)-1-[[2-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethoxy]-phenoxyl]-acetyl]-pyrrolidine-2-carboxylic acid Ro-63-7777: (R)-1-[[4-[2-[(R)-2-Carboxy-pyrrolidin-1-yl]-2-oxo-ethyl]-phenyl]-acetyl]-pyrrolidine-2-carboxylic acid
Results
[0075] The capacity of the compounds tested to inhibit binding of SAP to meningococci is expressed as the percentage by which SAP binding was reduced compared to binding in the absence of any inhibitor (Table 1). All binding was inhibited by EDTA, confirming the specific, calcium dependent, nature of the interaction. Phosphoethanolamine, a well known ligand of SAP (25,32), produced inhibition at high concentration, but only modest effects when diluted. Phosphocholine, the specific ligand of C-reactive protein, the other human plasma pentraxin protein closely related to SAP, had virtually no effect, as expected since there is no other evidence that SAP recognises and binds to phosphocholine under physiological conditions. The Ro-63-8695 family of molecules were potent inhibitors with IC 50 values in the sub-micromolar range in several cases. These compounds are thus candidates for further testing according to the present invention.
[0000]
TABLE 1
Percent inhibition by various compounds of binding of radiolabelled SAP
to immobilized Neisseria meningitidis
Molarity
Compound
2 mM
200 μM
20 μM
2 μM
200 nM
None
0
0
0
0
0
EDTA 10 mM
100
nd
nd
nd
nd
Phosphoethanolamine
95
41
32
18
7
Phosphocholine
24
3
4
5
0
Ro-63-8695
100
79
74
61
5
Ro-64-4383
100
100
95
76
1
Ro-64-2856
100
65
74
65
0
Ro-63-3300
100
69
73
68
28
Ro-15-3479
77
54
50
42
3
Ro-64-2848
100
100
93
64
1
Ro-64-2668
100
100
92
64
28
Ro-64-2845
100
93
92
74
19
Ro-64-2600
100
100
93
73
31
Ro-64-5607
100
100
89
69
13
Ro-64-5445
100
100
81
72
30
Ro-63-8593
100
100
87
77
18
Ro-63-7777
100
100
73
64
7
Example C
Screening for Inhibitors of Binding of 125 I Radiolabeled SAP to Chromatin Immobilized in Microtitre Plates
Materials and Methods
[0076] A solution containing 100 μg/ml chicken erythrocyte native long chromatin (27), in PBS adjusted to pH 9, was dispensed to microtitre plates containing N-oxysuccinimide-activated surfaces, at 50 μl volumes per well and left at room temperature for 1 h. All wells were then washed three times with 200 μl volumes of PBS, pH 7.4, containing 0.05% v/v Tween 20 (PBST) and unreacted active sites were blocked by the addition of 50 μl of 2% w/v BSA in PBS, pH 7.4, to each well, for 30 min at room temperature. Wells were then washed three times with 200 μl volumes of PBST prior to equilibration for 2 min with 0.01M Tris buffered 0.14M NaCl/0.002M CaCl 2 at pH 8.0 (TC buffer), containing 4% w/v BSA and 0.05% v/v Tween 20 (TCBT buffer). The wells were then emptied before adding to each one the following reagents. For control uninhibited maximal binding: 35 μl TCBT buffer (containing 2.3 mM CaCl 2 , 5.72% w/v BSA, 0.072% v/v Tween 20), 10 μl TC and 5 μl SAP radiolabelled with 125 I-in 0.01M Tris buffered 0.14M NaCl at pH 8.0 (TN buffer), to provide final concentrations of BSA, 4%; Ca 2+ , 2 mM; Tween 20, 0.05%. For background, non specific, non calcium dependent, binding in the presence of EDTA: 5 μl radiolabelled SAP in TN and 45 μl 0.01M Tris buffered 0.14M NaCl at pH 8.0 containing 11.1 mM EDTA, 4.4% w/v BSA and 0.06% w/v Tween 20 (TEBT buffer) to provide final concentrations of EDTA, 10 mM; BSA, 4%; Tween 20, 0.05%. For testing of inhibitors: 35 μl of TCBT (containing 2.3 mM Ca 2+ , 5.72% BSA and 0.072% Tween 20), 10 μl TC containing test compounds at 10 mM, 1 mM, 100 μM, 10 μM or 1 μM, and 5 μl of radiolabelled SAP in TN. All wells were then incubated at room temperature for 2 h before being washed three times with 200 μl volumes of TCBT, allowed to dry for 1 h at room temperature, and bound radiolabelled SAP was then counted. The compounds tested in the experiment shown here were the same as those specified in Example B above.
Results
[0077] The capacity of the compounds tested to inhibit binding of SAP to chromatin is expressed as the percentage by which SAP binding was reduced compared to binding in the absence of any inhibitor (Table 2). All binding was inhibited by EDTA, confirming the specific, calcium dependent, nature of the interaction. Binding to control wells without chromatin and just blocked with BSA was at the same background level as seen with complete inhibition by EDTA or the specific inhibitors. Phosphoethanolamine, a well known ligand of SAP (25,32), produced inhibition at high concentration, but only modest effects when diluted. Phosphocholine, the specific ligand of C-reactive protein, the other human plasma pentraxin protein closely related to SAP, had virtually no effect, as expected since there is no other evidence that SAP recognises and binds to phosphocholine under physiological conditions. The Ro-63-8695 family of molecules were potent inhibitors with IC 50 values in the micromolar range in several cases. These compounds are thus candidates for further testing according to the present invention, although interestingly this assay was less sensitive than that using meningococci as the immobilised ligand.
[0000]
TABLE 2
Percent inhibition by various compounds of binding of radiolabelled SAP
to immobilized native long chromatin
Molarity
Compound
2 mM
200 μM
20 μM
2 μM
200 nM
None
0
0
0
0
0
Phosphoethanolamine
94
59
36
9
3
Phosphocholine
19
3
0
0
2
Ro-63-8695
93
87
69
29
1
Ro-64-4383
97
88
78
45
0
Ro-64-2856
91
75
56
36
1
Ro-63-3300
99
88
69
34
3
Ro-15-3479
81
46
72
14
0
Ro-64-2848
98
95
65
22
0
Ro-64-2668
98
94
56
18
0
Ro-64-2845
100
96
75
Nd
11
Ro-64-2600
100
94
67
35
1
Ro-64-5607
100
96
77
35
15
Ro-64-5445
96
82
74
51
12
Ro-63-8593
96
89
77
34
7
Ro-63-7777
92
66
39
19
4
Example D
Screening for Inhibitors of Binding of 125 I Radiolabelled SAP to Influenza Virus Immobilized in Microtitre Plates
Materials and Methods
[0078] A concentrated suspension of purified influenza virus A/Shanghai/24/90 at 10 mg protein per ml in PBS was diluted 1:50 in PBS and then dispensed to polystyrene microtitre plates at 50 μl volumes per well, and left overnight at 4° C. All wells were then emptied before blocking by addition to each well of 200 μl of 2% w/v BSA in PBS and incubation at room temperature for 1 h. All wells were then washed three times with 200 μl volumes of PBS containing 0.05% v/v Tween 20, prior to equilibration for 2 min with 0.01M Tris buffered 0.14M NaCl/0.002M CaCl 2 at pH 8.0 (TC buffer), containing 4% w/v BSA and 0.05% v/v Tween 20 (TCBT buffer). The wells were then emptied before adding to each one the following reagents. For control uninhibited maximal binding: 35 μl TCBT buffer (containing 2.3 mM CaCl 2 , 5.72% w/v BSA, 0.072% v/v Tween 20), 10 μl TC and 5 μl SAP radiolabelled with 125 I (32) in 0.01M Tris buffered 0.14M NaCl at pH 8.0 (TN buffer), to provide final concentrations of BSA, 4%; Ca 2+ , 2 mM; Tween 20, 0.05%. For background, non-specific, non calcium dependent, binding in the presence of EDTA: 5 μl radiolabelled SAP in TN and 45 μl 0.01M Tris buffered 0.14M NaCl at pH 8.0 containing 11.1 mM EDTA, 4.4% w/v BSA and 0.06% w/v Tween 20 (TEBT buffer) to provide final concentrations of EDTA, 10 mM; BSA, 4%; Tween 20, 0.05%. For testing of inhibitors: 35 μl of TCBT (containing 2.3 mM Ca 2+ , 5.72% BSA and 0.072% Tween 20), 10 μl TC containing test compounds at 10 mM, 1 mM, 100 μM, 10 μM or 1 μM, and 5 μl of radiolabelled SAP in TN. All wells were then incubated at room temperature for 2 h before being washed three times with 200 μl volumes of TCBT, allowed to dry for 1 h at room temperature, and bound radiolabelled SAP was then counted. The compounds tested in the experiment shown here were the same as those specified in Example B above.
Results
[0079] The capacity of the compounds tested to inhibit binding of SAP to the immobilised influenza virus is expressed as the percentage by which SAP binding was reduced compared to binding in the absence of any inhibitor (Table 3). All binding was inhibited by EDTA, confirming the specific, calcium dependent, nature of the interaction. Binding to control wells without virus and just blocked with BSA was at the same background level as seen with complete inhibition by EDTA or the specific inhibitors. Phosphoethanolamine, a well known ligand of SAP (25,32), produced inhibition at high concentration, but only modest effects when diluted. Phosphocholine, the specific ligand of C-reactive protein, the other human plasma pentraxin protein closely related to SAP, had virtually no effect, as expected since there is no other evidence that SAP recognises and binds to phosphocholine under physiological conditions. The Ro-63-8695 family of molecules were potent inhibitors with IC 50 values in the sub-micromolar, high nanomolar, range in several cases. These compounds are thus candidates for further testing according to the present invention, and interestingly this assay was more sensitive than those using either whole meningococci or native long chromatin as the immobilised ligand.
[0000]
TABLE 3
Percent inhibition by various compounds of binding of radiolabelled SAP
to immobilized influenza virus
Molarity
Compound
2 mM
200 μM
20 μM
2 μM
200 nM
None
0
0
0
0
0
Phosphoethanolamine
69
51
42
8
1
Phosphocholine
3
5
5
2
0
Ro-63-8695
98
96
90
81
36
Ro-64-4383
89
89
80
57
24
Ro-64-2856
87
84
82
77
3
Ro-63-3300
91
91
90
78
47
Ro-15-3479
68
51
40
30
12
Ro-64-2848
85
81
81
65
24
Ro-64-2668
82
77
73
68
25
Ro-64-2845
89
77
62
52
16
Ro-64-2600
92
89
83
76
0
Ro-64-5607
98
94
95
64
4
Ro-64-5445
80
76
64
51
23
Ro-63-8593
94
93
88
68
44
Ro-63-7777
89
89
85
65
37
Example E
Accumulation of Labelled SAP in Joints of Patients Suffering from Arthritis
[0080] Accumulation of labelled SAP was found in joints of patients without dialysis amyloidosis who were suffering from other forms of arthritis: 5 individuals with osteoarthritis ( FIG. 4 ), 12 with rheumatoid arthritis, and one subject with a traumatic effusion. In each of these patients, labelled SAP was detected in all joints with a significant effusion, regardless of aetiology. This in itself is not surprising since it is known that plasma proteins enter joint effusions. However, in 20 out of 30 patients with various different arthropathies we have also observed uptake of labelled SAP into some joints that did not have clinically detectable effusions.
[0081] FIG. 4 shows a scintigraphic image of the hands of a patient with osteoarthritis 24 h after intravenous injection of 123 I-labelled SAP. Uptake and retention of SAP is indicated in both carpal areas, in the second metacarpophalangeal joints, and some interphalangeal joints.
[0082] One possible mechanism for localisation of SAP from the blood to a diseased joint may be the presence within the joint of amyloid deposits in articular and peri-articular structures. There is indeed extensive evidence for the widespread presence of microscopic amyloid deposits in the synovium, articular cartilage and/or joint capsules of elderly individuals (33-44). However the overall impression from these observational studies of autopsy and/or resection specimens is that the amyloid deposits are mainly associated with increasing age of the subjects and not particularly with extent or severity of clinical or pathological manifestations of osteoarthritis. Alternatively, or in addition, SAP may be binding to ligands on structures other than amyloid fibrils that are present in inflamed or damaged joints. The calcium-dependent binding of SAP to glycosaminoglycans in vitro has been reported (45), but was specific for heparan and dermatan sulphates, rather than the chrondroitin sulphate and hyaluronic acid that are most abundant in cartilage and synovial fluid respectively. Nevertheless, glycosaminoglycans are ubiquitous in connective tissue and may be abnormally exposed and thereby provide ligands for SAP in and around diseased joints. Another ligand to which SAP binds avidly, in vivo as well as in vitro, is DNA (26,27), both free and within chromatin when this is exposed by cell death (46), and SAP also binds to apoptotic cells in vivo (47). Increased cell death in inflamed joints, whether by apoptosis or by necrosis, exposing chromatin, may provide an abnormal density of ligands and thus a focus for SAP deposition.
Example F
SAP Binding to Ligands in Diseased Joints
[0083] In order to test whether SAP may be binding to ligands in diseased joints, we first compared the distribution of radiolabelled human serum albumin with that of SAP in two patients. In one with proven dialysis associated amyloid, the joint uptake of SAP was very much greater than that of albumin, showing that the SAP localisation was specific for amyloid. In contrast, in a patient with active rheumatoid arthritis and multiple affected joints with effusions, the localisation of albumin and SAP were generally comparable, suggesting a similar non-specific process of effusion into the synovial space for both proteins, although occasional joints showed greater retention of SAP than of albumin. Furthermore, in one patient whose knee joint effusions were aspirated to dryness 24 h after injection of radiolabelled SAP, there remained strong localisation of SAP in the joints. Secondly, we measured the synovial fluid and serum concentrations of SAP and other plasma proteins in paired samples from 15 patients with joint effusions of different aetiologies, and calculated the synovial fluid:serum ratios. There is a well known inverse linear relationship between this ratio and the relative molecular mass of the proteins, reflecting their relative ease of access by diffusion from the circulation into the joint space. However, the ratio was remarkably and substantially lower for SAP than expected for a protein of its molecular mass ( FIG. 5 ). This indicates that SAP, which evidently can gain access to the synovial fluid, as shown by our studies with labelled SAP, is probably binding to structure(s) within the joint and is therefore not available for detection and assay in the synovial fluid itself.
[0084] FIG. 5 shows the ratio of the concentration of various plasma proteins in the synovial fluid and serum from patients with various forms of arthritis causing effusions. There is a linear relationship, r=0.62, between the relative molecular mass and the synovial fluid/serum concentration ratio for all the proteins shown here except SAP, for which the synovial fluid concentration is markedly lower than predicted from its molecular mass and serum concentration. (Key: α 1 AG, α 1 -acid glycoprotein; Alb, albumin; Trf, transferrin; Cer, ceruloplasmin; α 2 M, α 2 -macroglobulin.)
[0085] The very common and widespread microscopic amyloid deposits in aged and osteoarthritic joints have not hitherto been thought to contribute to the pathogenesis or symptoms of osteoarthritis. It is also not clear how binding of SAP to either amyloid fibrils or other structures in joints might be pathogenetic in osteoarthritis. Although artificially aggregated SAP can activate the complement system (48), and could thereby be pro-inflammatory, the binding of SAP to any of its known ligands not only does not activate complement, but actually inhibits complement activation by the substrate itself (49,50). Also, there is no evidence for complement activation either locally or systemically in patients with osteoarthritis. Nevertheless, in the light of our observations of SAP localisation to joints and the unexpectedly low concentration of SAP free in synovial fluid, we tested whether SAP might be involved in osteoarthritis.
Example G
Treatment of Patients with Osteoarthritis
[0086] Two examples demonstrate the efficacy of such treatment.
[0087] 1) RJ, a 64 year old retired General Practitioner living in New Zealand, has a long history of bone and joint injuries, starting as a child on a farm and continuing as a teenager and then adult playing rugby and skiing. From the age of 42 he has suffered from pain and swelling of previously damaged joints following manual work and especially in cold weather. The proximal interphalangeal joints of the left middle and right fourth fingers, the right elbow and the mid-thoracic intervertebral joints have been most affected. Symptoms and signs have progressively worsened over the past 22 years, so that his capacity for physical work had become very restricted and during winter he has required frequent or continuous treatment with non-steroidal anti-inflammatory drugs. These are all typical manifestations of osteoarthritis. In 2000 the discovery of impaired renal function led eventually to a second, and completely separate diagnosis of hereditary systemic amyloidosis caused by a mutation in the gene for fibrinogen A α-chain. This type of amyloidosis does not affect the joints and its pathogenesis and clinical manifestations are completely unrelated to osteoarthritis.
[0088] He started experimental treatment for his amyloidosis on 9 Oct. 2001 with (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid, 10 mg b.d. by subcutaneous injection. In January 2002, after three months on this potent SAP depleting drug and with his plasma SAP concentration consistently reduced by over 95%, he first noted that his symptoms of arthritis were less troublesome than before. This improvement was sustained and increased so that by April 2002, the autumn in New Zealand, it was impressively beyond doubt. Throughout that winter, for the first time in many years, he no longer required treatment with non-steroidal anti-inflammatory drugs, despite increased physical activity. He has continued treatment with (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid up to the present (June 2003) and all his symptoms of osteoarthritis have, remarkably, remained in remission. Over the past few months he has been doing regular hard physical work on the land, fencing and landscaping, including lifting and carrying significant weights, without suffering any of the pain and swelling that previously severely affected him even without the stress of unusual physical activity.
[0089] 2) CD, a 49 year old service worker from Wales, had a 6-8 year history of pain and reduced function in several joints. Her shoulders were painful, particularly when reaching up or behind her head, making drying her hair and some household tasks painful and difficult. She had mid-thoracic back pain and bilateral ankle aches on most days, usually caused by prolonged standing. She also experienced pain in her right wrist when performing some tasks, particularly opening jars, a manoeuvre that she found difficult. These symptoms are all compatible with osteoarthritis.
[0090] CD has hereditary systemic amyloidosis caused by a mutation in the gene for apolipoprotein AI, diagnosed in October 2001 during investigation of chronic renal impairment. This type of amyloidosis does not affect the joints or cause arthritic symptoms. She started experimental treatment for her amyloidosis on 22 Oct. 2001 with (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid, 15 mg b.d. by subcutaneous injection. In December 2001, after two months on this potent SAP depleting drug and with her plasma SAP concentration consistently reduced by over 95%, she first noted that her joint symptoms were significantly less troublesome than before. This improvement was sustained and increased so that by January 2002 she was free of pain and had normal function of her joints. Treatment with (R)-1-[6-[(R)-2-Carboxy-pyrrolidin-1-yl]-6-oxo-hexanoyl]pyrrolidine-2-carboxylic acid finished in October 2002 and her remarkable remission has continued to the present (June 2003).
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Use of an agent capable of inhibiting SAP ligand binding activity or depleting SAP from the plasma of a subject for the production of a medicament for treatment or prevention of osteoarthritis in the subject.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority to U.S. Provisional Patent Application Ser. No. 61/180,321 filed May 21, 2009, hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention provides compositions and methods to treat lymphoma and cancer. In particular, the present invention provides treatment of lymphoma and cancer using anti-HERV-K(HML-2) therapies. The present invention further provides compositions and methods for characterizing patient samples to, for example, select or identify therapeutic options or assess the impact of therapies.
BACKGROUND OF THE INVENTION
[0003] Non Hodgkin's lymphoma(NHL) has an annual incidence of approximately 12.8 cases/year/100000 persons from 2000-2003 as compared to breast cancer at 82.7, prostate cancer at 60, lung cancer at 27.2 and colorectal cancer at 20.5 cases/year/100,000 people. In individuals with HIV infection from 1992-1995 the incidence of NHL was 1011.8 cases/100000 HIV patients/year or 59.5 times higher than the general population but this incidence has fallen dramatically to 212.5 cases/year/100,000 HIV infected patients from 2000-2003 (16.6 times higher than the general population). Central nervous system lymphoma and diffuse large B cell lymphoma have been most dramatically affected. This fall in incidence is due mostly to the advent of highly active antiretroviral therapy (HAART) and represents one of the greatest triumphs in cancer prevention in modern medicine. In addition to reduction in incidence of lymphoma, HAART has allowed better survival of patients when they are treated with chemotherapy so that in some studies the survival of HIV infected patients from DHBCL is almost as good as in non HIV patients.
[0004] Epstein Barr Virus (EBV) and Human Herpes Virus-8 (HHV-8) have been postulated to be the principal viral agents associated with HIV associated lymphomas. EBV is found in almost 100% of central nervous system lymphoma and is present in most cases of diffuse large B cell lymphoma (DLBCL) with immunoblastic morphology. EBV is present in over 60% of Burkitt's lymphoma and most cases of HIV associated Hodgkin's lymphoma. The recently discovered virus HHV 8 has been found in all cases of Kaposi's sarcoma. In the rare cases of primary effusion lymphomas (PEL) and its solid variant plasmablastic lymphoma (PBL) of the oral cavity 100% of tumor cells carry multiple copies of HHV8 in addition to carrying EBV in up to 90% of tumors. HHV8 is also present in 100% of large B cell lymphoma arising in Kaposi's sarcoma-associated herpes virus (KSHV) associated multicentric Castleman's disease. In this rare lymphoma the KSHV infected B cells have a pre plasma cell phenotype and plasmacytic/plasmablastic morphology. In spite of the association of these viruses with the above HIV associated lymphomas, these two gamma herpes viruses cannot account for over 60% of DLBCL which lack immunoblastic plasmacytoid features (which are the most common lymphomas occurring in HIV) and over 30% of HIV associated Burkitt's lymphoma. In non HIV infected patients including the most common lymphomas notably DLBCL and follicular lymphoma, EBV and HHV 6 are uncommonly found except possibly in some Burkitt's lymphoma where it is found only in patients from epidemic areas and is often absent in sporadic BL.
[0005] With the sequencing of the human genome it is apparent that over 8% of the human genome is composed of retroviral elements. HERV K (HML2) appears to be one of the most recent elements to have entered the primate genome having its first entry estimated to be about 30,000,000 years ago. This virus has made multiple subsequent entries with the last being proposed to be about 200,000 years ago. Fully intact HERV K (HML2) DNA is present in about 52 different chromosomal locations. Most of these elements have developed deleterious mutations in gag, pol and env rendering them unable to replicate. However, some have intact gag, some an intact pot and some an intact env.
[0006] HERV K (HML2) exists in 2 forms, type 1 and type 2. The type 1 viruses have a 292 base pair deletion in env which prevents these viruses from making competent envelopes but these virions can produce a regulatory protein called Np9 which has oncogenic properties. Some have intact pol and gag sequences. The type 2 virus have no such deletion and they are able to make envelope protein. The type 2 virus is found in approximately 10 different chromosomal locations in the human genome. Two HERV K (HML2) family members notably HERV K 113 and K115 possess a complete set of viral genes with intact open reading frames which are insertionally polymorphic in man and are probably the most recent HERV K (HML2) entries into the human genome. Type 2 virus also produces a regulatory protein called Rec. Rec is a 14,000 base pair protein which is similar to HIV Rev. This protein acts as a chaperone for mRNA generated in the nucleus to conduct it through the nuclear pore where it can be transcribed into protein. Replicating virions of HERV K (HML2) should produce Rev and this can induce antibody in patients if virus is activated.
[0007] There is growing interest in these viruses to search for active forms which might still have capacity to replicate either by a fully competent virus that may have entered the human genome even more recently than K113 and K115, and/or from some virus which emerges as a fully competent infectious virus through recombination and or through complementation from the wide variety of HERV K (HML2) insertions in the genome.
[0008] Viral particles can be produced by HERV K (HML2) and these were first seen in teratocarcinoma cell lines and antibody to HERV K (HML2) has been demonstrated in some patients with teratocarcinoma. Many breast cancer cell lines produce these particles but how they are linked to breast cancer is not yet known. Recently HERV K (HML2) viral antigens have been demonstrated in malignant melanoma skin biopsies and lymph node metastases and viral particles can be seen in melanoma cell lines. These patients also have antibody present to HERV K (HML2) viral antigens and the higher titers appear to be associated with more wide spread metastatic disease. These viruses appear linked in some way to neoplastic disease.
[0009] To better understand how these viruses might replicate, two laboratories have reconstructed full length HERV K (HML2) viral clones with CMV promoters called the “Phoenix virus” and HERV Kcon and have shown that these reconstituted viruses have capacity to replicate. In patients with HIV, HERV K (HML2) viral RNA can be found in the plasma of HIV patients at high concentration. Furthermore, in both HIV and non HIV associated lymphoma patients, there is a dramatic increase in the HERV K (HML2) viral RNA present in the plasma of these patients. Free HERV K (HML2) viral particles can be visualized in plasma by immune electron microscopy. These particles have the appropriate density for a retrovirus and have packaged both gag and env proteins as demonstrated by western blot.
SUMMARY
[0010] In some embodiments, the present invention comprises a method for treating cancer comprising treating a subject suffering from cancer with one or more compounds sufficient to reduce the viral load of HERV K (HML-2). In some embodiments of the present invention, a subject suffers from lymphoma. In some embodiments of the present invention, a subject suffers from HIV-associated lymphoma. In some embodiments of the present invention, a subject suffers from non-HIV-associated lymphoma. In some embodiments of the present invention, compounds comprise antiretroviral pharmaceuticals. In some embodiments of the present invention, antiretroviral pharmaceuticals comprise reverse transcriptase inhibitors. In some embodiments, reverse transcriptase inhibitors are selected from nucleoside analog reverse transcriptase inhibitors, nucleotide analog reverse transcriptase inhibitors, and non-nucleoside reverse transcriptase inhibitors. In some embodiments, reducing the viral load of HERV K (HML-2) causes a reduction in tumor burden.
[0011] In some embodiments, the present invention provides a method of screening compounds useful in the treatment of cancer comprising screening compounds for activity in reducing viral load of HERV K (HML-2). In some embodiments, the screening is performed in vitro. In some embodiments, the screening is performed in vivo. In some embodiments, the screening comprises administering one or more compounds to cells and assaying cells for a reduction in viral load of HERV K (HML-2). In some embodiments, the screen comprises high throughput screening. In some embodiments, compounds are further assayed for usefulness in treating cancer. In some embodiments, cancer comprises lymphoma. In some embodiments, lymphoma comprises HIV-associated lymphoma. In some embodiments, lymphoma comprises non-HIV-associated lymphoma. In some embodiments, compounds comprise antiretroviral pharmaceuticals. In some embodiments, antiretroviral pharmaceuticals comprise reverse transcriptase inhibitors. In some embodiments, reverse transcriptase inhibitors are selected from nucleoside analog reverse transcriptase inhibitors, nucleotide analog reverse transcriptase inhibitors, and non-nucleoside reverse transcriptase inhibitors.
[0012] In some embodiments, the presence of, amount of, or type of (e.g., sequence of) HERV K in a subject is identified to characterize a subject. This information may be used to select or monitor a therapy or other intervention. In some embodiments, HERV K is analyzed prior to therapy (i.e., test then treat). In some embodiments, HERV K may further be analyzed during or following treatment (e.g., test/treat/test or treat/test). In some embodiments, therapy is altered following testing (e.g., test/treat/test/treat or treat/test/treat). Various combinations of treatment and assessment of HERV K status are contemplated by the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing summary and detailed description is better understood when read in conjunction with the accompanying drawings which are included by way of example and not by way of limitation.
[0014] FIG. 1 shows a graph depicting the correlation between HERV K (HML-2) type 2 RNA load and large B-cell lymphoma.
[0015] FIG. 2 shows a graph depicting the correlation between HERV K (HML-2) type 2 RNA load and follicular lymphoma.
[0016] FIG. 3 shows a graph depicting a reduction in HERV K (HML-2) type 2 viral load upon cancer remission.
[0017] FIG. 4 shows reduction of reverse transcriptase activity upon treatment of cells with antiretrovirals.
[0018] FIG. 5 shows reduction of reverse transcriptase activity and HERV K (HML-2) type 2 viral load upon treatment of cells with antiretrovirals.
[0019] FIG. 6 shows a graph depicting the effect of AZT and PFA on NCCIT cells.
DEFINITIONS
[0020] To facilitate an understanding of the present invention, a number of terms and phrases are defined below:
[0021] The term “epitope” as used herein refers to that portion of an antigen that makes contact with a particular antibody.
[0022] When a protein or fragment of a protein is used to immunize a host animal, numerous regions of the protein may induce the production of antibodies which bind specifically to a given region or three-dimensional structure on the protein; these regions or structures are referred to as “antigenic determinants”. An antigenic determinant may compete with the intact antigen (i.e., the “immunogen” used to elicit the immune response) for binding to an antibody.
[0023] The terms “specific binding” or “specifically binding” when used in reference to the interaction of an antibody and a protein or peptide means that the interaction is dependent upon the presence of a particular structure (i.e., the antigenic determinant or epitope) on the protein; in other words the antibody is recognizing and binding to a specific protein structure rather than to proteins in general. For example, if an antibody is specific for epitope “A,” the presence of a protein containing epitope A (or free, unlabelled A) in a reaction containing labeled “A” and the antibody will reduce the amount of labeled A bound to the antibody.
[0024] As used herein, the terms “non-specific binding” and “background binding” when used in reference to the interaction of an antibody and a protein or peptide refer to an interaction that is not dependent on the presence of a particular structure (i.e., the antibody is binding to proteins in general rather that a particular structure such as an epitope).
[0025] As used herein, the term “subject” refers to any animal (e.g., a mammal), including, but not limited to, humans, non-human primates, rodents, and the like, which is to be the recipient of a particular treatment. Typically, the terms “subject” and “patient” are used interchangeably herein in reference to a human subject.
[0026] In some embodiments, a subject is selected from a group consisting of subject at risk for developing cancer, a subject suspected of having cancer, a subject suspected of having cancer metastasis, a subject suspected of having cancer recurrence, a subject known to have cancer, a subject undergoing cancer therapy, and a subject that has completed cancer therapy.
[0027] As used herein, the term “subject suspected of having cancer” refers to a subject that presents one or more symptoms indicative of a cancer) or is being screened for a cancer (e.g., during a routine physical). A subject suspected of having cancer may also have one or more risk factors. A subject suspected of having cancer has generally not been tested for cancer. However, a “subject suspected of having cancer” encompasses an individual who has received an initial diagnosis (e.g., a CT scan showing a mass or increased VSA level, breast cancer or lymphoma biopsy, leukemic cells in the circulation or marrows), but for whom the stage of cancer is not known. The term further includes people who once had cancer (e.g., an individual in remission).
[0028] As used herein, the term “subject at risk for cancer” refers to a subject with one or more risk factors for developing a specific cancer. Risk factors include, but are not limited to, gender, age, genetic predisposition, environmental expose, previous incidents of cancer, preexisting non-cancer diseases, and lifestyle.
[0029] As used herein, the term “characterizing cancer in subject” refers to the identification of one or more properties of a cancer sample in a subject, including but not limited to, the presence of benign, pre-cancerous or cancerous tissue, the stage of the cancer, and the subject's prognosis. Cancers may be characterized by the identification of the expression of one or more cancer marker genes, including but not limited to, the cancer markers disclosed herein.
[0030] As used herein, the term “characterizing cancer tissue in a subject” refers to the identification of one or more properties of a cancer tissue sample (e.g., including but not limited to, the presence of cancerous tissue, the presence of pre-cancerous tissue that is likely to become cancerous, and the presence of cancerous tissue that is likely to metastasize). In some embodiments, tissues are characterized by the identification of the expression of one or more cancer markers, including but not limited to, the cancer markers disclosed herein.
[0031] As used herein, the term “cancer marker” refers to any biologic compound, molecule, macromolecule, or complex (e.g. virus (e.g. HERV-K (HML-2)) whose presence or level, alone or in combination with other factors is correlated with cancer or prognosis of cancer. The correlation may relate to either an increased or decreased expression or production. For example, the presence of viral particles ((e.g. HERV-K (HML-2)) may be indicative of cancer, or lack of expression of a gene may be correlated with poor prognosis in a cancer patient. The “cancer marker” may be correlated with cancer or may be causative.
[0032] As used herein, the term “cancer marker genes” refers to a gene or genes whose presence or expression level, alone or in combination with other genes, is correlated with cancer or prognosis of cancer. The correlation may relate to either an increased or decreased expression of the gene. For example, the expression of the gene may be indicative of cancer, or lack of expression of the gene may be correlated with poor prognosis in a cancer patient.
[0033] As used herein, the term “a reagent that specifically detects the presence or absence of HERV-K(HML-2) target” refers to reagents used to detect the presence of or expression of one or more HERV-K(HML-2) targets (e.g., including but not limited to, the cancer markers of the present invention). Examples of suitable reagents include but are not limited to, nucleic acid probes capable of specifically hybridizing to the HERV-K(HML-2) targets of interest, PCR primers capable of specifically amplifying the gene of interest, and antibodies capable of specifically binding to proteins expressed by the gene of interest. Other non-limiting examples can be found in the description and examples below.
[0034] As used herein, the term “instructions for using said kit for detecting cancer in said subject” includes instructions for using the reagents contained in the kit for the detection and characterization of cancer in a sample from a subject. In some embodiments, the instructions further comprise the statement of intended use required by the U.S. Food and Drug Administration (FDA) in labeling in vitro diagnostic products.
[0035] As used herein, the terms “computer memory” and “computer memory device” refer to any storage media readable by a computer processor. Examples of computer memory include, but are not limited to, RAM, ROM, computer chips, digital video disc (DVDs), compact discs (CDs), hard disk drives (HDD), and magnetic tape.
[0036] As used herein, the term “computer readable medium” refers to any device or system for storing and providing information (e.g., data and instructions) to a computer processor. Examples of computer readable media include, but are not limited to, DVDs, CDs, hard disk drives, magnetic tape and servers for streaming media over networks.
[0037] As used herein, the terms “processor” and “central processing unit” or “CPU” are used interchangeably and refer to a device that is able to read a program from a computer memory (e.g., ROM or other computer memory) and perform a set of steps according to the program.
[0038] As used herein, the term “stage of cancer” refers to a qualitative or quantitative assessment of the level of advancement of a cancer. Criteria used to determine the stage of a cancer include, but are not limited to, the size of the tumor, whether the tumor has spread to other parts of the body and where the cancer has spread (e.g., within the same organ or region of the body or to another organ).
[0039] As used herein, the term “providing a prognosis” refers to providing information regarding the impact of the presence of cancer (e.g., as determined by the diagnostic methods of the present invention) on a subject's future health (e.g., expected morbidity or mortality, the likelihood of getting cancer, and the risk of metastasis).
[0040] As used herein, the term “initial diagnosis” refers to results of initial cancer diagnosis (e.g. the presence or absence of cancerous cells). An initial diagnosis does not include information about the stage of the cancer of the risk.
[0041] As used herein, the term “biopsy tissue” refers to a sample of tissue that is removed from a subject for the purpose of determining if the sample contains cancerous tissue. In some embodiment, biopsy tissue is obtained because a subject is suspected of having cancer. The biopsy tissue is then examined (e.g., by microscopy) for the presence or absence of cancer.
[0042] As used herein, the term “non-human animals” refers to all non-human animals including, but are not limited to, vertebrates such as rodents, non-human primates, ovines, bovines, ruminants, lagomorphs, porcines, caprines, equines, canines, felines, ayes, etc.
[0043] As used herein, the term “gene transfer system” refers to any means of delivering a composition comprising a nucleic acid sequence to a cell or tissue. For example, gene transfer systems include, but are not limited to, vectors (e.g., retroviral, adenoviral, adeno-associated viral, and other nucleic acid-based delivery systems), microinjection of naked nucleic acid, polymer-based delivery systems (e.g., liposome-based and metallic particle-based systems), biolistic injection, and the like. As used herein, the term “viral gene transfer system” refers to gene transfer systems comprising viral elements (e.g., intact viruses, modified viruses and viral components such as nucleic acids or proteins) to facilitate delivery of the sample to a desired cell or tissue. As used herein, the term “adenovirus gene transfer system” refers to gene transfer systems comprising intact or altered viruses belonging to the family Adenoviridae.
[0044] As used herein, the term “nucleic acid molecule” refers to any nucleic acid containing molecule, including but not limited to, DNA or RNA. The term encompasses sequences that include any of the known base analogs of DNA and RNA including, but not limited to, 4-acetylcytosine, 8-hydroxy-N6-methyladenosine, aziridinylcytosine, pseudoisocytosine, 5-(carboxyhydroxylmethyl)uracil, 5-fluorouracil, 5-bromouracil, 5-carboxymethylaminomethyl-2-thiouracil, 5-carboxymethylaminomethyluracil, dihydrouracil, inosine, N6-isopentenyladenine, 1-methyladenine, 1-methylpseudouracil, 1-methylguanine, 1-methyl inosine, 2,2-dimethylguanine, 2-methyladenine, 2-methylguanine, 3-methylcytosine, 5-methylcytosine, N6-methyladenine, 7-methylguanine, 5-methylaminomethyluracil, 5-methoxyaminomethyl-2-thiouracil, beta-D-mannosylqueosine, 5′-methoxycarbonylmethyluracil, 5-methoxyuracil, 2-methylthio-N6-isopentenyladenine, uracil-5-oxyacetic acid methylester, uracil-5-oxyacetic acid, oxybutoxosine, pseudouracil, queosine, 2-thiocytosine, 5-methyl-2-thiouracil, 2-thiouracil, 4-thiouracil, 5-methyluracil, N-uracil-5-oxyacetic acid methylester, uracil-5-oxyacetic acid, pseudouracil, queosine, 2-thiocytosine, and 2,6-diaminopurine.
[0045] The term “gene” refers to a nucleic acid (e.g., DNA) sequence that comprises coding sequences necessary for the production of a polypeptide, precursor, or RNA (e.g., rRNA, tRNA). The polypeptide can be encoded by a full length coding sequence or by any portion of the coding sequence so long as the desired activity or functional properties (e.g., enzymatic activity, ligand binding, signal transduction, immunogenicity, etc.) of the full-length or fragment are retained. The term also encompasses the coding region of a structural gene and the sequences located adjacent to the coding region on both the 5′ and 3′ ends for a distance of about 1 kb or more on either end such that the gene corresponds to the length of the full-length mRNA. Sequences located 5′ of the coding region and present on the mRNA are referred to as 5′ non-translated sequences. Sequences located 3′ or downstream of the coding region and present on the mRNA are referred to as 3′ non-translated sequences. The term “gene” encompasses both cDNA and genomic forms of a gene. A genomic form or clone of a gene contains the coding region interrupted with non-coding sequences termed “introns” or “intervening regions” or “intervening sequences.” Introns are segments of a gene that are transcribed into nuclear RNA (hnRNA); introns may contain regulatory elements such as enhancers. Introns are removed or “spliced out” from the nuclear or primary transcript; introns therefore are absent in the messenger RNA (mRNA) transcript. The mRNA functions during translation to specify the sequence or order of amino acids in a nascent polypeptide.
[0046] As used herein, the term “heterologous gene” refers to a gene that is not in its natural environment. For example, a heterologous gene includes a gene from one species introduced into another species. A heterologous gene also includes a gene native to an organism that has been altered in some way (e.g., mutated, added in multiple copies, linked to non-native regulatory sequences, etc). Heterologous genes are distinguished from endogenous genes in that the heterologous gene sequences are typically joined to DNA sequences that are not found naturally associated with the gene sequences in the chromosome or are associated with portions of the chromosome not found in nature (e.g., genes expressed in loci where the gene is not normally expressed).
[0047] As used herein, the term “gene expression” refers to the process of converting genetic information encoded in a gene into RNA (e.g., mRNA, rRNA, tRNA, or snRNA) through “transcription” of the gene (i.e., via the enzymatic action of an RNA polymerase), and for protein encoding genes, into protein through “translation” of mRNA. Gene expression can be regulated at many stages in the process. “Up-regulation” or “activation” refers to regulation that increases the production of gene expression products (i.e., RNA or protein), while “down-regulation” or “repression” refers to regulation that decrease production. Molecules (e.g., transcription factors) that are involved in up-regulation or down-regulation are often called “activators” and “repressors,” respectively.
[0048] In addition to containing introns, genomic forms of a gene may also include sequences located on both the 5′ and 3′ end of the sequences that are present on the RNA transcript. These sequences are referred to as “flanking” sequences or regions (these flanking sequences are located 5′ or 3′ to the non-translated sequences present on the mRNA transcript). The 5′ flanking region may contain regulatory sequences such as promoters and enhancers that control or influence the transcription of the gene. The 3′ flanking region may contain sequences that direct the termination of transcription, post-transcriptional cleavage and polyadenylation.
[0049] The term “wild-type” refers to a gene or gene product isolated from a naturally occurring source. A wild-type gene is that which is most frequently observed in a population and is thus arbitrarily designed the “normal” or “wild-type” form of the gene. In contrast, the term “modified” or “mutant” refers to a gene or gene product that displays modifications in sequence and or functional properties (i.e., altered characteristics) when compared to the wild-type gene or gene product. It is noted that naturally occurring mutants can be isolated; these are identified by the fact that they have altered characteristics (including altered nucleic acid sequences) when compared to the wild-type gene or gene product.
[0050] As used herein, the terms “nucleic acid molecule encoding,” “DNA sequence encoding,” and “DNA encoding” refer to the order or sequence of deoxyribonucleotides along a strand of deoxyribonucleic acid. The order of these deoxyribonucleotides determines the order of amino acids along the polypeptide (protein) chain. The DNA sequence thus codes for the amino acid sequence.
[0051] As used herein, the terms “an oligonucleotide having a nucleotide sequence encoding a gene” and “polynucleotide having a nucleotide sequence encoding a gene,” means a nucleic acid sequence comprising the coding region of a gene or in other words the nucleic acid sequence that encodes a gene product. The coding region may be present in a cDNA, genomic DNA or RNA form. When present in a DNA form, the oligonucleotide or polynucleotide may be single-stranded (i.e., the sense strand) or double-stranded. Suitable control elements such as enhancers/promoters, splice junctions, polyadenylation signals, etc. may be placed in close proximity to the coding region of the gene if needed to permit proper initiation of transcription and/or correct processing of the primary RNA transcript. Alternatively, the coding region utilized in the expression vectors of the present invention may contain endogenous enhancers/promoters, splice junctions, intervening sequences, polyadenylation signals, etc. or a combination of both endogenous and exogenous control elements.
[0052] As used herein, the term “oligonucleotide,” refers to a short length of single-stranded polynucleotide chain. Oligonucleotides are typically less than 200 residues long (e.g., between 15 and 100), however, as used herein, the term is also intended to encompass longer polynucleotide chains. Oligonucleotides are often referred to by their length. For example a 24 residue oligonucleotide is referred to as a “24-mer”. Oligonucleotides can form secondary and tertiary structures by self-hybridizing or by hybridizing to other polynucleotides. Such structures can include, but are not limited to, duplexes, hairpins, cruciforms, bends, and triplexes.
[0053] As used herein, the terms “complementary” or “complementarity” are used in reference to polynucleotides (i.e., a sequence of nucleotides) related by the base-pairing rules. For example, the sequence “5′-A-G-T-3′,” is complementary to the sequence “3′-T-C-A-5′.” Complementarity may be “partial,” in which only some of the nucleic acids' bases are matched according to the base pairing rules. Or, there may be “complete” or “total” complementarity between the nucleic acids. The degree of complementarity between nucleic acid strands has significant effects on the efficiency and strength of hybridization between nucleic acid strands. This is of particular importance in amplification reactions, as well as detection methods that depend upon binding between nucleic acids.
[0054] The term “homology” refers to a degree of complementarity. There may be partial homology or complete homology (i.e., identity). A partially complementary sequence is a nucleic acid molecule that at least partially inhibits a completely complementary nucleic acid molecule from hybridizing to a target nucleic acid is “substantially homologous.” The inhibition of hybridization of the completely complementary sequence to the target sequence may be examined using a hybridization assay (Southern or Northern blot, solution hybridization and the like) under conditions of low stringency. A substantially homologous sequence or probe will compete for and inhibit the binding (i.e., the hybridization) of a completely homologous nucleic acid molecule to a target under conditions of low stringency. This is not to say that conditions of low stringency are such that non-specific binding is permitted; low stringency conditions require that the binding of two sequences to one another be a specific (i.e., selective) interaction. The absence of non-specific binding may be tested by the use of a second target that is substantially non-complementary (e.g., less than about 30% identity); in the absence of non-specific binding the probe will not hybridize to the second non-complementary target.
[0055] When used in reference to a double-stranded nucleic acid sequence such as a cDNA or genomic clone, the term “substantially homologous” refers to any probe that can hybridize to either or both strands of the double-stranded nucleic acid sequence under conditions of low stringency as described above.
[0056] A gene may produce multiple RNA species that are generated by differential splicing of the primary RNA transcript. cDNAs that are splice variants of the same gene will contain regions of sequence identity or complete homology (representing the presence of the same exon or portion of the same exon on both cDNAs) and regions of complete non-identity (for example, representing the presence of exon “A” on cDNA 1 wherein cDNA 2 contains exon “B” instead). Because the two cDNAs contain regions of sequence identity they will both hybridize to a probe derived from the entire gene or portions of the gene containing sequences found on both cDNAs; the two splice variants are therefore substantially homologous to such a probe and to each other.
[0057] When used in reference to a single-stranded nucleic acid sequence, the term “substantially homologous” refers to any probe that can hybridize (i.e., it is the complement of) the single-stranded nucleic acid sequence under conditions of low stringency as described above.
[0058] As used herein, the term “hybridization” is used in reference to the pairing of complementary nucleic acids. Hybridization and the strength of hybridization (i.e., the strength of the association between the nucleic acids) is impacted by such factors as the degree of complementary between the nucleic acids, stringency of the conditions involved, the T m , of the formed hybrid, and the G:C ratio within the nucleic acids. A single molecule that contains pairing of complementary nucleic acids within its structure is said to be “self-hybridized.”
[0059] As used herein, the term “T m ” is used in reference to the “melting temperature.” The melting temperature is the temperature at which a population of double-stranded nucleic acid molecules becomes half dissociated into single strands. The equation for calculating the T m of nucleic acids is well known in the art. As indicated by standard references, a simple estimate of the T m value may be calculated by the equation: T m =81.5+0.41(% G+C), when a nucleic acid is in aqueous solution at 1 M NaCl (See e.g., Anderson and Young, Quantitative Filter Hybridization, in Nucleic Acid Hybridization [1985]). Other references include more sophisticated computations that take structural as well as sequence characteristics into account for the calculation of T m .
[0060] As used herein the term “stringency” is used in reference to the conditions of temperature, ionic strength, and the presence of other compounds such as organic solvents, under which nucleic acid hybridizations are conducted. Under “low stringency conditions” a nucleic acid sequence of interest will hybridize to its exact complement, sequences with single base mismatches, closely related sequences (e.g., sequences with 90% or greater homology), and sequences having only partial homology (e.g., sequences with 50-90% homology). Under ‘stringency conditions,” a nucleic acid sequence of interest will hybridize only to its exact complement, sequences with single base mismatches, and closely relation sequences (e.g., 90% or greater homology). Under “high stringency conditions,” a nucleic acid sequence of interest will hybridize only to its exact complement, and (depending on conditions such a temperature) sequences with single base mismatches. In other words, under conditions of high stringency the temperature can be raised so as to exclude hybridization to sequences with single base mismatches.
[0061] “High stringency conditions” when used in reference to nucleic acid hybridization comprise conditions equivalent to binding or hybridization at 42.degree. C. in a solution consisting of 5.times.SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.5% SDS, 5.times.Denhardt's reagent and 100 .mu.g/ml denatured salmon sperm DNA followed by washing in a solution comprising 0.1.times.SSPE, 1.0% SDS at 42.degree. C. when a probe of about 500 nucleotides in length is employed.
[0062] “Medium stringency conditions” when used in reference to nucleic acid hybridization comprise conditions equivalent to binding or hybridization at 42.degree. C. in a solution consisting of 5.times.SSPE (43.8 g/l NaCl, 6.9 g/lNaH 2 PO 4 H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.5% SDS, 5.times.Denhardt's reagent and 100 .mu.g/ml denatured salmon sperm DNA followed by washing in a solution comprising 1.0.times.SSPE, 1.0% SDS at 42.degree. C. when a probe of about 500 nucleotides in length is employed.
[0063] “Low stringency conditions” comprise conditions equivalent to binding or hybridization at 42.degree. C. in a solution consisting of 5.times.SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.1% SDS, 5.times.Denhardt's reagent [50.times.Denhardt's contains per 500 ml: 5 g Ficoll (Type 400, Pharamcia), 5 g BSA (Fraction V; Sigma)] and 100 .mu.g/ml denatured salmon sperm DNA followed by washing in a solution comprising 5.times.SSPE, 0.1% SDS at 42.degree. C. when a probe of about 500 nucleotides in length is employed.
[0064] The art knows well that numerous equivalent conditions may be employed to comprise low stringency conditions; factors such as the length and nature (DNA, RNA, base composition) of the probe and nature of the target (DNA, RNA, base composition, present in solution or immobilized, etc.) and the concentration of the salts and other components (e.g., the presence or absence of formamide, dextran sulfate, polyethylene glycol) are considered and the hybridization solution may be varied to generate conditions of low stringency hybridization different from, but equivalent to, the above listed conditions. In addition, the art knows conditions that promote hybridization under conditions of high stringency (e.g., increasing the temperature of the hybridization and/or wash steps, the use of formamide in the hybridization solution, etc.) (see definition above for “stringency”).
[0065] As used herein the term “portion” when in reference to a nucleotide sequence (as in “a portion of a given nucleotide sequence”) refers to fragments of that sequence. The fragments may range in size from four nucleotides to the entire nucleotide sequence minus one nucleotide (10 nucleotides, 20, 30, 40, 50, 100, 200, etc.).
[0066] The terms “in operable combination,” “in operable order,” and “operably linked” as used herein refer to the linkage of nucleic acid sequences in such a manner that a nucleic acid molecule capable of directing the transcription of a given gene and/or the synthesis of a desired protein molecule is produced. The term also refers to the linkage of amino acid sequences in such a manner so that a functional protein is produced.
[0067] The term “isolated” when used in relation to a nucleic acid, as in “an isolated oligonucleotide” or “isolated polynucleotide” refers to a nucleic acid sequence that is identified and separated from at least one component or contaminant with which it is ordinarily associated in its natural source. Isolated nucleic acid is such present in a form or setting that is different from that in which it is found in nature. In contrast, non-isolated nucleic acids as nucleic acids such as DNA and RNA found in the state they exist in nature. For example, a given DNA sequence (e.g., a gene) is found on the host cell chromosome in proximity to neighboring genes; RNA sequences, such as a specific mRNA sequence encoding a specific protein, are found in the cell as a mixture with numerous other mRNAs that encode a multitude of proteins. However, isolated nucleic acid encoding a given protein includes, by way of example, such nucleic acid in cells ordinarily expressing the given protein where the nucleic acid is in a chromosomal location different from that of natural cells, or is otherwise flanked by a different nucleic acid sequence than that found in nature. The isolated nucleic acid, oligonucleotide, or polynucleotide may be present in single-stranded or double-stranded form. When an isolated nucleic acid, oligonucleotide or polynucleotide is to be utilized to express a protein, the oligonucleotide or polynucleotide will contain at a minimum the sense or coding strand (i.e., the oligonucleotide or polynucleotide may be single-stranded), but may contain both the sense and anti-sense strands (i.e., the oligonucleotide or polynucleotide may be double-stranded).
[0068] As used herein, the term “purified” or “to purify” refers to the removal of components (e.g., contaminants) from a sample. For example, antibodies are purified by removal of contaminating non-immunoglobulin proteins; they are also purified by the removal of immunoglobulin that does not bind to the target molecule. The removal of non-immunoglobulin proteins and/or the removal of immunoglobulins that do not bind to the target molecule results in an increase in the percent of target-reactive immunoglobulins in the sample. In another example, recombinant polypeptides are expressed in bacterial host cells and the polypeptides are purified by the removal of host cell proteins; the percent of recombinant polypeptides is thereby increased in the sample.
[0069] As used herein, the term “vector” is used in reference to nucleic acid molecules that transfer DNA segment(s) from one cell to another. The term “vehicle” is sometimes used interchangeably with “vector.” Vectors are often derived from plasmids, bacteriophages, or plant or animal viruses.
[0070] The term “expression vector” as used herein refers to a recombinant DNA molecule containing a desired coding sequence and appropriate nucleic acid sequences necessary for the expression of the operably linked coding sequence in a particular host organism. Nucleic acid sequences necessary for expression in prokaryotes usually include a promoter, an operator (optional), and a ribosome binding site, often along with other sequences. Eukaryotic cells are known to utilize promoters, enhancers, and termination and polyadenylation signals.
[0071] The terms “overexpression” and “overexpressing” and grammatical equivalents, are used in reference to levels of mRNA to indicate a level of expression approximately 3-fold higher (or greater) than that observed in a given tissue in a control or non-transgenic animal. Levels of mRNA are measured using any of a number of techniques known to those skilled in the art including, but not limited to Northern blot analysis. Appropriate controls are included on the Northern blot to control for differences in the amount of RNA loaded from each tissue analyzed (e.g., the amount of 28S rRNA, an abundant RNA transcript present at essentially the same amount in all tissues, present in each sample can be used as a means of normalizing or standardizing the mRNA-specific signal observed on Northern blots). The amount of mRNA present in the band corresponding in size to the correctly spliced transgene RNA is quantified; other minor species of RNA which hybridize to the transgene probe are not considered in the quantification of the expression of the transgenic mRNA.
[0072] The term “transfection” as used herein refers to the introduction of foreign DNA into eukaryotic cells. Transfection may be accomplished by a variety of means known to the art including calcium phosphate-DNA co-precipitation, DEAE-dextran-mediated transfection, polybrene-mediated transfection, electroporation, microinjection, liposome fusion, lipofection, protoplast fusion, retroviral infection, and biolistics.
[0073] The term “stable transfection” or “stably transfected” refers to the introduction and integration of foreign DNA into the genome of the transfected cell. The term “stable transfectant” refers to a cell that has stably integrated foreign DNA into the genomic DNA.
[0074] The term “transient transfection” or “transiently transfected” refers to the introduction of foreign DNA into a cell where the foreign DNA fails to integrate into the genome of the transfected cell. The foreign DNA persists in the nucleus of the transfected cell for several days. During this time the foreign DNA is subject to the regulatory controls that govern the expression of endogenous genes in the chromosomes. The term “transient transfectant” refers to cells that have taken up foreign DNA but have failed to integrate this DNA.
[0075] As used herein, the term “selectable marker” refers to the use of a gene that encodes an enzymatic activity that confers the ability to grow in medium lacking what would otherwise be an essential nutrient (e.g. the HIS3 gene in yeast cells); in addition, a selectable marker may confer resistance to an antibiotic or drug upon the cell in which the selectable marker is expressed. Selectable markers may be “dominant”; a dominant selectable marker encodes an enzymatic activity that can be detected in any eukaryotic cell line. Examples of dominant selectable markers include the bacterial aminoglycoside 3′ phosphotransferase gene (also referred to as the neo gene) that confers resistance to the drug G418 in mammalian cells, the bacterial hygromycin G phosphotransferase (hyg) gene that confers resistance to the antibiotic hygromycin and the bacterial xanthine-guanine phosphoribosyl transferase gene (also referred to as the gpt gene) that confers the ability to grow in the presence of mycophenolic acid. Other selectable markers are not dominant in that their use must be in conjunction with a cell line that lacks the relevant enzyme activity. Examples of non-dominant selectable markers include the thymidine kinase (tk) gene that is used in conjunction with tk − cell lines, the CAD gene that is used in conjunction with CAD-deficient cells and the mammalian hypoxanthine-guanine phosphoribosyl transferase (hprt) gene that is used in conjunction with hprt − cell lines. A review of the use of selectable markers in mammalian cell lines is provided in Sambrook, J. et al., Molecular Cloning: A Laboratory Manual, 2nd ed., Cold Spring Harbor Laboratory Press, New York (1989) pp. 16.9-16.15.
[0076] As used herein, the term “cell culture” refers to any in vitro culture of cells. Included within this term are continuous cell lines (e.g., with an immortal phenotype), primary cell cultures, transformed cell lines, finite cell lines (e.g., non-transformed cells), and any other cell population maintained in vitro.
[0077] As used, the term “eukaryote” refers to organisms distinguishable from “prokaryotes.” It is intended that the term encompass all organisms with cells that exhibit the usual characteristics of eukaryotes, such as the presence of a true nucleus bounded by a nuclear membrane, within which lie the chromosomes, the presence of membrane-bound organelles, and other characteristics commonly observed in eukaryotic organisms. Thus, the term includes, but is not limited to such organisms as fungi, protozoa, and animals (e.g., humans).
[0078] As used herein, the term “in vitro” refers to an artificial environment and to processes or reactions that occur within an artificial environment. In vitro environments can consist of, but are not limited to, test tubes and cell culture. The term “in vivo” refers to the natural environment (e.g., an animal or a cell) and to processes or reaction that occur within a natural environment.
[0079] The terms “test compound” and “candidate compound” refer to any chemical entity, pharmaceutical, drug, and the like that is a candidate for use to treat or prevent a disease, illness, sickness, or disorder of bodily function (e.g., cancer). Test compounds comprise both known and potential therapeutic compounds. A test compound can be determined to be therapeutic by screening using the screening methods of the present invention. In some embodiments of the present invention, test compounds include antisense compounds.
[0080] As used herein, the term “sample” is used in its broadest sense. In one sense, it is meant to include a specimen or culture obtained from any source, as well as biological and environmental samples. Biological samples may be obtained from animals (including humans) and encompass fluids, solids, tissues, and gases. Biological samples include blood products, such as plasma, serum, and non-blood products, for example, urine, spinal fluid, bile, saliva, stool, tears, sweat, mucous, semen, cells, and tissues, and the like. Environmental samples include environmental material such as surface matter, soil, water, and industrial samples. Such examples are not however to be construed as limiting the sample types applicable to the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0081] The present invention provides methods to treat and diagnose lymphoma and cancer. In particular, the present invention provides treatment of lymphoma and cancer using anti-HERV-K (HML-2) therapies. Accordingly, the present invention provides methods, reagents, and kits for the detection of markers, drug screening, and therapeutic applications. In some embodiments, HERV-K(HML-2) is a cancer marker (e.g. marker of lymphoma). In some embodiments, HERV-K(HML-2) is a cancer causative agent.
[0082] The practice of the present invention will employ, unless indicated specifically to the contrary, conventional methods of virology, immunology, microbiology, molecular biology and recombinant DNA techniques within the skill of the art, many of which are described below for the purpose of illustration. Such techniques are explained fully in the literature. See, e.g., Sambrook, et al. Molecular Cloning: A Laboratory Manual (2nd Edition, 1989); Maniatis et al. Molecular Cloning: A Laboratory Manual (1982); DNA Cloning: A Practical Approach, vol. I & II (D. Glover, ed.); Oligonucleotide Synthesis (N. Gait, ed., 1984); Nucleic Acid Hybridization (B. Flames & S. Higgins, eds., 1985); Transcription and Translation (B. Hames & S. Higgins, eds., 1984); Animal Cell Culture (R. Freshney, ed., 1986); Perbal, A Practical Guide to Molecular Cloning (1984).
[0083] The human genome harbors numerous retroviral sequences that comprise up to 8% of the host genome, many of which have accumulated lethal mutations that have impaired their ability to replicate. (Nelson et al. Mol Pathol 2003; 56:11-18; Wang-Johanning et al. Oncogene 2003; 22:1528-1535; Hughes et al. Proc Natl Acad Sci USA 2004; 101: 1688-1672). The human endogenous retrovirus type-K (HERV-K.HML-2) family is represented by many proviruses, some of which possess intact open reading frames (ORFs) for gag, prt, pol, and env genes. (Barbulescu et al. Curr Biol 1999; 9:861-868; Paces et al. Nucleic Acids Res 2002; 30:205-206). HERV-K(HML-2) is an endogenous retroviral subfamily with the ability to produce viral particles. (Bannert et al. Proc Natl Acad Sci USA 2002; 101 Suppl 2:14572-14579; Simpson et al. Virology 1996; 222:451-456; Bieda et al. J Gen Virol 2001; 3:591-596; Boller et al. Virology 1993; 1:349-353). However, an intact HERV-K proviral sequence (K113) and perhaps other unidentified unfixed elements may code for replication-competent viruses. (Turner et al. Curr Biol 2001; 11:1531-1535; Moyes et al. Genomics 2005; 86:337-341; Bleshaw et al. J Virol 2005; 79: 12507-12514). The detection of anti-HERV-K antibodies in the plasma of 70% of HIV-1 patients compared to only 3% of healthy blood donors. (Lower et al. Proc Natl Acad Sci USA 1996; 93:5177-5184). Antibodies to HERV-K were also detectable in drug users, but only after HIV-1 seroconversion. (Vogetseder et al. AIDS Res Hum Retroviruses 1993; 9:687-694). U.S. Patent Application 20080261216, herein incorporated by reference in its entirety, describes that it was found that if HERV-K viral particles are made, they may be protected by viral envelopes in plasma of HIV-1 infected individuals, and that the RNA genome is directly amplified from viral RNA extractions of plasma. All of the above references are herein incorporated by reference in their entireties.
[0084] In some embodiments, the present invention provides therapies for cancer and cancer-related illnesses (e.g. Acute Lymphoblastic Leukemia, Acute Myeloid Leukemia, Adrenocortical Carcinoma, AIDS-Related Cancers, AIDS-Related Lymphoma, Anal Cancer, Appendix Cancer, Astrocytoma, Atypical Teratoid/Rhabdoid Tumor,
[0000] Basal Cell Carcinoma, Bile Duct Cancer, Bladder Cancer, bone cancer (e.g. Osteosarcoma or Malignant Fibrous Histiocytoma), Brain Stem Glioma, Brain Tumor (e.g. Adult, Childhood, Brain Stem Glioma, Atypical Teratoid/Rhabdoid Tumor, Embryonal Tumors, Cerebellar Astrocytoma, Cerebral Astrocytoma, Malignant Glioma, Craniopharyngioma, Ependymoblastoma, Ependymoma, Medulloblastoma, Medulloepithelioma, Pineal Parenchymal Tumors of Intermediate Differentiation, Supratentorial Primitive Neuroectodermal Tumors and Pineoblastoma, Visual Pathway and Hypothalamic Glioma, Brain and Spinal Cord Tumors), Breast Cancer, Bronchial Tumors, Burkitt Lymphoma, Carcinoid Tumor, Carcinoma, Atypical Teratoid/Rhabdoid Tumor, Embryonal Tumors, Central Nervous System Lymphoma, Cerebellar Astrocytoma, Cervical Cancer, Childhood Cancers, Chordoma, Chronic Lymphocytic Leukemia, Chronic Myelogenous Leukemia, Chronic Myeloproliferative Disorders, Colon Cancer, Colorectal Cancer, Craniopharyngioma, Cutaneous T-Cell Lymphoma, Embryonal Tumors, Endometrial Cancer, Ependymoblastoma, Ependymoma, Esophageal Cancer, Ewing Family of Tumors, Extracranial Germ Cell Tumor, Extragonadal Germ Cell Tumor, Extrahepatic Bile Duct Cancer, Eye Cancer (e.g. Intraocular Melanoma, Retinoblastoma, etc.), Gallbladder Cancer, Gastric (Stomach) Cancer, Gastrointestinal Carcinoid Tumor, Gastrointestinal Stromal Tumor (GIST), Germ Cell Tumor (e.g. Extracranial, Extragonadal, Ovarian, etc.), Gestational Trophoblastic Tumor, Glioma (e.g., Adult, Childhood, Brain Stem, Cerebral Astrocytoma, Visual Pathway and Hypothalamic, etc.), Hairy Cell Leukemia, Head and Neck Cancer, Hepatocellular (Liver) Cancer, Hodgkin Lymphoma, Hypopharyngeal Cancer, Hypothalamic and Visual Pathway Glioma, Intraocular Melanoma, Islet Cell Tumors (Endocrine Pancreas), Kaposi Sarcoma, Kidney (Renal Cell) Cancer, Laryngeal Cancer, Leukemia (e.g. Acute, Lymphoblastic, Adult, Childhood, Acute Myeloid, Chronic Lymphocytic, Chronic Myelogenous, Hairy Cell, etc.), Lip and Oral Cavity Cancer, Liver Cancer, Lung Cancer (e.g. Non-Small Cell, Small Cell, etc.), Lymphoma (e.g. AIDS-Related, Burkitt, Cutaneous T-Cell, Mycosis Fungoides, Sézary Syndrome, Hodgkin, Adult, Childhood, Non-Hodgkin, Primary Central Nervous System, etc.), Macroglobulinemia, Malignant Fibrous Histiocytoma of Bone and Osteosarcoma, Medulloblastoma, Medulloepithelioma, Melanoma, Merkel Cell Carcinoma, Mesothelioma, Metastatic Squamous Neck Cancer, Mouth Cancer, Multiple Endocrine Neoplasia Syndrome, Multiple Myeloma/Plasma Cell Neoplasm, Mycosis Fungoides, Myelodysplastic Syndromes, Myelodysplastic/Myeloproliferative Diseases, Myelogenous Leukemia (e.g. Chronic, Acute, etc.), Myeloid Leukemia, Myeloma, Myeloproliferative Disorders, Nasal Cavity and Paranasal Sinus Cancer, Nasopharyngeal Cancer, Neuroblastoma, Oral Cancer, Oropharyngeal Cancer, Osteosarcoma and Malignant Fibrous Histiocytoma of Bone, Ovarian Cancer (e.g. Childhood, Ovarian Epithelial Cancer, Ovarian Germ Cell Tumor, Ovarian Low Malignant Potential Tumor, etc.), Pancreatic Cancer, Islet Cell Tumors, Papillomatosis, Paranasal Sinus and Nasal Cavity Cancer, Parathyroid Cancer, Penile Cancer, Pharyngeal Cancer, Pheochromocytoma, Pineal Parenchymal Tumors of Intermediate Differentiation, Pineoblastoma and Supratentorial Primitive Neuroectodermal Tumors, Pituitary Tumor, Plasma Cell Neoplasm/Multiple Myeloma, Pleuropulmonary Blastoma, Pregnancy and Breast Cancer, Primary Central Nervous System Lymphoma, Prostate Cancer, Rectal Cancer, Renal Cell (Kidney) Cancer, Renal Pelvis and Ureter, Respiratory Tract Carcinoma Involving the NUT Gene on Chromosome 15, Retinoblastoma, Rhabdomyosarcoma, Salivary Gland Cancer
Sarcoma, (e.g. Ewing Family of Tumors, Kaposi, Soft Tissue, Adult, childhood, Uterine, etc.), Sézary Syndrome, Skin Cancer (e.g. Nonmelanoma, Childhood, Melanoma, Carcinoma, Merkel Cell, etc.) Small Intestine Cancer, Soft Tissue Sarcoma, Squamous Cell Carcinoma, Squamous Neck Cancer with Occult Primary, Stomach (Gastric) Cancer, Supratentorial Primitive Neuroectodermal Tumors, T-Cell Lymphoma, Testicular Cancer, Throat Cancer, Thymoma and Thymic Carcinoma, Thyroid Cancer, Transitional Cell Cancer of the Renal Pelvis and Ureter, Trophoblastic Tumor, Unknown Primary Site, Unusual Cancers of Childhood Ureter and Renal Pelvis, Urethral Cancer, Uterine Cancer (e.g. Endometrial, Uterine Sarcoma, etc.), Vaginal Cancer, Visual Pathway and Hypothalamic Glioma, Vulvar Cancer, Waldenström Macroglobulinemia, Wilms Tumor, etc.).
[0085] In some embodiments of the present invention, pharmaceutical compositions are used for the treatment of cancer. In some embodiments of the present invention, pharmaceutical compositions are used for the treatment of viral infection (e.g. HERV-K(HML-2)). In some embodiments of the present invention, pharmaceutical compositions are used for the treatment of cancer by the reduction of retroviral load (e.g. HERV-K(HML-2)). Within such methods, the pharmaceutical compositions described herein are administered to a patient, typically a warm-blooded animal (e.g. a human). A patient may or may not be afflicted with cancer. Accordingly, the above pharmaceutical compositions may be used to prevent the development of a cancer or to treat a patient afflicted with a cancer. A patient may or may not have circulating viral particles (e.g. HERV-K(HML-2) particles). Accordingly, the above pharmaceutical compositions may be used to prevent the spread or production of a viral particles (e.g. HERV-K(HML-2)) or to treat a patient afflicted with viral particles (e.g. HERV-K(HML-2)). In some embodiments, a patient treated by the present invention is not infected with HIV (e.g. HIV-1, HIV-2, etc.). Pharmaceutical compositions and vaccines may be administered either prior to or following surgical removal of primary tumors and/or treatment such as administration of radiotherapy or conventional chemotherapeutic drugs. As discussed herein, administration of the pharmaceutical compositions may be by any suitable method, including administration by intravenous, intraperitoneal, intramuscular, subcutaneous, intranasal, intradermal, anal, vaginal, topical and oral routes.
[0086] In some embodiments, the present invention provides therapies that kill cancer cells, induce apoptosis in cancer cells, stop or slow the spread of cancer, stop or reduce cancer metastasis, stop or reduce tumor formation, reduce tumor load, minimize the effects of cancer, support the ability of the body to fight cancer, and/or serve as an antagonist to cancer, cancer cells, or cancer-related diseases. In some embodiments, the compounds act as a cancer therapy by directly or indirectly targeting a cancer marker (e.g. HERV-K(HML-2)). In some embodiments, the present invention provides methods, regents, and kits that are cancer therapies. In some embodiments, the present invention treats cancer (e.g. lymphoma) by reducing or eliminating the viral load (e.g. one of more retroviruses (e.g. HERV-K(HML-2))) within a subject.
[0087] In some embodiments, one or more retroviruses and/or retroviral elements (e.g. HERV-K(HML-2)) are a cause of, the cause of, a contributing factor to, and/or an aggravating factor to cancer (e.g. breast cancer, lymphoma, etc.) and/or cancer-related illnesses. In some embodiments, reducing the viral load of HERV-K(HML-2) and/or other retroviruses provides a cancer therapy (e.g. killing cancer cells, reducing tumor load, etc.). In some embodiments, HERV-K(HML-2) viral proteins are expressed from exogenous genes (e.g. genes which have infected a subject). In some embodiments, HERV-K(HML-2) viral proteins are expressed from endogenous genes (e.g. viral protein genes which are integrated into the subject's genome). In some embodiments, HERV-K(HML-2) viral proteins expressed within a subject are capable of assembling into a viral element (e.g. virion, virus, mature virus, viral particle, etc.). In some embodiments, viral elements (e.g. virion, virus, mature virus, viral particle, etc.) produced and assembled within a subject are capable of reinfecting the subject, infecting another subject, reproducing, and/or replicating. In some embodiments, HERV-K(HML-2) viral proteins expressed within a subject are not capable of assembling into a viral element (e.g. virion, virus, mature virus, viral particle, etc.). In some embodiments, viral elements (e.g. virion, virus, mature virus, viral particle, etc.) produced and assembled within a subject are not capable of reinfecting the subject, infecting another subject, reproducing, and/or replicating. In some embodiments, viral proteins (e.g. HERV-K(HML-2) viral proteins) are expressed from one or more endogenous genes within a subject's genome.
[0088] In some embodiments, the present invention provides one or more antiviral therapies. In some embodiments, compounds of the present invention inhibit one or more retroviruses or retroviral elements (e.g. HIV-1, HIV-2, HERV-K(HML-2, etc.). As one skilled in the art will appreciate, the compounds of the present invention may inhibit a variety of retroviruses, retroviral elements, and may inhibit viruses, other than retroviruses. Compounds which inhibit one or more of the following may also find utility in the present invention: HERV-K(HML-2) type 1, HERV-K(HML-2) type 2, Type C and Type D retroviruses, HTLV-1, HTLV-2, HIV, FLV, SIV, MLV, BLV, BIV, equine infections, anemia virus, avian sarcoma viruses, such as Rous sarcoma virus (RSV), hepatitis type A, B, non-A and non-B viruses, arboviruses, varicella viruses, measles, mumps, rubella viruses, etc. In some embodiments, the present invention provides antiviral therapies in doses and/or combinations which are not useful (or are sub-optimally useful) as therapies against HIV (e.g. removal of a pharmaceutical form a combinatorial therapy (e.g. removal of a fusion inhibitor from a multi-drug antiviral therapy, or removal of a protease from a multi-drug antiviral therapy), replacement of a pharmaceutical in a combinatorial therapy, or a dose which would be ineffective or not commonly used in treating HIV). In some embodiments, the present invention provides antiviral therapies in doses and/or combinations which are not preferred as a therapy against HIV. In some embodiments, the treatment regimens of the present invention differ from the most effective HIV treatment regimens (Robbins et al. 2003, N Engl J Med, 349; 24, Shafer et al. 2003, N Engl J Med, 349; 24, herein incorporated by reference in their entireties) in one or more ways (e.g. dose, combination of drugs, etc.). In some embodiments, treatments of the present invention find utility in treating HIV-infected subject and/or non-HIV-infected subjects.
[0089] In some embodiments, the present invention provides antiretroviral drugs comprising one or more of, but not limited to, reverse transcriptase inhibitors, nucleoside analog reverse transcriptase inhibitors (e.g. Zidovudine, Didanosine, Zalcitabine, Stavudine, Lamivudine, Abacavir, Emtricitabine, Atricitabine, etc.), nucleotide analog reverse transcriptase inhibitors (e.g. Tenofovir, Adefovir, etc.), non-nucleoside reverse transcriptase inhibitors (e.g. Efavirenz, Nevirapine, Delavirdine, Etravirine, etc.), protease inhibitors (e.g. Saquinavir, Ritonavir, Indinavir, Nelfinavir, Amprenavir, Lopinavir, Atazanavir, Fosamprenavir, tipranavir, Darunavir, etc.), fusion inhibitors (e.g. Maraviroc, Enfuvirtide, etc.), integrase inhibitors (e.g. Raltegravir, Elitegravir, etc.), entry inhibitors (e.g. Maraviroc, Enfuvirtide, etc.), maturation inhibitors (e.g. Bevirimat, etc.), portmanteau inhibitors, etc. In some embodiments, the present invention provides any compounds that function as an antiretroviral (e.g. AZT (Zidovudine), FTC (Emtricitabine), 3TC (Lamivudine), ddC (zalcitabine), d4T (Stavudine), ddI (Dideoxyinosine), TDF (Tenofovir disoproxyl fumarato), ABC (Abacavir), β-d hydroxy cytidine, Efavirenz, Nevirapine, Etravirine, Atazanavir, Ritonavir, Indinavir, Amprenavir, etc.). In some embodiments, the present invention provides antiretroviral therapies that include administration of one or more pharmaceutical compounds (e.g. 1 compound, 2 compounds, 3 compounds, 4 compounds, 5 compounds, 6 compounds, 7 compounds, 8 compounds, 9 compounds, 10 compounds, >10 compounds). In some embodiments, the present invention provides combination therapy in which two or more compounds are simultaneously administered or administered in sequence. In some embodiments, the present invention provides highly active antiretroviral therapy (HAART) or the administration of a plurality of different antiretroviral drugs in combination to overwhelm the ability of a retrovirus to develop resistance to a single therapy: In some embodiments, the present invention provides a regimen involving administration of one or more approaches including but not limited to antiretrovirals, cancer chemotherapy, radiation, diet, exercise, surgery, nutrition, supplementation, etc. In some embodiments, one or more antiretroviral therapies (e.g. one or more pharmaceuticals) are administered in combination with one or more cancer therapies (e.g. chemotherapy, radiation, etc.).
[0090] In some embodiments, the present invention provides drug screening assays (e.g., to screen for anticancer drugs). The screening methods of the present invention utilize cancer markers identified using the methods of the present invention (e.g., including but not limited to, HERV-K(HML-2) targets). For example, in some embodiments, the present invention provides methods of screening for compounds that alter (e.g., decrease) the production of cancer markers. The compounds or agents may interfere with transcription. The compounds or agents may interfere with mRNA produced from: HERV-K(HML-2) (e.g., by RNA interference, antisense technologies, etc.). The compounds or agents may interfere with pathways that are upstream or downstream of the biological activity of the HERV-K(HML-2) target. In some embodiments, candidate compounds are antisense or interfering RNA agents (e.g., oligonucleotides) directed against cancer markers (e.g. HERV-K(HML-2). In some embodiments, compounds or agents may interfere with HERV-K(HML-2) replication.
[0091] In other embodiments, candidate compounds are antibodies or small molecules that specifically bind to a cancer marker regulators or expression products of the present invention and inhibit its biological function.
[0092] In one screening method, candidate compounds are evaluated for their ability to alter cancer marker production by contacting a compound with a cell producing a cancer marker and then assaying for the effect of the candidate compounds on expression. In some embodiments, the effect of candidate compounds on production of a cancer marker is assayed for by detecting the level of cancer marker mRNA expressed by the cell. mRNA expression can be detected by any suitable method. In other embodiments, the effect of candidate compounds on expression of cancer marker genes is assayed by measuring the level of polypeptide encoded by the cancer markers. The level of polypeptide expressed can be measured using any suitable method, including but not limited to, those disclosed herein.
[0093] Specifically, the present invention provides screening methods for identifying modulators, i.e., candidate or test compounds or agents (e.g., proteins, peptides, peptidomimetics, peptoids, small molecules or other drugs) which bind to cancer markers of the present invention, have an inhibitory (or stimulatory) effect on, for example, cancer marker production or cancer marker activity, or have a stimulatory or inhibitory effect on, for example, the expression or activity of a cancer marker substrate. Compounds thus identified can be used to modulate the activity of target gene products (e.g., cancer marker genes (e.g. (e.g., HERV-K(HML-2) gene or genes)) either directly or indirectly in a therapeutic protocol, to elaborate the biological function of the target gene product, or to identify compounds that disrupt normal target gene interactions. Compounds that inhibit the activity or expression of cancer markers are useful in the treatment of proliferative disorders, e.g., cancer, particularly lymphoma, leukemia and breast cancer.
[0094] In one embodiment, the invention provides assays for screening candidate or test compounds that are substrates of a cancer marker protein or polypeptide or a biologically active portion thereof (e.g., HERV-K(HML-2) proteins). In another embodiment, the invention provides assays for screening candidate or test compounds that bind to or modulate the activity of a cancer marker protein or polypeptide or a biologically active portion thereof (e.g., HERV-K(HML-2) proteins). In some embodiments, the invention provides assays for screening candidate or test compounds that are inhibitors of viral replication (e.g. retroviral replication (e.g. HERV-K(HML-2) replication)). In another embodiment, the invention provides assays for screening candidate or test compounds that bind to or modulate the effects of viruses (e.g. retroviruses (e.g. HERV-K(HML-2))), spread of viruses, expression of viral proteins, etc.
[0095] The test compounds of the present invention can be obtained using any of the numerous approaches in combinatorial library methods known in the art, including biological libraries; peptoid libraries (libraries of molecules having the functionalities of peptides, but with a novel, non-peptide backbone, which are resistant to enzymatic degradation but which nevertheless remain bioactive; see, e.g., Zuckennann et al., J. Med. Chem. 37: 2678-85 [1994]); spatially addressable parallel solid phase or solution phase libraries; synthetic library methods requiring deconvolution; the one-bead one-compound library method; and synthetic library methods using affinity chromatography selection. The biological library and peptoid library approaches are preferred for use with peptide libraries, while the other four approaches are applicable to peptide, non-peptide oligomer or small molecule libraries of compounds (Lam (1997) Anticancer Drug Des. 12:145).
[0096] Examples of methods for the synthesis of molecular libraries can be found in the art, for example in: DeWitt et al., Proc. Natl. Acad. Sci. U.S.A. 90:6909 [1993]; Erb et al., Proc. Nad. Acad. Sci. USA 91:11422 [1994]; Zuckermann et al., J. Med. Chem. 37:2678 [1994]; Cho et al., Science 261:1303 [1993]; Carrell et al., Angew. Chem. Int. Ed. Engl. 33.2059 [1994]; Carell et al., Angew. Chem. Int. Ed. Engl. 33:2061 [1994]; and Gallop et al., J. Med. Chem. 37:1233 [1994].
[0097] Libraries of compounds may be presented in solution (e.g., Houghten, Biotechniques 13:412-421 [1992]), or on beads (Lam, Nature 354:82-84 [1991]), chips (Fodor, Nature 364:555-556 [1993]), bacteria or spores (U.S. Pat. No. 5,223,409; herein incorporated by reference), plasmids (Cull et al., Proc. Nad. Acad. Sci. USA 89:18651869 [1992]) or on phage (Scott and Smith, Science 249:386-390 [1990]; Devlin Science 249:404-406 [1990]; Cwirla et al., Proc. Natl. Acad. Sci. 87:6378-6382 [1990]; Felici, J. Mol. Biol. 222:301 [1991]).
[0098] In some embodiments, an assay is a cell-based assay in which a cell that expresses a cancer marker mRNA or protein, a biologically active portion thereof, or a viral particle cancer marker (e.g. HERV-K(HML-2)) is contacted with a test compound, and the ability of the test compound to the modulate cancer marker's activity is determined. Determining the ability of the test compound to modulate cancer marker activity can be accomplished by monitoring, for example, changes in enzymatic activity, destruction or mRNA, viral load, or the like.
[0099] The ability of the test compound to modulate cancer marker binding to a compound, e.g., a cancer marker substrate or modulator, can also be evaluated. This can be accomplished, for example, by coupling the compound, e.g., the substrate, with a radioisotope or enzymatic label such that binding of the compound, e.g., the substrate, to a cancer marker can be determined by detecting the labeled compound, e.g., substrate, in a complex.
[0100] This invention further pertains to novel agents identified by the above-described screening assays (See e.g., below description of cancer therapies). Accordingly, it is within the scope of this invention to further use an agent identified as described herein (e.g., a cancer marker modulating agent, an antisense cancer marker nucleic acid molecule, a siRNA molecule, a cancer marker specific antibody, or a cancer marker-binding partner) in an appropriate animal model (such as those described herein) to determine the efficacy, toxicity, side effects, or mechanism of action, of treatment with such an agent. Furthermore, novel agents identified by the above-described screening assays can be, e.g., used for treatments as described herein.
[0101] In some embodiments, the present invention provides therapies for cancer (e.g., lymphoma, leukemia or breast cancer). In some embodiments, therapies directly or indirectly target cancer markers (e.g., HERV-K(HML-2) target).
[0102] In some embodiments, the present invention targets the production of cancer markers (e.g., HERV-K(HML-2). For example, in some embodiments, the present invention employs compositions comprising oligomeric antisense or RNAi compounds, particularly oligonucleotides (e.g., those identified in the drug screening methods described above), for use in modulating the function of nucleic acid molecules encoding cancer markers of the present invention (e.g., HERV-K(HML-2), ultimately modulating the amount of cancer marker expressed.
[0103] In some embodiments, RNAi is utilized to inhibit HERV-K(HML-2) target function. RNAi represents an evolutionary conserved cellular defense for controlling the expression of foreign genes in most eukaryotes, including humans. RNAi is typically triggered by double-stranded RNA (dsRNA) and causes sequence-specific mRNA degradation of single-stranded target RNAs homologous in response to dsRNA. The mediators of mRNA degradation are small interfering RNA duplexes (siRNAs), which are normally produced from long dsRNA by enzymatic cleavage in the cell. siRNAs are generally approximately twenty-one nucleotides in length (e.g., 21-23 nucleotides in length), and have a base-paired structure characterized by two nucleotide 3′-overhangs. Following the introduction of a small RNA, or RNAi, into the cell, it is believed the sequence is delivered to an enzyme complex called RISC(RNA-induced silencing complex). RISC recognizes the target and cleaves it with an endonuclease. It is noted that if larger RNA sequences are delivered to a cell, RNase III enzyme (Dicer) converts longer dsRNA into 21-23 nt ds siRNA fragments. In some embodiments, RNAi oligonucleotides are designed to target the HERV-K(HML-2) proteins.
[0104] Chemically synthesized siRNAs have become powerful reagents for genome-wide analysis of mammalian gene function in cultured somatic cells. Beyond their value for validation of gene function, siRNAs also hold great potential as gene-specific therapeutic agents (Tuschl and Borkhardt, Molecular Intervent. 2002; 2(3):158-67, herein incorporated by reference).
[0105] The transfection of siRNAs into animal cells results in the potent, long-lasting post-transcriptional silencing of specific genes (Caplen et al, Proc Natl Acad Sci U.S.A. 2001; 98: 9742-7; Elbashir et al., Nature. 2001; 411:494-8; Elbashir et al., Genes Dev. 2001; 15: 188-200; and Elbashir et al., EMBO J. 2001; 20: 6877-88, all of which are herein incorporated by reference). Methods and compositions for performing RNAi with siRNAs are described, for example, in U.S. Pat. No. 6,506,559, herein incorporated by reference.
[0106] siRNAs are extraordinarily effective at lowering the amounts of targeted RNA, and by extension proteins, frequently to undetectable levels. The silencing effect can last several months, and is extraordinarily specific, because one nucleotide mismatch between the target RNA and the central region of the siRNA is frequently sufficient to prevent silencing (Brummelkamp et al, Science 2002; 296:550-3; and Holen et al, Nucleic Acids Res. 2002; 30:1757-66, both of which are herein incorporated by reference).
[0107] An important factor in the design of siRNAs is the presence of accessible sites for siRNA binding. Bahoia et al., (J. Biol. Chem., 2003; 278: 15991-15997; herein incorporated by reference) describe the use of a type of DNA array called a scanning array to find accessible sites in mRNAs for designing effective siRNAs. These arrays comprise oligonucleotides ranging in size from monomers to a certain maximum, usually synthesized using a physical barrier (mask) by stepwise addition of each base in the sequence. Thus the arrays represent a full oligonucleotide complement of a region of the target gene. Hybridisation of the target mRNA to these arrays provides an exhaustive accessibility profile of this region of the target mRNA. Such data are useful in the design of antisense oligonucleotides (ranging from 7 mers to 25 mers), where it is important to achieve a compromise between oligonucleotide length and binding affinity, to retain efficacy and target specificity (Sohail et al, Nucleic Acids Res., 2001; 29(10): 2041-2045). Additional methods and concerns for selecting siRNAs are described for example, in WO 05054270, WO05038054A1, WO03070966A2, J. Mol. Biol. 2005 May 13; 348(4):883-93, J. Mol. Biol. 2005 May 13; 348(4):871-81, and Nucleic Acids Res. 2003 Aug. 1; 31(15):4417-24, each of which is herein incorporated by reference in its entirety. In addition, software (e.g., the MWG online siMAX siRNA design tool) is commercially or publicly available for use in the selection of siRNAs.
[0108] In some embodiments, HERV-K(HML-2) protein expression is modulated using antisense compounds that specifically hybridize with one or more nucleic acids encoding cancer markers of the present invention. The specific hybridization of an oligomeric compound with its target nucleic acid interferes with the normal function of the nucleic acid. This modulation of function of a target nucleic acid by compounds that specifically hybridize to it is generally referred to as “antisense.” The functions of DNA to be interfered with include replication and transcription. The functions of RNA to be interfered with include all vital functions such as, for example, translocation of the RNA to the site of protein translation, translation of protein from the RNA, splicing of the RNA to yield one or more mRNA species, and catalytic activity that may be engaged in or facilitated by the RNA. The overall effect of such interference with target nucleic acid function is modulation of the expression of cancer markers of the present invention. In the context of the present invention, “modulation” means either an increase (stimulation) or a decrease (inhibition) in the expression of a gene. For example, expression may be inhibited to potentially prevent tumor proliferation.
[0109] In some embodiments, specific nucleic acids are targeted for antisense. “Targeting” an antisense compound to a particular nucleic acid, in the context of the present invention, is a multi-step process. The process usually begins with the identification of a nucleic acid sequence whose function is to be modulated. This may be, for example, a cellular gene (or mRNA transcribed from the gene) whose expression is associated with a particular disorder or disease state, or a nucleic acid molecule from an infectious agent. In the present invention, the target is a nucleic acid molecule encoding a cancer marker of the present invention. The targeting process also includes determination of a site or sites within this gene for the antisense interaction to occur such that the desired effect, e.g., detection or modulation of expression of the protein, will result. Within the context of the present invention, a preferred intragenic site is the region encompassing the translation initiation or termination codon of the open reading frame (ORF) of the gene. Since the translation initiation codon is typically 5′-AUG (in transcribed mRNA molecules; 5′-ATG in the corresponding DNA molecule), the translation initiation codon is also referred to as the “AUG codon,” the “start codon” or the “AUG start codon”. A few genes have a translation initiation codon having the RNA sequence 5′-GUG, 5′-UUG or 5′-CUG, and 5′-AUA, 5′-ACG and 5′-CUG have been shown to function in vivo. Thus, the terms “translation initiation codon” and “start codon” can encompass many codon sequences, even though the initiator amino acid in each instance is typically methionine (in eukaryotes) or formylmethionine (in prokaryotes). Eukaryotic and prokaryotic genes may have two or more alternative start codons, any one of which may be preferentially utilized for translation initiation in a particular cell type or tissue, or under a particular set of conditions. In the context of the present invention, “start codon” and “translation initiation codon” refer to the codon or codons that are used in vivo to initiate translation of an mRNA molecule transcribed from a gene encoding a tumor antigen of the present invention, regardless of the sequence(s) of such codons.
[0110] Translation termination codon (or “stop codon”) of a gene may have one of three sequences (i.e., 5′-UAA, 5′-UAG and 5′-UGA; the corresponding DNA sequences are 5′-TAA, 5′-TAG and 5′-TGA, respectively). The terms “start codon region” and “translation initiation codon region” refer to a portion of such an mRNA or gene that encompasses from about 25 to about 50 contiguous nucleotides in either direction (i.e., 5′ or 3′) from a translation initiation codon. Similarly, the terms “stop codon region” and “translation termination codon region” refer to a portion of such an mRNA or gene that encompasses from about 25 to about 50 contiguous nucleotides in either direction (i.e., 5′ or 3′) from a translation termination codon.
[0111] The open reading frame (ORF) or “coding region,” which refers to the region between the translation initiation codon and the translation termination codon, is also a region that may be targeted effectively. Other target regions include the 5′ untranslated region (5′ UTR), referring to the portion of an mRNA in the 5′ direction from the translation initiation codon, and thus including nucleotides between the 5′ cap site and the translation initiation codon of an mRNA or corresponding nucleotides on the gene, and the 3′ untranslated region (3′ UTR), referring to the portion of an mRNA in the 3′ direction from the translation termination codon, and thus including nucleotides between the translation termination codon and 3′ end of an mRNA or corresponding nucleotides on the gene. The 5′ cap of an mRNA comprises an N7-methylated guanosine residue joined to the 5′-most residue of the mRNA via a 5′-5′ triphosphate linkage. The 5′ cap region of an mRNA is considered to include the 5′ cap structure itself as well as the first 50 nucleotides adjacent to the cap. The cap region may also be a preferred target region.
[0112] Although some eukaryotic mRNA transcripts are directly translated, many contain one or more regions, known as “introns,” that are excised from a transcript before it is translated. The remaining (and therefore translated) regions are known as “exons” and are spliced together to form a continuous mRNA sequence. mRNA splice sites (i.e., intron-exon junctions) may also be preferred target regions, and are particularly useful in situations where aberrant splicing is implicated in disease, or where an overproduction of a particular mRNA splice product is implicated in disease. It has also been found that introns can also be effective, and therefore preferred, target regions for antisense compounds targeted, for example, to DNA or pre-mRNA.
[0113] In some embodiments, target sites for antisense inhibition are identified using commercially available software programs (e.g., Biognostik, Gottingen, Germany; SysArris Software, Bangalore, India; Antisense Research Group, University of Liverpool, Liverpool, England; GeneTrove, Carlsbad, Calif.). In other embodiments, target sites for antisense inhibition are identified using the accessible site method described in U.S. Patent WO0198537A2, herein incorporated by reference.
[0114] Once one or more target sites have been identified, oligonucleotides are chosen that are sufficiently complementary to the target (i.e., hybridize sufficiently well and with sufficient specificity) to give the desired effect. For example, in preferred embodiments of the present invention, antisense oligonucleotides are targeted to or near the start codon.
[0115] In the context of this invention, “hybridization,” with respect to antisense compositions and methods, means hydrogen bonding, which may be Watson-Crick, Hoogsteen or reversed Hoogsteen hydrogen bonding, between complementary nucleoside or nucleotide bases. For example, adenine and thymine are complementary nucleobases that pair through the formation of hydrogen bonds. It is understood that the sequence of an antisense compound need not be 100% complementary to that of its target nucleic acid to be specifically hybridizable. An antisense compound is specifically hybridizable when binding of the compound to the target DNA or RNA molecule interferes with the normal function of the target DNA or RNA to cause a loss of utility, and there is a sufficient degree of complementarity to avoid non-specific binding of the antisense compound to non-target sequences under conditions in which specific binding is desired (i.e., under physiological conditions in the case of in vivo assays or therapeutic treatment, and in the case of in vitro assays, under conditions in which the assays are performed).
[0116] Antisense compounds are commonly used as research reagents and diagnostics. For example, antisense oligonucleotides, which are able to inhibit gene expression with specificity, can be used to elucidate the function of particular genes. Antisense compounds are also used, for example, to distinguish between functions of various members of a biological pathway.
[0117] The specificity and sensitivity of antisense is also applied for therapeutic uses. For example, antisense oligonucleotides have been employed as therapeutic moieties in the treatment of disease states in animals and man. Antisense oligonucleotides have been safely and effectively administered to humans and numerous clinical trials are presently underway. It is thus established that oligonucleotides are useful therapeutic modalities that can be configured to be useful in treatment regimes for treatment of cells, tissues, and animals, especially humans.
[0118] While antisense oligonucleotides are a preferred form of antisense compound, the present invention comprehends other oligomeric antisense compounds, including but not limited to oligonucleotide mimetics such as are described below. The antisense compounds in accordance with this invention preferably comprise from about 8 to about 30 nucleobases (i.e., from about 8 to about 30 linked bases), although both longer and shorter sequences may find use with the present invention. Particularly preferred antisense compounds are antisense oligonucleotides, even more preferably those comprising from about 12 to about 25 nucleobases.
[0119] Specific examples of preferred antisense compounds useful with the present invention include oligonucleotides containing modified backbones or non-natural internucleoside linkages. As defined in this specification, oligonucleotides having modified backbones include those that retain a phosphorus atom in the backbone and those that do not have a phosphorus atom in the backbone. For the purposes of this specification, modified oligonucleotides that do not have a phosphorus atom in their internucleoside backbone can also be considered to be oligonucleosides.
[0120] Preferred modified oligonucleotide backbones include, for example, phosphorothioates, chiral phosphorothioates, phosphorodithioates, phosphotriesters, aminoalkylphosphotriesters, methyl and other alkyl phosphonates including 3′-alkylene phosphonates and chiral phosphonates, phosphinates, phosphoramidates including 3′-amino phosphoramidate and aminoalkylphosphoramidates, thionophosphoramidates, thionoalkylphosphonates, thionoalkylphosphotriesters, and boranophosphates having normal 3′-5′ linkages, 2′-5′ linked analogs of these, and those having inverted polarity wherein the adjacent pairs of nucleoside units are linked 3′-5′ to 5′-3′ or 2′-5′ to 5′-2′. Various salts, mixed salts and free acid forms are also included.
[0121] Preferred modified oligonucleotide backbones that do not include a phosphorus atom therein have backbones that are formed by short chain alkyl or cycloalkyl internucleoside linkages, mixed heteroatom and alkyl or cycloalkyl internucleoside linkages, or one or more short chain heteroatomic or heterocyclic internucleoside linkages. These include those having morpholino linkages (formed in part from the sugar portion of a nucleoside); siloxane backbones; sulfide, sulfoxide and sulfone backbones; formacetyl and thioformacetyl backbones; methylene formacetyl and thioformacetyl backbones; alkene containing backbones; sulfamate backbones; methyleneimino and methylenehydrazino backbones; sulfonate and sulfonamide backbones; amide backbones; and others having mixed N, O, S and CH 2 component parts.
[0122] In other preferred oligonucleotide mimetics, both the sugar and the internucleoside linkage (i.e., the backbone) of the nucleotide units are replaced with novel groups. The base units are maintained for hybridization with an appropriate nucleic acid target compound. One such oligomeric compound, an oligonucleotide mimetic that has been shown to have excellent hybridization properties, is referred to as a peptide nucleic acid (PNA). In PNA compounds, the sugar-backbone of an oligonucleotide is replaced with an amide containing backbone, in particular an aminoethylglycine backbone. The nucleobases are retained and are bound directly or indirectly to aza nitrogen atoms of the amide portion of the backbone. Representative United States patents that teach the preparation of PNA compounds include, but are not limited to, U.S. Pat. Nos. 5,539,082; 5,714,331; and 5,719,262, each of which is herein incorporated by reference. Further teaching of PNA compounds can be found in Nielsen et al., Science 254:1497 (1991).
[0123] Most preferred embodiments of the invention are oligonucleotides with phosphorothioate backbones and oligonucleosides with heteroatom backbones, and in particular —CH 2 , —NH—O—CH 2 —, —CH 2 —N(CH 3 )—O—CH 2 —[known as a methylene (methylimino) or MMI backbone], —CH 2 —O—N(CH 3 )—CH 2 —, —CH 2 —N(CH 3 )—N(CH 3 )—CH 2 —, and —O—N(CH 3 )—CH 2 —CH 2 —[wherein the native phosphodiester backbone is represented as —O—P—O—CH 2 —] of the above referenced U.S. Pat. No. 5,489,677, and the amide backbones of the above referenced U.S. Pat. No. 5,602,240. Also preferred are oligonucleotides having morpholino backbone structures of the above-referenced U.S. Pat. No. 5,034,506.
[0124] Modified oligonucleotides may also contain one or more substituted sugar moieties. Preferred oligonucleotides comprise one of the following at the 2′ position: OH; F; O-, S-, or N-alkyl; O-, S-, or N-alkenyl; O-, S- or N-alkynyl; or O-alkyl-O-alkyl, wherein the alkyl, alkenyl and alkynyl may be substituted or unsubstituted C 1 to C 10 alkyl or C 2 to C 11 alkenyl and alkynyl. Particularly preferred are O[(CH 2 ),O] m CH 3 , O(CH 2 ) n OCH 3 , O(CH 2 ) n NH 2 , O(CH 2 ) n CH 3 , O(CH 2 ) n ONH 2 , and O(CH 2 ) n ON[(CH 2 ) n CH 3 )]2, where n and m are from 1 to about 10. Other preferred oligonucleotides comprise one of the following at the 2′ position: C 1 to C 10 lower alkyl, substituted lower alkyl, alkaryl, aralkyl, O-alkaryl or O-aralkyl, SH, SCH 3 , OCN, Cl, Br, CN, CF 3 , OCF 3 , SOCH 3 , SO 2 CH 3 , ONO 2 , NO 2 , N 3 , NH 2 , heterocycloalkyl, heterocycloalkaryl, aminoalkylamino, polyalkylamino, substituted silyl, an RNA cleaving group, a reporter group, an intercalator, a group for improving the pharmacokinetic properties of an oligonucleotide, or a group for improving the pharmacodynamic properties of an oligonucleotide, and other substituents having similar properties. A preferred modification includes 2′-methoxyethoxy (2′-O—-CH 2 CH 2 OCH 3 , also known as 2′-O-(2-methoxyethyl) or 2′-MOE) (Martin et al., Helv. Chim. Acta 78:486 [1995]) i.e., an alkoxyalkoxy group. A further preferred modification includes 2′-dimethylaminooxyethoxy (i.e., a O(CH 2 ) 2 ON(CH 3 ) 2 group), also known as 2′-DMAOE, and 2′-dimethylaminoethoxyethoxy (also known in the art as 2′-O-dimethylaminoethoxyethyl or 2′-DMAEOE), i.e., 2′-O—CH 2 —O—CH 2 —N(CH 2 ) 2 .
[0125] Other preferred modifications include 2′-methoxy(2′-O—CH 3 ), 2′-aminopropoxy(2′-OCH 2 CH 2 CH 2 NH 2 ) and 2′-fluoro (2′-F). Similar modifications may also be made at other positions on the oligonucleotide, particularly the 3′ position of the sugar on the 3′ terminal nucleotide or in 2′-5′ linked oligonucleotides and the 5′ position of 5′ terminal nucleotide. Oligonucleotides may also have sugar mimetics such as cyclobutyl moieties in place of the pentofuranosyl sugar.
[0126] Oligonucleotides may also include nucleobase (often referred to in the art simply as “base”) modifications or substitutions. As used herein, “unmodified” or “natural” nucleobases include the purine bases adenine (A) and guanine (G), and the pyrimidine bases thymine (T), cytosine (C) and uracil (U). Modified nucleobases include other synthetic and natural nucleobases such as 5-methylcytosine (5-me-C), 5-hydroxymethyl cytosine, xanthine, hypoxanthine, 2-aminoadenine, 6-methyl and other alkyl derivatives of adenine and guanine, 2-propyl and other alkyl derivatives of adenine and guanine, 2-thiouracil, 2-thiothymine and 2-thiocytosine, 5-halouracil and cytosine, 5-propynyl uracil and cytosine, 6-azo uracil, cytosine and thymine, 5-uracil (pseudouracil), 4-thiouracil, 8-halo, 8-amino, 8-thiol, 8-thioalkyl, 8-hydroxyl and other 8-substituted adenines and guanines, 5-halo particularly 5-bromo, 5-trifluoromethyl and other 5-substituted uracils and cytosines, 7-methylguanine and 7-methyladenine, 8-azaguanine and 8-azaadenine, 7-deazaguanine and 7-deazaadenine and 3-deazaguanine and 3-deazaadenine. Further nucleobases include those disclosed in U.S. Pat. No. 3,687,808. Certain of these nucleobases are particularly useful for increasing the binding affinity of the oligomeric compounds of the invention. These include 5-substituted pyrimidines, 6-azapyrimidines and N-2, N-6 and O-6 substituted purines, including 2-aminopropyladenine, 5-propynyluracil and 5-propynylcytosine. 5-methylcytosine substitutions have been shown to increase nucleic acid duplex stability by 0.6-1.2.degree. C. and are presently preferred base substitutions, even more particularly when combined with 2′-O-methoxyethyl sugar modifications.
[0127] Another modification of the oligonucleotides of the present invention involves chemically linking to the oligonucleotide one or more moieties or conjugates that enhance the activity, cellular distribution or cellular uptake of the oligonucleotide. Such moieties include but are not limited to lipid moieties such as a cholesterol moiety, cholic acid, a thioether, (e.g., hexyl-5-tritylthiol), a thiocholesterol, an aliphatic chain, (e.g., dodecandiol or undecyl residues), a phospholipid, (e.g., di-hexadecyl-rac-glycerol or triethylammonium 1,2-di-O-hexadecyl-rac-glycero-3-H-phosphonate), a polyamine or a polyethylene glycol chain or adamantane acetic acid, a palmityl moiety, or an octadecylamine or hexylamino-carbonyl-oxycholesterol moiety.
[0128] One skilled in the relevant art knows well how to generate oligonucleotides containing the above-described modifications. The present invention is not limited to the antisense oligonucleotides described above. Any suitable modification or substitution may be utilized.
[0129] It is not necessary for all positions in a given compound to be uniformly modified, and in fact more than one of the aforementioned modifications may be incorporated in a single compound or even at a single nucleoside within an oligonucleotide. The present invention also includes antisense compounds that are chimeric compounds. “Chimeric” antisense compounds or “chimeras,” in the context of the present invention, are antisense compounds, particularly oligonucleotides, which contain two or more chemically distinct regions, each made up of at least one monomer unit, i.e., a nucleotide in the case of an oligonucleotide compound. These oligonucleotides typically contain at least one region wherein the oligonucleotide is modified so as to confer upon the oligonucleotide increased resistance to nuclease degradation, increased cellular uptake, and/or increased binding affinity for the target nucleic acid. An additional region of the oligonucleotide may serve as a substrate for enzymes capable of cleaving RNA:DNA or RNA:RNA hybrids. By way of example, RNaseH is a cellular endonuclease that cleaves the RNA strand of an RNA:DNA duplex. Activation of RNase H, therefore, results in cleavage of the RNA target, thereby greatly enhancing the efficiency of oligonucleotide inhibition of gene expression. Consequently, comparable results can often be obtained with shorter oligonucleotides when chimeric oligonucleotides are used, compared to phosphorothioate deoxyoligonucleotides hybridizing to the same target region. Cleavage of the RNA target can be routinely detected by gel electrophoresis and, if necessary, associated nucleic acid hybridization techniques known in the art.
[0130] Chimeric antisense compounds of the present invention may be formed as composite structures of two or more oligonucleotides, modified oligonucleotides, oligonucleosides and/or oligonucleotide mimetics as described above.
[0131] The present invention also includes pharmaceutical compositions and formulations that include the antisense compounds of the present invention as described below.
[0132] The present invention contemplates the use of any genetic manipulation for use in modulating the expression of cancer markers of the present invention. Examples of genetic manipulation include, but are not limited to, gene knockout (e.g., removing a HERV-K(HML-2) gene from the chromosome using, for example, recombination), expression of antisense constructs with or without inducible promoters, and the like. Delivery of nucleic acid construct to cells in vitro or in vivo may be conducted using any suitable method. A suitable method is one that introduces the nucleic acid construct into the cell such that the desired event occurs (e.g., expression of an antisense construct). Genetic therapy may also be used to deliver siRNA or other interfering molecules that are expressed in vivo (e.g., upon stimulation by an inducible promoter (e.g., an androgen-responsive promoter)).
[0133] Introduction of molecules carrying genetic information into cells is achieved by any of various methods including, but not limited to, directed injection of naked DNA constructs, bombardment with gold particles loaded with said constructs, and macromolecule mediated gene transfer using, for example, liposomes, biopolymers, and the like. Preferred methods use gene delivery vehicles derived from viruses, including, but not limited to, adenoviruses, retroviruses, vaccinia viruses, and adeno-associated viruses. Because of the higher efficiency as compared to retroviruses, vectors derived from adenoviruses are the preferred gene delivery vehicles for transferring nucleic acid molecules into host cells in vivo. Adenoviral vectors have been shown to provide very efficient in vivo gene transfer into a variety of solid tumors in animal models and into human solid tumor xenografts in immune-deficient mice. Examples of adenoviral vectors and methods for gene transfer are described in PCT publications WO 00/12738 and WO 00/09675 and U.S. Pat. Nos. 6,033,908, 6,019,978, 6,001,557, 5,994,132, 5,994,128, 5,994,106, 5,981,225, 5,885,808, 5,872,154, 5,830,730, and 5,824,544, each of which is herein incorporated by reference in its entirety.
[0134] Vectors may be administered to subject in a variety of ways. For example, in some embodiments of the present invention, vectors are administered into tumors or tissue associated with tumors using direct injection. In other embodiments, administration is via the blood or lymphatic circulation (See e.g., PCT publication 99/02685 herein incorporated by reference in its entirety). Exemplary dose levels of adenoviral vector are preferably 10 8 to 10 11 vector particles added to the perfusate.
[0135] In some embodiments, the present invention provides antibodies that target tumors that express a cancer marker of the present invention (e.g., HERV-K(HML-2) or associated target proteins). Any suitable antibody (e.g., monoclonal, polyclonal, or synthetic) may be utilized in the therapeutic methods disclosed herein. In preferred embodiments, the antibodies used for cancer therapy are humanized antibodies. Methods for humanizing antibodies are well known in the art (See e.g., U.S. Pat. Nos. 6,180,370, 5,585,089, 6,054,297, and 5,565,332; each of which is herein incorporated by reference).
[0136] In some embodiments, the therapeutic antibodies comprise an antibody generated against a cancer marker of the present invention (e.g., HERV-K(HML-2)), wherein the antibody is conjugated to a cytotoxic agent. In such embodiments, a tumor specific therapeutic agent is generated that does not target normal cells, thus reducing many of the detrimental side effects of traditional chemotherapy. For certain applications, it is envisioned that the therapeutic agents will be pharmacologic agents that will serve as useful agents for attachment to antibodies, particularly cytotoxic or otherwise anticellular agents having the ability to kill or suppress the growth or cell division of endothelial cells. The present invention contemplates the use of any pharmacologic agent that can be conjugated to an antibody, and delivered in active form. Exemplary anticellular agents include chemotherapeutic agents, radioisotopes, and cytotoxins. The therapeutic antibodies of the present invention may include a variety of cytotoxic moieties, including but not limited to, radioactive isotopes (e.g., iodine-131, iodine-123, technetium-99m, indium-111, rhenium-188, rhenium-186, gallium-67, copper-67, yttrium-90, iodine-125 or astatine-211), hormones such as a steroid, antimetabolites such as cytosines (e.g., arabinoside, fluorouracil, methotrexate or aminopterin; an anthracycline; mitomycin C), vinca alkaloids (e.g., demecolcine; etoposide; mithramycin), and antitumor alkylating agent such as chlorambucil or melphalan. Other embodiments may include agents such as a coagulant, a cytokine, growth factor, bacterial endotoxin or the lipid A moiety of bacterial endotoxin. For example, in some embodiments, therapeutic agents will include plant-, fungus- or bacteria-derived toxin, such as an A chain toxins, a ribosome inactivating protein, .alpha.-sarcin, aspergillin, restrictocin, a ribonuclease, diphtheria toxin or pseudomonas exotoxin, to mention just a few examples. In some preferred embodiments, deglycosylated ricin A chain is utilized.
[0137] In any event, it is proposed that agents such as these may, if desired, be successfully conjugated to an antibody, in a manner that will allow their targeting, internalization, release or presentation to blood components at the site of the targeted tumor cells as required using known conjugation technology (See, e.g., Ghose et al., Methods Enzymol., 93:280 [1983]).
[0138] For example, in some embodiments the present invention provides immunotoxins targeted a cancer marker of the present invention (e.g., HERV-K(HML-2)). Immunotoxins are conjugates of a specific targeting agent typically a tumor-directed antibody or fragment, with a cytotoxic agent, such as a toxin moiety. The targeting agent directs the toxin to, and thereby selectively kills, cells carrying the targeted antigen. In some embodiments, therapeutic antibodies employ crosslinkers that provide high in vivo stability (Thorpe et al., Cancer Res., 48:6396 [1988]).
[0139] In other embodiments, particularly those involving treatment of solid tumors, antibodies are designed to have a cytotoxic or otherwise anticellular effect against the tumor vasculature, by suppressing the growth or cell division of the vascular endothelial cells. This attack is intended to lead to a tumor-localized vascular collapse, depriving the tumor cells, particularly those tumor cells distal of the vasculature, of oxygen and nutrients, ultimately leading to cell death and tumor necrosis.
[0140] In preferred embodiments, antibody based therapeutics are formulated as pharmaceutical compositions as described below. In preferred embodiments, administration of an antibody composition of the present invention results in a measurable decrease in cancer (e.g., decrease or elimination of tumor).
[0141] The present invention further provides pharmaceutical compositions (e.g., comprising pharmaceutical agents that modulate the expression or activity of HERV-K(HML-2) of the present invention). The pharmaceutical compositions of the present invention may be administered in a number of ways depending upon whether local or systemic treatment is desired and upon the area to be treated. Administration may be topical (including ophthalmic and to mucous membranes including vaginal and rectal delivery), pulmonary (e.g., by inhalation or insufflation of powders or aerosols, including by nebulizer; intratracheal, intranasal, epidermal and transdermal), oral or parenteral. Parenteral administration includes intravenous, intraarterial, subcutaneous, intraperitoneal or intramuscular injection or infusion; or intracranial, e.g., intrathecal or intraventricular, administration.
[0142] Pharmaceutical compositions and formulations for topical administration may include transdermal patches, ointments, lotions, creams, gels, drops, suppositories, sprays, liquids and powders. Conventional pharmaceutical carriers, aqueous, powder or oily bases, thickeners and the like may be necessary or desirable.
[0143] Compositions and formulations for oral administration include powders or granules, suspensions or solutions in water or non-aqueous media, capsules, sachets or tablets. Thickeners, flavoring agents, diluents, emulsifiers, dispersing aids or binders may be desirable.
[0144] Compositions and formulations for parenteral, intrathecal or intraventricular administration may include sterile aqueous solutions that may also contain buffers, diluents and other suitable additives such as, but not limited to, penetration enhancers, carrier compounds and other pharmaceutically acceptable carriers or excipients.
[0145] Pharmaceutical compositions of the present invention include, but are not limited to, solutions, emulsions, and liposome-containing formulations. These compositions may be generated from a variety of components that include, but are not limited to, preformed liquids, self-emulsifying solids and self-emulsifying semisolids.
[0146] The pharmaceutical formulations of the present invention, which may conveniently be presented in unit dosage form, may be prepared according to conventional techniques well known in the pharmaceutical industry. Such techniques include the step of bringing into association the active ingredients with the pharmaceutical carrier(s) or excipient(s). In general the formulations are prepared by uniformly and intimately bringing into association the active ingredients with liquid carriers or finely divided solid carriers or both, and then, if necessary, shaping the product.
[0147] The compositions of the present invention may be formulated into any of many possible dosage forms such as, but not limited to, tablets, capsules, liquid syrups, soft gels, suppositories, and enemas. The compositions of the present invention may also be formulated as suspensions in aqueous, non-aqueous or mixed media. Aqueous suspensions may further contain substances that increase the viscosity of the suspension including, for example, sodium carboxymethylcellulose, sorbitol and/or dextran. The suspension may also contain stabilizers.
[0148] In one embodiment of the present invention the pharmaceutical compositions may be formulated and used as foams. Pharmaceutical foams include formulations such as, but not limited to, emulsions, microemulsions, creams, jellies and liposomes. While basically similar in nature these formulations vary in the components and the consistency of the final product.
[0149] Agents that enhance uptake of oligonucleotides at the cellular level may also be added to the pharmaceutical and other compositions of the present invention. For example, cationic lipids, such as lipofectin (U.S. Pat. No. 5,705,188), cationic glycerol derivatives, and polycationic molecules, such as polylysine (WO 97/30731), also enhance the cellular uptake of oligonucleotides.
[0150] The compositions of the present invention may additionally contain other adjunct components conventionally found in pharmaceutical compositions. Thus, for example, the compositions may contain additional, compatible, pharmaceutically-active materials such as, for example, antipruritics, astringents, local anesthetics or anti-inflammatory agents, or may contain additional materials useful in physically formulating various dosage forms of the compositions of the present invention, such as dyes, flavoring agents, preservatives, antioxidants, opacifiers, thickening agents and stabilizers. However, such materials, when added, should not unduly interfere with the biological activities of the components of the compositions of the present invention. The formulations can be sterilized and, if desired, mixed with auxiliary agents, e.g., lubricants, preservatives, stabilizers, wetting agents, emulsifiers, salts for influencing osmotic pressure, buffers, colorings, flavorings and/or aromatic substances and the like which do not deleteriously interact with the nucleic acid(s) of the formulation.
[0151] Certain embodiments of the invention provide pharmaceutical compositions containing (a) one or more antisense compounds and (b) one or more other chemotherapeutic agents that function by a non-antisense mechanism. Examples of such chemotherapeutic agents include, but are not limited to, anticancer drugs such as daunorubicin, dactinomycin, doxorubicin, bleomycin, mitomycin, nitrogen mustard, chlorambucil, melphalan, cyclophosphamide, 6-mercaptopurine, 6-thioguanine, cytarabine (CA), 5-fluorouracil (5-FU), floxuridine (5-FUdR), methotrexate (MTX), colchicine, vincristine, vinblastine, etoposide, teniposide, cisplatin and diethylstilbestrol (DES). Anti-inflammatory drugs, including but not limited to nonsteroidal anti-inflammatory drugs and corticosteroids, and antiviral drugs, including but not limited to ribivirin, vidarabine, acyclovir and ganciclovir, may also be combined in compositions of the invention. Other non-antisense chemotherapeutic agents are also within the scope of this invention. Two or more combined compounds may be used together or sequentially.
[0152] Dosing is dependent on severity and responsiveness of the disease state to be treated, with the course of treatment lasting from several days to several months, or until a cure is effected or a diminution of the disease state is achieved. Optimal dosing schedules can be calculated from measurements of drug accumulation in the body of the patient. The administering physician can easily determine optimum dosages, dosing methodologies and repetition rates. Optimum dosages may vary depending on the relative potency of individual oligonucleotides, and can generally be estimated based on EC 50 s found to be effective in in vitro and in vivo animal models or based on the examples described herein. In general, dosage is from 0.01 μg to 100 g per kg of body weight, and may be given once or more daily, weekly, monthly or yearly. The treating physician can estimate repetition rates for dosing based on measured residence times and concentrations of the drug in bodily fluids or tissues. Following successful treatment, it may be desirable to have the subject undergo maintenance therapy to prevent the recurrence of the disease state, wherein the oligonucleotide is administered in maintenance doses, ranging from 0.01 μg to 100 g per kg of body weight, once or more daily, to once every 20 years.
[0153] In some embodiments, the present invention provides compositions, kits, and methods for managing patient care. For example, in some embodiments, a diagnostic test that detects the presence of, or amount of, a HERV-K(HML-2) marker is conducted before an appropriate therapy is applied (i.e., test, then treat). In some embodiments, HERV-K(HML-2) markers are detected after treatment to monitor the success of the treatment and allow the treating physician to alter the treatment (e.g., change the compound, change the dose, discontinue, etc.) if needed or desired (i.e., treat and test, which in some embodiments, involves testing, then treating, then testing). In some embodiments, depending on the outcome of the diagnostic test, therapy is altered (i.e., treat, test, treat).
EXPERIMENTAL
Example 1
[0154] Plasma samples were collected from newly diagnosed lymphoma patients. Subjects with chronic lymphocytic leukemia were not included. Samples were obtained from over 150 patients with new onset lymphoma. HERV K (HML2) was measured in each samples using quantitative RT PCR assay that measures gag viral RNA (SEE FIG. 1 ). This assay indicates that in untreated lymphoma there is a considerable level of free HERV K (HML2) in plasma with non HIV associated DLCBL and HD having the highest levels of virus while patients with follicular lymphoma have somewhat lower levels of virus. The RT PCR does not distinguish type 1 from type 2 HERV K (HML2). A nucleic acid sequence based amplification assay (NASBA) was developed which allows type 1 and type 2 env to be distinguished in plasma. The assay was applied to a subset of the FL patients and to patients with DLBCL. Patients with FL with disease limited to isolated nodes and skin lesions had lower levels of viremia than those who, on bone marrow examination, were found to have lymphoma cells in the marrow as judged by flow based assays and or by immunocytogenetic analysis (SEE FIG. 2 ).
[0155] Levels of antibody to the Rec protein were examined. Rec is only be made by actively replicating virions. Patients with DLCBL, and HD had rather high levels of antibody to this protein while those with FL had slightly lower levels in contrast to normal patients who donated plasma samples who rarely had antibody to.
[0156] The high levels of endogenous virus in plasma is similar to the recent studies of an epidemic of lymphoma in the Australian Koala bear. East coast Koalas have been dying of lymphoma. Scientists studying these animals have discovered a new retrovirus virus called KoRv. This virus appears to have become endogenized in the Koala in the past century from a virus similar to the Gibbon ape leukemia virus (GALV). Koalas that have this endogenous virus in their genome at birth develop progressive KoRv viremia as they age and at the peak of viremia develop an aggressive often fatal lymphoma. The prolonged KoRv viremia that occurs in the Koala prior to onset of lymphoma is similar to the prolonged HERV K (HML2) viremia that we have documented in some HIV lymphoma patients in whom we have been able to measure HERV K (HML2) viral load years before the onset of lymphoma. This indicates that HERV K (HML2) becomes more infectious as time progresses causing a gradual rise in viral load and that in both HIV lymphoma and non HIV lymphoma, some recombinant or some new virus which arises through complementation may form in these plasmas which now begins to have oncogenic potential and infectious potential.
[0157] The Hamster CHO cell line can become infected with plasma associated virus from lymphoma patients.
[0158] HIV associated lymphoma is dramatically reduced by highly active antiretroviral therapy (HAART). This phenomenon suggests that improved immunity as a result of HAART allows for better immune surveillance of cancer cells and or better control of EBV and HHV8. This phenomenon further indicates that one or more retroviruses ((e.g., HERV-K(HML-2) has a causative effect on lymphoma. Control of HIV TAT may also be important in reducing oncogenic risk. Experiments performed during development of embodiments of the present invention indicate that the antivirals that treat HIV, especially the nucleoside reverse transcriptase inhibitors, also have an effect on the replicative capacity of HERV K (HML2) and thereby indirectly reduce the activity of these viruses. Data indicated that these viruses play a role in lymphoma oncogenesis, and that antivirals against HERV K (HML2) reduce the risk of development of lymphoma and improve survival from lymphoma. Patients treated for lymphoma might show a reduction of the HERV K (HML2) viral load with successful lymphoma treatment. It has been demonstrated in a small group of HIV patients with different lymphomas that there was a marked drop of the HERV K (HML-2) viral load commensurate with successful cancer chemotherapy (SEE FIG. 3 ).
[0159] HIV antivirals were assayed to determine which antiviral agents have an antiviral effect against HERV K (HML2). The NCCIT cell line derived from a teratocarcinoma produces many HERV K (HML2) viral particles. NCCIT cells were maintained at 40% confluence in 6-well plates in RPMI medium and incubated for 7 days in the presence of increasing doses of nucleoside or non-nucleoside reverse transcriptase inhibitors or HIV protease inhibitors. Drugs, provided as lyophilized powders by the AIDS Research and Reference Reagent Program, were resuspended to a final concentration of 10 mg/mL (except for PFA: 60 mg/mL) in different solvents as recommended (SEE table 1). Cells were incubated for 7 days at increasing doses of drugs or the vehicle of solution as controls. Supernatants were collected and cell debris was removed by centrifugation at 2300 rpm for 20 min. Supernatant was assessed for Reverse Transcriptase Activity using the Reverse Transcription Assay Kit (Invitrogen) as described by the manufacturer. In addition, supernatants were treated with 20 units of DNAse (Roche) for 1 hour at 37° C. and viral RNA was extracted using the Viral RNA mini kit (Qiagen) as described by the manufacturer. The HERV-K type 2 viral load was measured by quantitative Real Time RT-PCR using primers that expand the type-2 env gene region, which is absent in type-1 viruses, Kenv type2F: 5′-AGA CAC CGC AAT CGA GCA CCG TTG A-3′ (SEQ ID NO. 1), and Kenv type2R: 5′-ATC AAG GCT GCA AGC AGC ATA CTC-3′ (SEQ ID NO. 2). Standard curves were generated using serial dilutions of in vitro RNA transcripts as external calibrators. In a similar way, quantities of HERV-K type 2 proviruses were measured by Real Time PCR using 500 ng of isolated DNA.
[0000]
TABLE 1
AZT (Zidovudine)
PBS
FTC (Emtricitabine)
PBS
3TC (Lamivudine)
PBS
ddC (zalcitabine)
DMSO
d4T (Stavudine)
PBS
ddI (Dideoxyinosine)
DMSO
TDF (Tenofovir disoproxyl fumarato)
PBS
ABC (Abacavir)
DMSO
β-d hydroxy cytidine
DMSO
Non-Nucleoside Reverse Transcriptase Inhibitors (NNRTIs)
Efavirenz
DMSO
Nevirapine
DMSO
Etravirine
Acetone
Protease Inhibitors (PIs)
Atazanavir
DMSO
Ritonavir
DMSO
Indinavir
PBS
Amprenavir
DMSO
[0160] The NRTIs produced reduction in the HERV K (HML2) RT activity as shown for lamivudine and tenofovir disoproxil, AZT, FTC, ddC, Abacavir, β-D hydroxycytidine, d4T, and ddI (SEE FIGS. 4A-I ). The other agents notably azidothymidine, didianosine, emtricitabine abacavir and stavudine all had activity while there was no activity from the NNRT is medications and or the protease or entry inhibitors. These latter drugs which have been designed for specific viral targets would not be expected to have activity against HERV K (HML2). However, it is contemplated that other protease inhibitors, entry inhibitors, and non-nucleoside inhibitors may demonstrate activity. In addition, HERV K-HML2 Viral RNA was also reduced (SEE FIG. 5 ).
[0161] NRTI antivirals can be given to patients with lymphoma to reduce the viral load of HERV K (HML2) in plasma and provide an antitumor effect on lymphoma which would demonstrate a causative role for HERV K (HML2) viruses in lymphoma.
Example 2
[0162] Plasma samples were collected from patients who developed diffuse large B cell lymphoma as a complication of HIV infection before and after the diagnosis of lymphoma. RNA extracted from the plasma samples using the QIAamp Viral RNA Mini Kit (Qiagen, Inc. Valencia, Calif.) was subjected to RT-PCR using env-specific primers antecedent to sequencing the RT-PCR products. Genotypic trees assembled by comparing env sequences from plasma samples to known HERV K HML-2 retrovirus sequences within the human genome revealed patient specific genotypes comprising HML2 Type 1 or Type 2 viral sequences, and/or recombinant sequences between Type 1 and Type 1 viruses, Type 2 and Type 2 viruses, and/or Type 1 and Type 2 viruses. Accordingly, env sequences obtained from plasma samples find use to identify competent viruses indicative of HERV K HML2 replication and the presence of lymphoma. In some embodiments, plasma samples are subjected to detection or analysis (e.g., sequencing) using, for example, beads, microarrays, pores, and other solid and fluid high-throughput sequencing formats and platforms, or other analysis technique.
REFERENCES
[0163] The following references, and all reference above, are herein incorporated by reference in their entireties:
Oken, et al. Am J Clin Oncol 5:649-655, 1982. Karnofsky et al. Cancer. 1948; 1:634-656. Painter et al. Curr Top Med. Chem. 2004; 4(10):1035-44. Lee et al. Cancer Res. 59:5514-5520, 1999 Gill et al. N Engl J Med 332:1744-1748, 1995. Harrington et al. Lancet 1996:348; 833. Ruprecht et al. Nature 1986:323; 467-469. White et al. Leukemia and Lymphoma, 2001 40:287-294. Patel et al. Ann Int Med 2008:148 728-736. Kurokowa et al. Blood 2005:106:235-240. Aboulafia et al. AIDS Patient Care and STDs 2007:21:900-907 Armstrong et al. J Oral Maxillofac. Surg. 2007:65: 1361-1364 Fatkenheuer et al. Eur J Med Res 2000 5:236-240. Al-Yamany et al. J Neurooncol 1999 42:151-9 Contreras-Galindo et al. AIDS Res Hum Retroviruses. 2006 10:979-84. Kaplan et al. Amer J Med 82(3):389-396, 1987. Contreras-Galindo et al. J. Virology 82(19):9329-9336, 2008. Thio et al. AIDS Reviews 2007:9:40-53. Levy et al. Clinical Infectious Diseases 2006:43; 904-910 Marcellin et al. N Engl J Med 2008 359:2442-2455. Tarlington et al. Mol. Lif. Sci 2008 65:3413-3421. Thelader et al. Leukemia and Lymphoma 2008; 49:1042-49. Tempescul A et al. Ann Hematol. Published on line. Brody et al. Critcal Rev Oncology Hematol: 2006; 58257-265. Zelenetz et al. Ann One 2006:17 (supplement 4) Lv12-1v14. Moller et al. Brit J Hematol 2006; 133:43-49. Tan et al. Hematol Oncol Clin N Am 2008 22:863-882. Tilly et al. Leukemia and Lymphoma 2008; 49(S1):7-17. DePaepe et al. Leukemia 2006 1-7. Friedberg et al. Hematol Oncol Clin N Am 2008; 22:941-52. Smith et al. Curr Opin Hematol 2008; 15:415-421. Shakir et al. J Clin Pathol 2008; 61:920-927. Zhou et al. Cancer 2008; 113:791-8. Peinert et al. Hematol Oncol Clin N Am 2008 22:903-940. Leleu et al. European J of Hematol 2008; 82:1-12. Sargent et al. Am J Surg Pathol 2008: 32:1643-1653.
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Compositions and methods to treat lymphoma and cancer are disclosed. In particular, the method teaches treatment of lymphoma and cancer using anti-HERV-K(HML-2) therapies. Further taught are compositions and methods for characterizing patient samples to, for example, select or identify therapeutic options or assess the impact of therapies.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns an airbag module with a gas generator, a gas bag, a housing with an exit opening for the deploying gas bag, as well as a holder. The gas generator and the holder are located inside the gas bag and the gas generator is fixed radially and axially to the housing.
2. Description of Related Art
A related airbag module is described in DE 298 06 402 U1. In this regard, a holder, placed inside the gas bag and which fastens the gas bag to the housing using separate bolts passing through the fabric of the gas bag, is connected to the housing. The application piece is U-shaped which corresponds in its shape to the housing, which is also U-shaped. The housing has an exit opening, between its U-legs. The gas bag is folded up in the housing, and exit opening is closed with a cover. The U-shaped holder is coordinated in its dimensions to the housing in such a manner that a narrow region exists between the housing walls and the holder to house the gas bag. The gas bag itself is folded into the U-shaped housing between the exit opening and the holder.
Generally, in airbag modules, the requirement also exists to direct the gases released by the gas generator when it fires into predetermined areas of the folded gas bag by placing deflectors as gas directing surfaces, in this manner assuring a controlled or even sequential deployment of the gas bag. For example, DE 197 36 243 A1 discloses an air bag device in which the interior of a module housing is subdivided into differing areas or internal spaces for the placement of the gas generator, on the one hand, and of at least one or more fold packets of the folded gas bag, on the other hand. The intermediate walls cause a pre-determined introduction of the gas stream into a pre-determined folding area of the gas bag, which then, as it unfolds, extracts further folding regions of the gas bag from the housing and releases them for the introduction of gas.
The problem to be solved by the invention, therefore, is to provide an airbag module with the general characteristics of simple attachment for the folded gas bag and simple construction of the gas direction system.
The solution to this problem is shown in the content of the patent claims that follow this description, including advantageous embodiments and further developments of the invention.
SUMMARY OF THE INVENTION
In its basic form, the invention provides a holder placed between the gas generator and the housing with an attachment area. The holder has a deflector segment directed toward the exit opening and surrounding the gas generator externally. The deflector segment has a deflector surface to direct the gas generated by the gas generator into at least one of the fold packets of the gas bag placed on both sides of the deflector segment.
The invention also provides an advantage that the holder provided for attaching the gas bag may also be made in the shape of a deflector. The deflector, due to its shape, divides the interior of the housing into various partial spaces or into various inside rooms, in which at least two fold packets are placed and through which, as a result of the gas conducted by the holder itself, receive gas differently. As a result of the double function so arranged for the holder to fasten the gas bag, on the one hand, and to direct the gas, on the other hand, a decrease in the size and weight of the air bag module as well as simplification of its structure is provided. This results in saving manufacturing time and manufacturing costs.
According to a first embodiment of the invention, the gas generator may be placed in a corner area of the housing. The holder has a section which, on one side, encloses the gas generator, where a fold packet is placed between the gas generator and the exit opening, and a further fold packet in the interior space formed by the outside wall of the housing facing away from the gas generator. In this connection, the U-shaped holder may be provided with an additional segment running along the facing outside wall of the housing.
In an alternative embodiment, the gas generator may be placed in a central area of the housing. The holder is designed to be U-shaped with two deflector segments enclosing the gas generator between them. In this connection, the gas bag may be provided with two fold packets, each of which is placed in the interior space that exists between the deflector segment of the holder and the facing outside housing wall. A gas bag location connecting the two fold packets bridges the space located between the deflector segments and the gas generator placed therein. For the purpose of good deployment of the fold packets, the individual folds of the fold packets of the gas bag may be placed transversely to the direction of ejection of the gas bag from the housing.
In another alternative embodiment of the invention, three fold packets of the gas bag are provided, of which two fold packets are placed, each in the interior space between the deflector segments and the outer housing wall, and an intermediate fold packet between the gas generator and the exit opening. The individual folds of the outer packets may run transversely to the ejection direction of the gas bag and the individual folds of the central fold packet run in the ejection direction.
In order to obtain a greater variety in inflating the fold packets of the gas bag folded in the housing, according to one sample embodiment of the invention, at least one deflector segment passage opening is placed in the interior space defined by the deflector segment for the passage of gas from the gas generator.
In alternative embodiments of the invention, then, each deflector segment serving as a deflector surface may extend along a portion of the extension of the gas generator in the direction of the exit opening or corresponding to the extension of the gas generator in this direction or also extend beyond the gas generator in the direction of the exit opening.
The end of each deflector segment may be directed toward the exit opening from the housing is bent inward or outward with respect to the gas generator.
In an alternative embodiment of the invention, the gas generator may be placed centrally in the housing. The holder includes a gas generator with a deflector segment placed on one side, where three fold packets of the gas bag are provided, of which one fold packet is placed between the deflector segment and the outside housing wall. The other two fold packets are placed in the interior space of the housing divided off by the deflector segment in which the gas generator is placed. In this case, the deflector segment is placed on one side, and an extension that extends parallel to the exit opening from the housing surround the gas generator. One of the three fold packets is placed in the space between the extension of the deflector segment running parallel to the exit opening and the exit opening itself. According to one embodiment of the invention, the holder is connected to the housing.
In an especially suitable embodiment of the invention, the holder is placed without fastening between the gas generator and the housing. In this regard, the holder, in particular, is held fast by the gas generator without being firmly fixed to the gas bag or the gas generator or the housing on the side of the gas generator opposite the exit opening between the housing wall of the module housing and the gas generator. The holder absorbs the forces that arise during deployment of the gas bag and transmits them to the gas generator and its fastening to the module housing. Thus, the fastening of the gas bag in this sample embodiment is done in a kind of floating fastening because the gas bag fabric is guided without separate fixation or attachment around the holder. The holder is placed inside the gas bag, where the holder braces against the gas generator fastened inside the module housing, in the case of stressing due to the tensile forces applied to the gas bag as it deploys, and thereby transmits the forces. This has the advantage that the gas bag fabric is braced against the surface of the holder for the transmission of forces, and there is no point stress. As a result, no reinforcement will be applied in the manufacture of the gas bag. Also, the manufacture and installation of the airbag module are simplified, because no special measures are required on the gas bag fabric for the fastening of the holder.
Finally, according to one sample embodiment of the invention, the holder has a dimension coinciding with the parallel length of the gas generator in its support area oriented parallel to the housing floor; in this manner, an especially small design is assured for the airbag module, because only the necessary area of extension of the holder is used for the fastening of the gas bag fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other features and advantages of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be 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:
FIGS. 1 a – 1 c show an airbag module with a gas generator placed in a corner area and a holder with a one-legged deflector segment in its original condition and in different stages of deployment of the gas bag.
FIGS. 2 a – 2 c show another sample embodiment of the airbag module in the representation in accordance with FIGS. 1 a – 1 c , with additional gas passage openings in the deflector segment of the holder.
FIGS. 3 a – 3 c show an air bag module with a centrally placed gas generator and a U-shaped holder placed on both sides of the gas generation, with deflector segments in a representation corresponding to FIGS. 1 a – 1 c.
FIGS. 4 a – 4 c show the subject of FIGS. 3 a – 3 c with the addition of gas passage openings.
FIGS. 5 a – 5 c show a further sample embodiment of the airbag module in a representation according to FIGS. 1 a – 1 c , with a centrally placed gas generator and a one-legged holder.
FIGS. 6 a – 6 c show the subject of FIGS. 5 a – 5 c with an extension added to the deflector segment of the holder extending parallel to the passage opening of the housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method of the present invention, as represented in FIGS. 1 a through 6 c , is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.
The housing 10 represented in FIGS. 1 a through 1 c of an airbag module consists of a floor area 12 and outside walls 11 extending upward therefrom, which, between themselves, define an exit opening 13 for the gas bag 15 folded in the interior of the housing 10 . In the housing 10 , generally a gas generator 14 is placed and fixed to the housing 10 . The gas generator 14 may be fixed radially, axially, or radially and axially to the housing.
In the sample embodiment represented in FIGS. 1 a through 1 c , the gas generator 14 is placed in a corner area of the housing 10 near the floor area 12 , where the gas generator 14 is inside the folded gas bag 15 and placed in the interior of a U-shaped holder 19 . The holder 19 has a leg 22 extending parallel to the outside wall 11 of the housing 10 , which, in the sample embodiment represented, works not as a deflector, but only encloses a gas bag position for the folded gas bag 15 between it and the outside wall 11 . The same applies for the support area 20 of the holder 19 . The deflector segment 21 , which extends in the direction of the exit opening 13 on the inside of the attachment area of the holder 19 , serves at the same time as a limitation for two partial spaces in which two fold packets 16 and 18 of the gas bag 15 are placed. A fold packet 18 is placed between the gas generator 14 and the exit opening 13 of the housing 10 , while a second fold packet 16 is accommodated in the space lying between the deflector segment 21 and the opposite outside wall 11 of the housing. Both folding bags 16 , 18 have individual folds 30 running parallel to the exit opening 13 or transverse to the expulsion direction of the gas bag. In the embodiment represented in FIGS. 1 a – 1 c , the end 24 of the deflector segment 21 is bent outward, that is, away from the gas generator 14 .
In all sample embodiments represented and to be described below, the holder, with deflector segment or deflector segments, is laid, without being firmly fixed to the gas bag 15 or the gas generator 14 or the housing 10 , into the interior of the gas bag 15 , so that, upon deployment of the gas bag, as shown in FIGS. 1 b and 1 c , the holder is pulled with its support area 20 from the gas bag position between the support area 20 and the floor area 12 of the housing, against the gas generator 14 and thereby transfers the corresponding forces to the gas generator and its fastening to the housing 10 . The support area 20 may be oriented parallel to the housing floor 12 , and it has a dimension that substantially coincides with the dimension of the gas generator, along a plane parallel to the support area.
In FIGS. 1 b and 1 c , the incipient deployment of the gas bag 15 due to the arrangement described of the fold packets in the housing can be recognized; it can be seen in which sequence the fold packets 18 followed by 16 are thrown out.
The sample embodiment represented in FIGS. 2 a through 2 c differs from the sample embodiment described in FIGS. 1 a through 1 c only through the placement of at least one additional gas passage opening 26 in the deflector segment 21 , so that substantially parallel to the gas flow in the direction of the fold packet 18 , simultaneously gas also flows through the gas passage opening 26 into the fold packet 16 beside the gas generator 14 , and provides for its early deployment.
The sample embodiment represented in FIGS. 3 a through 3 c has a gas generator 14 placed centrally in the housing 10 . In this orientation, leg 22 functions as a deflector segment, so that the U-shaped holder 19 has two deflector segments 21 and 22 with the gas generator 14 disposed between the deflector segments 21 and 22 . Correspondingly, in this sample embodiment, three fold packets are provided, of which the outside two fold packets 16 and 17 are each placed in the intermediate space existing between the outer wall 11 and the neighboring deflector segment 21 or 22 . In addition, there is placed a third fold packet 18 in the central area between the gas generator 14 and the exit opening 13 . While the individual folds of the two outside fold packets run parallel to the exit opening 13 , the individual folds 30 of the central fold packet 18 run in the expulsion direction of the gas bag 15 from the housing 10 . FIGS. 3 b and 3 c show, in detail, the effect of the gas flow from the gas generator 14 on the deployment of the fold packets 18 as well as 16 and 17 .
The embodiment represented in FIGS. 4 a through 4 c shows, as a supplement to the embodiment described in FIGS. 3 a through 3 c , supplementary deflector segments 21 and 22 of the holder 19 , through which a more rapid deployment of the outside fold packets 16 and 17 is initiated. The ends 23 of the deflector segments 21 and 22 facing the exit opening 13 are bent inward to the gas generator. In addition, openings 26 allow gas from the gas generator 24 to enter fold packets 16 and 17 beside the gas generator 14 and provide for early deployment of the gas bag 15 .
The sample embodiment shown in FIGS. 5 a through 5 c shows a centrally placed gas generator 14 and a holder 19 with one deflector segment 21 , where the placement of the fold packets 16 , 17 , 18 corresponds in principle to that of the sample embodiments described in FIGS. 3 a – 3 c and 4 a – 4 c . The removal of a deflector segment and the asymmetrical shape of the holder with respect to the deflector segments results in the deployment process represented in FIGS. 5 b and 5 c.
In the sample embodiment shown in FIGS. 6 a through 6 c , with a centrally located gas generator 14 and a holder 19 , with only one leg and therefore only one deflector segment 21 , the free end of the deflector segment 21 , unlike the sample embodiment according to FIGS. 5 a – 5 c , transitions into an extension 25 which extends parallel to the exit opening 13 , where the center fold packet 18 is located in the area between the extension 25 and the exit opening 13 . As a result, the beginning of the deployment sequence is transferred to the fold packet 17 facing the open side of the holder 19 , which provides for the pulling out of the further fold packet 18 and then 16 .
The characteristics of the subject of these documents revealed in this description, in the patent claims, in the summary and the drawings, can be utilized individually or in any combination for the creation of the invention in its various embodiments. The present invention may be embodied in other specific forms without departing from its structures, methods, or other characteristics as described herein and claimed hereinafter. The described embodiments are to be considered only as illustrative, and not restrictive.
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An airbag module with a gas generator, a gas bag, a housing containing an exit opening for the deploying gas bag, and a holder. The gas generator and holder are located inside the gas bag, and the gas generator is fixed to the housing. The holder ( 19 ) has a support area ( 20 ) and at least one deflector segment ( 21, 22 ) directed toward the exit opening ( 13 ). The holder is placed between the gas generator ( 14 ) and the housing ( 10 ). The deflector segment at least partially surrounds the gas generator ( 14 ) and directs the gas generated by the gas generator ( 14 ) into at least one of a plurality of fold packets ( 16, 17, 18 ) of the gas bag ( 15 ) placed on both sides of the deflector segment ( 21, 22 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon provisional patent application 60/227,623 filed Aug. 18, 2000.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to access control, and more particularly to user control of appliances. The appliances include a wide range of appliances such as personal computers, firearms including handguns, rifles, and shotguns, as well as other user controlled devices. An apparatus and method of the present invention facilitate usage of an appliance only by an authorized user or users. A particular example of the invention described herein relates to firearm safety by which only someone authorized to use a firearm can fire the weapon, and then only when that authorized person is in a preferred position (i.e., behind) with respect to the weapon. Further, the act of firing the weapon (or usage of the appliance) is recorded so data is subsequently available as to who fired the weapon and when it was fired. With respect to other appliances, the recorded information would indicate who used the appliance and when.
[0004] Referring to FIG. 3 of the drawings, in the prior art, access control is a method or procedure by which entry into a facility F (whether it be a building or a portion thereof) can be limited only to persons authorized to have access. There are a number of access control methods, one of which is referred to as RFID, an acronym for radio frequency identification. Basically operation of an RFID system is such that a person P authorized for entry into the facility is given a badge (“tag”) T which includes a transmitter transmitting an rf signal of a given frequency. The signal is encoded. An rf receiver R is located at an entry E of the facility. As the person approaches the facility, the receiver receives the signal transmitted by the badge. If the signal is the proper one, the person enters the facility unimpeded. An unauthorized person is however blocked from entry. An advantage of this type access control system is that it is transparent to the authorized person since he or she has to do nothing other than approach the entry, while a barrier is otherwise imposed to block entry of an unauthorized person. Other RFID systems include toll roads where a subscriber is given a RFID tag to place in their car. As the car approaches a prescribed gate at a toll station, the rf signal transmitted by the tag is received by a receiver at the gate and the vehicle is allowed to pass unimpeded through the gate. If an unauthorized person drives through the gate, an alarm is given. RFID tags are also placed, for example, on inventory items in warehouses so movement of merchandise can be automatically tracked as the merchandise is moved into and out of the warehouse.
[0005] In certain access control situations, as described herein, it may not be sufficient, or even inappropriate, that someone has access to an appliance. This is particularly so where use of the appliance (a handgun) by an unauthorized person (a child) can be harmful to that person or others, or where use of the appliance by unauthorized person can have other detrimental effects (access to a personal computer or automobile by one not supposed to be using it, for example).
[0006] Firearm safety is currently a major health issue. There are constant reports of children coming across a handgun kept in their home with tragic results. Stolen firearms are often used in the commission of crimes. Law enforcement records indicate that the vast majority of police and other law enforcement officers are killed with their own weapons taken from them by a criminal. Currently, a number of lawsuits have been filed against firearm manufacturers because of the relatively large number of people killed or injured due to weapons (particularly handguns) accidentally discharged. In some locales there are now programs to distribute gun locks to gun owners, and some firearm's manufacturers now provide gun locks with each weapon they sell.
[0007] Referring to FIGS. 4 A- 4 C, different types of prior art gun locks are shown. In FIG. 4A, a mechanical combination lock 102 is mounted on the grip 104 of pistol 100 . To use the weapon, the operator must enter a multi-digit code and turn a manual safety knob. This disengages a locking lever which otherwise blocks operation of the gun's firing mechanism.
[0008] In FIG. 4B, an electro-mechanical lock 106 has an associated motor which blocks the firing mechanism of the weapon. The lock provides a series of operating modes including unlocked and ready, locked and secure, and time delay locked and secure. Again an operator must enter a multi-digit code to enable the weapon.
[0009] In FIG. 4C, a magnet 108 installed in the gun blocks its firing mechanism. A potential user must wear a special ring 110 on one of his fingers, the ring also containing a magnet. By properly orienting the magnets, when ring 110 is brought into proximity with pistol 100 , the internal magnet 108 is pulled away from its blocking position allowing the weapon to be used.
[0010] In FIG. 4D, another prior art approach includes an attachment 112 incorporating a fingerprint scanner 114 and which attaches to handle 104 of the weapon. An electronic circuit installed in the weapon disables it from being fired. When the firearm is to be used, the user places the pad of his finger against scanner 114 which obtains an image of his fingerprint. If the scanned image compares with an image stored in the memory, the circuit enables the weapon to be fired.
[0011] Another prior art approach is a rf controlled weapon shown in FIG. 4E that includes a transponder 116 installed in a cuff 118 worn by the user on his wrist. A transmitter/receiver mounted in the weapon sends out signals. If the transponder is in proximity of the weapon, a reply signal sent by the transponder back to the weapon enables it for firing.
[0012] While each of these previous approaches has certain advantages, each also has disadvantages with respect to implementation, use, cost, and effectiveness. The most significant disadvantages, however, is with regard to safety. It has been shown, for example, that certain types of locks installed on weapons can be circumvented and the weapon fired with the lock still in place. A magnetic ring can be easily duplicated. In the case of a person wearing the transponder cuff and having his weapon taken away from him, if he is still close enough to the weapon, as would occur if he were struggling over the gun with an assailant, the weapon will still be enabled and can be used to injure or kill him.
[0013] The gun safety method described herein employs rf techniques combined with a directional control capability. It is particularly effective in controlling the use of handguns and is especially worthwhile for use by police and law enforcement officers so to eliminate incidents of harm to these individuals.
BRIEF SUMMARY OF THE INVENTION
[0014] Among the several objects of the present invention may be noted the apparatus and a method of controlling operation of a wide variety of appliances so the appliance can only be used by an authorized individual, and then only under certain specified conditions. The apparatus and method provide safe use of the appliance since only the person authorized to use the appliance is trained in its use, and where circumstances warrant, knows how to use it safely. It is a particular advantage of the invention to prevent unsafe use of the appliance, even by an authorized user.
[0015] The apparatus and method of the invention are, in one application, used for firearm safety. The apparatus, when used with a firearm enables a policeman or law enforcement agent to enable (authorize) the firearm, so it can be used while the person is on duty. Most importantly, the apparatus and method of the invention only enables the weapon to be fired when the authorized user is in a preferred position with respect to the weapon; i.e., behind it with the muzzle of the weapon pointed away from him. Thus, even if the weapon is taken away from him and he is still in close proximity to it, it cannot be used against him. This feature also is significant in non-law enforcement environments. Use of the apparatus and method with sporting firearms would prevent injury to hunters, for example, who might trip and fall while carrying a loaded rifle or shotgun. The prevention of household firearm accidents is also prevented because even if a child finds a loaded gun, he cannot accidentally discharge it. If the weapon is stolen, it cannot be used by the thief in the perpetration of other crimes.
[0016] Another feature of the invention is that more than one individual can be authorized to use the same weapon. In law enforcement or military scenarios, this means one person can use the weapon during one interval and another person at another time.
[0017] A further advantage of the invention is the use of encoded transmissions back and forth between the weapon and the authorized user. A coding scheme is employed which first prevents spoofing so that an unauthorized user cannot authorize the weapon. Next the method of the invention requires continuous, periodic reauthorization to maintain the weapon in its authorized state. The encoding of the signals sent back and forth between the weapon and authorized user is constantly changed to prevent tampering, or unauthorized use or duplication.
[0018] A further feature of the invention is that authorization of the appliance can be overridden in certain circumstances. For example, authorization to activate a firearm may be overridden in a schoolroom or courthouse.
[0019] Another provision of the invention is an apparatus and method in which a record of use of the appliance is maintained including information as to who was using the appliance at any particular time. The information is then readily accessible to one subsequently interrogating the appliance using a different code than that by which the appliance is authorized for use.
[0020] It is also a feature of the invention that the apparatus and method can be implemented as an original equipment (O.E.) feature, or can be retrofitted to an existing appliance.
[0021] Finally, it is a provision of the apparatus and method to be a reliable and relatively low cost safety and user control feature. One portion of the apparatus is easily incorporated into a weapon, PC, automobile, etc., with another portion incorporated into a badge, driver's license, or other device carried by the authorized users.
[0022] In accordance with the invention, generally stated, apparatus and a method of the present invention renders a weapon incapable of use unless authorized by a specified individual. More than one person may be authorized to use the weapon, however only one person may be authorized to use it at any one time. Each authorized person carries a badge or other device which includes an rf transmitter capable of transmitting a coded signal to a receiver installed in the weapon in response to a coded query from a unit installed in the weapon. If a properly coded transmission is received by the weapon from the correct direction, it becomes capable of being fired by the person who authorized its use. However, the weapon will not fire unless the person using the weapon is also standing behind the weapon. This prevents the weapon from being turned on the person authorized to use it. Further, a memory internal to the weapon retains a record of not only who is using the weapon at a given time, but if the weapon is discharged, how many times, when, and where.
[0023] Besides firearms, the apparatus and method of the invention are readily incorporated into other appliances whose use is to be controlled and/or which it is important to operate in a safe manner. Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] In the drawings, FIG. 1 is a block diagram of the gun safety mechanism of the invention;
[0025] [0025]FIG. 2 illustrates a directional control capability by which a weapon can be discharged only when in a specified relationship to an authorized user of the weapon;
[0026] [0026]FIG. 3 is a simplified representation of a prior art access control system using RFID; and,
[0027] FIGS. 4 A- 4 E are simplified representations of prior art gun safety technologies; and,
[0028] FIGS. 5 A- 5 C illustrate use of the apparatus and method of the invention in controlling use of a firearm; and,
[0029] [0029]FIG. 6 illustrates another embodiment of the invention.
[0030] Corresponding reference characters indicate corresponding parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to the drawings, apparatus of the present invention for providing user control of an appliance is indicated generally 10 . A representative illustration of the apparatus and method of the invention, and their use is a gun safety mechanism such as described with respect to FIGS. 1 and 2, and FIGS. 5 A- 5 C.
[0032] As now described, a key feature of the mechanism is the communication and cooperation between an electronic unit EU contained within a gun 12 , and a separate, authorizing unit AU carried by an “authorized user” of the gun. The authorizing unit is, for example, incorporated in a badge 14 worn by a policeman when on duty. Electronic unit EU, which is mounted or otherwise installed within gun 12 , first includes an electronic message generator EMG. Generator EMG generates a uniquely coded waveform which, as shown in FIG. 1, is transmitted by a transmitter TEU as an rf signal to authorizing unit AU to interrogate the authorizing unit. As further discussed hereinafter, apparatus 10 allows for more than one authorized user of the weapon. Accordingly, the message embodied in the transmitted coded waveform can authorize more than one authorizing unit AU. However, the message will authorize only those authorizing units which are complementary to the particular weapon. Upon receipt of an interrogation message by a receiver RAU of an authorizing unit AU, the message is decoded by a decoding electronics section DAU of the authorizing unit. The decoded message is then compared in a comparator COMP with a message previously stored in a memory MAU within the authorizing unit to determine if this particular authorizing unit AU is one authorized for use with this particular gun 12 . If it is, then a reply message generator RMG of the authorizing unit generates a reply message which also comprises a uniquely coded waveform. This reply message is then transmitted by a transmitter TAU as an rf signal back to electronics unit EU within gun 12 .
[0033] A reply message receiver REU within electronics unit EU receives the message and provides it to decoder electronics section DEU within the electronics unit. Decoder DEU decodes the reply signal. An output signal AS from decoder DEU, verifying that an authorized user of the weapon has responded to the query from the electronics unit, is now used to activate the weapon.
[0034] An important aspect of the method and apparatus of the invention is that more than one person can use the weapon. In a police or military environment, this means that one officer (or soldier) can use the weapon during one shift (tour of duty), and another officer (soldier) during another shift (or tour). Since there can be more than one authorized user for a given weapon, each authorizing unit AU includes a unique code within the reply message identifying which authorized user (police officer or soldier) is replying to the interrogation message. This information is stored within a memory MEU of electronics unit EU so a record is made as to which authorized user is controlling the weapon at a given time.
[0035] Referring to FIG. 2, receiver REU includes two separate antennas; an omni antenna A 1 , and a second antenna A 2 . Antenna A 2 has a gain of 3 dB (or more) in the horizontal plane. Because it only has 3 dB of gain, antenna A 2 has only 180° of coverage in the horizontal plane, i.e., it provides directional sensitivity. Antenna A 2 is set up such that its principal axis is in the plane of a gun barrel 16 , but points backwards away from the direction of firing of the gun barrel. The pattern of antenna A 2 shown in FIG. 2 is for the horizontal plane. In the vertical plane, both antennas A 1 and A 2 have 0 dB of gain.
[0036] Differencing the signals from antennas A 1 and A 2 (A 2 -A 1 ) and accepting only positive signals, ensures that only signals behind a plane BC of the gun authorizes operation of the gun. By way of example, a signal S, from the right of plane BC, results in (S 1 ×gain of A 2 )−(Si×gain of A 1 )=S 1 ×0=−S 1 ×1=−S 1 . This is a negative signal. On the other hand, a signal S 2 from the left of the plane BC results in (S 2 ×gain of A 2 )−(S 2 ×gain of A 1 )=S 2 ×2−S 2 ×1=S 2 . This is a positive signal. Further, this positive signal is measured against a threshold such that authorizing unit AU not only has to be behind plane BC, but also within a certain distance of gun 12 in order to authorize use of the weapon.
[0037] Upon receipt of a positive signal at receiver REU, the signal is decoded. If the decoded signal is from an appropriate authorizing unit AU, the decoder sends a message to a control unit CEU of the electronics unit. Upon receipt of this signal, the control unit deactivates a gun restraint unit GRU which is interconnected with the firing mechanism of the weapon. Deactivating the gun restraint unit frees the gun to fire. However, as discussed hereinafter, this is a controlled feature of the invention and the weapon must be re-authorized at predetermined intervals or else it will again be rendered unusable.
[0038] Control unit CEU performs a number of tasks. First, as described above, the control unit controls provides activation signals to the gun restraint unit. Second, the control unit effects a query and response cycle through message generator EMG. The query/response cycle is, for example, triggered once every second. If a correct response is received, and gun 12 has already been activated, the gun remains activated for another 1-2 seconds. In effect, gun 12 remains continuously activated in the presence of continuous queries from the gun's electronics unit and affirmative responses from the authorization unit carried by an authorized user of the weapon. If the weapon has been activated, but subsequently does not receive an affirmative response to a query, a second query and response cycle is immediately initiated. If an appropriate response is again not received, weapon 12 is rendered inactivate by gun restraint unit GRU. The initial interrogation cycle (the one second query/response cycle) then recommences. It will be understood by those skilled in the art that the time intervals specified herein are exemplary only and that other timing can be used. It will further be understood by those skilled in the art that the codes used in practicing the method of the invention can be automatically changed at predetermined intervals, including each time an interrogation signal and response signal are sent. Changing the coding makes it extremely difficult for unauthorized users to enable the appliance.
[0039] Both electronics unit EU and authorization unit AU are battery operated by batteries BAT. Battery life is dependent upon operational life and all attempts are used to preserve the battery life. Typical operations should achieve a 10 year life. A similar 10 year life is anticipated for the separate battery that operates the authorization unit. In one embodiment, the battery that resides in the gun is a rechargeable unit. However, issues of gun safety during recharging outweighs certain advantages this might offer.
[0040] In the electronics unit, control unit CEU minimizes power consumption. To save battery life, an auxiliary circuit AUX is employed which starts the query/response cycle. This circuit is activated, for example, when a person grips a handle of the gun. Picking up the gun by its handle closes a contact T which activates this interrogative and answer sequence. When the gun is no longer being held, the activates the auxiliary circuit to commence an interrogation cycle and to continue the cycle for a specified interval; for example, 15 seconds. With a positive response, the weapon is activated as above described. Otherwise, after the interval, control unit CEU returns electronics unit EU to a quiescent state in which essentially no power is consumed and in which the weapon is deactivated.
[0041] The interaction between authorization unit AU and electronics unit EU is to establish whether gun 12 is disabled or enabled. Gun restraint unit GRU actually enables or disables the weapon. The gun restraint unit is a fail safe device since in the event of loss of battery power, for example, the gun is disabled.
[0042] Apparatus 10 is available in two models. In one model, the gun is manufactured with apparatus 10 built in. In the other model, gun 12 is retrofitted with the apparatus. The apparatus includes, for example, a solenoid 20 which, when its coil 22 is deactivated, blocks the mechanical motion of the gun's hammer or trigger. When gun 12 receives an authorization signal AS from control unit CEU, coil 22 is energized and solenoid 20 retracts to clear the firing mechanism. Solenoid 20 is a discrete solenoid which operates in conjunction with a semiconductor 24 . The hammer and/or the trigger are now free to operate normally. Apparatus 10 does not supersede, interfere with, or otherwise effect a mechanical safety with which the gun is usually provided. Both apparatus 10 and the mechanical safety have to be disengaged before the weapon can be fired.
[0043] As shown in FIGS. 5 A- 5 C, the method of the invention involves two steps. In step 1 , the gun, in effect, transmits a coded signal. In step 2 , a coded reply signal is received back by the gun. The gun is then authorized to fire only if the reply signal is an appropriate response and if the reply signal is directed to the gun from a predetermined direction relative to the gun. Otherwise, the gun is not enabled for use even though the reply signal is an appropriate response. Thus, as shown in FIG. 5B, if the authorized user is behind the gun, the gun is enabled to fire. However, if the authorized user is in front of the gun, it is not enabled and cannot fire.
[0044] An additional feature of apparatus 10 is the provision of an electronic record of the use of the gun. As noted, electronics unit EU includes a memory unit MEU. Each time gun 12 is fired, data is provided to the memory which records the time, date and the authorized user employing the weapon at that time. A sensor N (see FIG. 2) senses movement of the gun's hammer H. An internal clock built into the electronics unit provides time information. Additionally, an optional global positioning unit GPU can be used to provide location information. To download this information from memory MEU, electronics unit EU receives a specific interrogation code or codes (which codes are different than the authorizing code). In response, memory unit MEU provides its stored data to transmitter TEU of the electronics unit for transmission to data receiver. Included in this transmission is the license number of the weapon. It will be noted that while the authorizing codes are unique to the gun they enable, the interrogating codes for data retrieval are universal codes available to the police and other law enforcement and other investigative agencies. Further, the activation code takes precedence over a data retrieval code and the downloaded data will not include the authorizing code for the weapon. Also, the use of codes allows for future developments in other areas. For example, in a courtroom or schoolroom setting, universal transmission of certain codes would override authorization of the weapon and inhibit the use of the gun in these settings.
[0045] Both electronics unit EU and authorization unit AU are fabricated in very compact form which parallels a RFID format using thin film technology. Importantly, apart from details of their operation, and directionality, these units employ existing technologies and utilize radio frequencies standard within the industry; for example, they can be implemented using “Bluetooth” technology. Both units are acceptable to Class 15 services.
[0046] Again with respect to FIGS. 5 A- 5 C, the importance of the apparatus and method of the present invention is that the weapon is authorized for use only when the authorized user is in a preferred position with respect to the weapon. That is, when the user is behind the weapon and the muzzle of the weapon is pointed away from him, the condition shown in FIG. 5B. In a law enforcement situation, if a police loses his weapon in a struggle with a criminal, the criminal cannot shoot the officer with the weapon because it will not fire, the condition shown in FIG. 5C. This is so, even if the assailant also has an authorization unit; because, as discussed, each unit is unique to a particular weapon. Were the person who got the weapon away from the policeman to try to use the weapon in commission of another crime, it would not fire. This does not mean that the fright effect caused by having the weapon pointed at someone would still not be there, but the victim could not be shot with the weapon.
[0047] In hunting situations, if the hunter were to drop a loaded weapon because of an accident or carelessness, the weapon would not discharge if the muzzle were to somehow come to be pointed at the user. Again, this is the condition shown in FIG. 5C. In home environments, a toddler or child who came across a weapon could not inadvertently shoot himself or another because the apparatus would not allow the weapon to fire.
[0048] While the foregoing discussion is directed to use of the apparatus and method of the invention in firearm's safety, those skilled in the art will appreciate that it can be used to effect user control of a myriad of appliances. These include home appliances such as televisions and VCR's, kitchen appliances such as stoves, laundry or bathroom items such as steam irons, hair dryers, curling irons, etc. That is, appliances where the ability to control when the device is turned on or off has safety implications and prevents injury, for example, to small children or senile adults who might otherwise inadvertently injure themselves. Alternatively, the invention prevents those who have no legitimate reason to be using someone else's property from using it. In industrial settings, machine tools can similarly be controlled so that only persons having the “right” to the use the equipment can turn it on and use it. If the person's position relative to the equipment can be such that they can be injured by the equipment, the apparatus and method of the present invention will insure that the equipment is activated only so long as the user remains in a safe position relative to the equipment; i.e., a position where he cannot be injured by it.
[0049] The apparatus and method may also be employed for theft prevention. Movable items such as automobiles, carts such as golf carts, trucks, vans, etc. can be effectively prevented from being started and driven away by incorporating the apparatus and method of the invention with the ignition or fuel delivery system of a vehicle, including those which are battery powered. Also included in this category of appliances also includes computer related appliances such as PC's and their associated peripherals, cellular phones, and other portable equipment. Here, while it may be possible to steal the appliance, the appliance is unusable by the thief. In each of these applications, the authorized user wears a badge or tag 14 and electronics unit EU is installed in the appliance. The apparatus further includes the two antennas A 1 and A 2 , the antenna A 1 being the omni-directional antenna, and antenna A 2 providing the directional sensitivity.
[0050] In an additional application, as shown in FIG. 6, a third antenna A 3 is employed by the apparatus. As with antenna A 2 , this antenna A 3 is also a directional antenna. Antenna A 3 is, however, pointed in a direction in which, for example, use of the appliance may cause injury to a person. Further, antenna A 3 has a very narrow cone for directionality; for example, 5°. In the above described firearm example, antenna A 3 points in the direction of the muzzle of the gun. Now, operation of the apparatus and method of the invention is such that the weapon is authorized for use in the manner previously described. However, if another authorized person, a policeman for example, moves in front of the weapon, the weapon is disabled for so long as he is there; and is enabled as soon as he moves away from in front of the muzzle. This feature prevents injury due to “friendly fire”. Those skilled in the art will recognize that this feature has significant military implications for combat. In industrial settings, this feature protects co-workers from inadvertent injuries if they come too close to the operating portion of a piece of equipment while it is in use. The advantage that this feature provides is that the authorized user actually operating the appliance does not to even have to be aware of the presence of the other for the safety feature to work.
[0051] Finally, in all of the above described applications, the apparatus and method of the invention have involved a person interacting with the appliance. Those skilled in the art, however, will recognize that there are applications where one appliance may be able to interact with one or more other appliances. Here, the user control issue is that it may desirable, or in some circumstances necessary, for the first appliance to interact with only one of the other appliances, and then only so long as the other appliance is a preferred orientation with respect to the first appliance. The apparatus and method of the present invention provide a way for accomplishing this.
[0052] In view of the foregoing, it will be seen that the several objects of the invention are achieved and other advantageous results are obtained.
[0053] As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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Apparatus ( 10 ) and a method for rendering a weapon ( 12 ) incapable of use unless authorized by a specified individual. More than one person may be authorized to use the weapon, however only one person may be authorized to use it at any one time. Each authorized person carries a badge ( 14 ) or other device which includes an rf transmitter (TAU) capable of transmitting a coded signal to a receiver (REU) installed in the weapon in response to a coded query from a unit (EU) installed in the weapon. If a properly coded transmission is received by the weapon, it becomes capable of being fired by the person who authorized its use. However, the weapon will not fire unless the person using the weapon is also standing behind the weapon. This prevents the weapon from being turned on the person authorized to use it. The apparatus stores details of the weapon's use (e.g., who, when, and where). This information is released upon receipt of an authorized code.
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BACKGROUND OF THE INVENTION
Workmen that require various tools in their jobs have the problem of how to carry these tools and yet have their hands free to do other things, e.g. climb a ladder. It is well known that many types of workmen have devised their own carriers that are suspended from a waist belt. A typical example is one who uses a military web belt with attachable pouches and loops that can carry screw drivers, hammers, pliers, chisels, wrenches, etc. In more recent times it has become a common practice to use hand tools that are powered by springs, electricity, compressed air, or the like, to do jobs originally done by hand, e.g. nailing, stapling, drilling, riveting, and the like. These powered hand tools are usually more bulky than their manual, unpowered predecessors, and there is a need to provide a means for carrying such tools around while leaving the hands free. One such means is a holster into which can be strapped to the body of the workman so as to be available when needed. The holsters which have appeared up to now do not have the desired adjustability so as to fit different sizes of bodies, and do not provide the most desirable facilities for carrying tool bits, keys, and the like.
It is an object of this invention to provide an improved tool organizer including a holster for a hand tool having a pistol grip handle. It is another object of this invention to provide a novel holster for a hand tool wherein the holster is adjustable in position and has optional attachments for holding tool bits, chuck key, and boxes of fasteners. Still other objects will become apparent from the more detailed description which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a hand tool organizer including a one-piece molded holster having an open top to receive a hand tool with a pistol grip handle. The holster has attached thereto on the portion next to the wearer an elongated strap having an upper end and a lower end and being formed of two coextensive layers fastened together by a plurality of longitudinally spaced threaded inserts through at least two of which such strap is fastened to the holster by removable fasteners, with other combinations of at least two threaded inserts providing the capability of adjusting the position of the holster along the length of the strap. The upper end of the strap extending above the holster with the two layers being releasably fastened together by a fastener to form a belt loop from which the holster is supported and readily released therefrom. The lower end of the elongated strap has a tunnel loop therein to receive an adjustable lateral strap having a releasable fastener for encircling the strap around the leg of the wearer.
In a preferred embodiment of this invention, there is a holder for tool bits fastened to the outside of the holster, the holder being a two-layer strap with a plurality of spaced rivets through both layers to provide, between rivets, places to insert and retain tool bits. In another preferred embodiment a channel clip is attached to the outside of the holster to receive and retain boxes of fasteners that might be used with a stud gun. In still another embodiment there is a strap loop releasably attached to the holster to hold a drill chuck key.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a side elevational view of one embodiment of the hand tool organizer of this invention;
FIG. 2 is a front elevational view of the organizer of FIG. 1;
FIG. 3 is a rear elevational view of the organizer of FIG. 1;
FIG. 4 is a side elevational view of a second embodiment of the hand tool organizer of this invention;
FIG. 5 is a front elevational view of the organizer of FIG. 4;
FIG. 6 is a schematic view showing the adjustability of the organizer of this invention;
FIG. 7 is a schematic view showing the organizer of this invention worn on the left side of the wearer; and
FIG. 8 is a schematic view showing the organizer of this invention worn on the right side of the wearer.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1-3 the details of this invention are readily seen. A hand tool, e.g., a power drill, 50 is enclosed in an organizer 60. The organizer 60 includes a holster 55 formed from a single piece of moldable material folded along the front portion 20 with two edges brought together at the back portion 21 and held together by a fastener 51 and a tension screw fastener 52. Holster 55 has two sidewalls 22 and 23, the former being positioned against the wearer's leg and the latter facing away from the wearer. This arrangement includes an open top 24, leading to an inside cavity into which hand tool 50 is inserted, and an open bottom 25 which permits the forward end of hand tool 50 to project downwardly. Sidewalls 22 and 23, and front portion 20 are molded to fit the outside contours of the hand tool 50.
Holster 55 is preferably made of a heat moldable thermoplastic material. Such materials are commercially available in sheet form in any of a variety of thickness. Each type of material has its own unique molding temperature, frequently known as the "softening temperature", at which level the sheet can be caused to assume any irregular shape. Generally, the preferred method of forming is to place a sheet of the thermoplastic material around an interval core of the proper contour and heat the thermoplastic to its forming temperature, press the material around the core while hot, and then cool the formed holster until it retains its formed shape. Other thermal forming methods may also be operable. Among the materials which are suitable for this purpose are polystyrene, acrylic-butadiene-styrene terpolymer, polyvinyl chloride, polyvinyl fluoride-acrylic copolymer, polyvinyl butyrate, and polycarbonate. There may be other thermoplastic sheet materials which are also suitable in this invention although the preferred types are listed above.
The thickness of the thermoplastic sheet material which is employed is not a critical limitation although it should be recognized that for larger and stronger holsters a thicker sheet material should be employed and for smaller more flexible holsters a thinner sheet material may be employed. As an overall range it may be said that the thermoplastic sheet material should have a thickness of about 0.05-0.15 inch, and for most holster applications this thickness is preferably 0.08-0.13 inch. Excellent results are obtained at a thickness of about 0.090-0.095 inch.
Holster 55 may be made solely of the moldable thermoplastic material described above, or it may be lined with a softer leather-like material to provide a more snug fit for the hand tool 50. On the other hand, holster 55 can be made to have any desired outside appearance by using any desired outside layer that will adhere to the thermoplastic material as it is being molded. The molding temperature of the thermoplastic material must be below the temperature which causes any destruction of any other layer of material being used. Generally, this temperature is about 400° F. For the most part the molding temperatures of such thermoplastic sheet materials is above about 175° F.
Holster 55 is releasably fastened to supporting strap 26 by two fasteners 31, preferably of a screw thread type. Strap 26 is about twice as long as holster 55 from open top 24 to open bottom 25, so that holster 55 may be positioned where desired by the wearer. For this purpose there are a plurality (three shown in the drawings) of grommets 30 which are spaced apart vertically the same as the space between threaded fasteners 40. This permits holster 55 to be positioned higher or lower on strap 26, as more specifically shown in FIG. 6, indicating positions 55 and 56 when selecting different combinations of grommets 30. Externally threaded fasteners 40 mate with internally threaded fasteners 40', one being shown in broken lines in FIG. 2, which may be in the form of a common T-nut with spaced prongs which embed in the side walls 22 and 23 to inhibit rotation thereof.
Supporting strap 26 is preferably made of two coextensive layers of strap material, which may be a woven textile, leather, or a plastic strap. At upper end 27 the two layers are separable as shown in FIG. 2 and have a snap fastener 29 at the extreme upper end to selectively fasten or unfasten those two layers. Preferably, fastener 29 is a directional snap fastener that opens and closes only when the two component parts are positioned in an indexed orientation with respect to each other. This arrangement permits an easy attachment to the waist belt of the wearer, without the awkward necessity of unfastening the waist belt and risking the wearer's pants dropping from the waist.
At lower end 28 of supporting strap 26 a tunnel loop is provided by an open space between the two layers of material in strap 26. This tunnel loop is adapted to receive a lateral strap 32 therethrough which is adjustable in length and includes a suitable buckle 33. Strap 32 and its buckle 33 are intended to provide a leg encircling band which holds bottom end 25 of holster 55 snugly against the leg of the wearer to prevent swinging or flapping of the holster during wearer movement, helping to insure that hand tool 50 will not inadvertently fall out of holster 55, and also, to make it easier to withdraw hand tool 50 from a tight fitting holster 55.
An optional feature of this invention is holder 34 which releasably snaps, by way of fastener 36, which also preferably is a directional fastener as described above, to front 20 of holster 55. Holder 34 is intended to retain a chuck key 35 for a power drill hand tool 50. Holder 34 and key 35 may be unsnapped from holster 55, used to attach or detach a drill bit from power drill 50, and then snapped back in place on holster 55. Any other type of small tool, key, wrench, or the like, may be fastened to holster 55 in a similar manner.
Another optional feature of this invention is a tool bit holding strap 37 fastened to the outside side wall 23 of holster 55 by releasable fasteners 40. Strap 37, in a preferred embodiment, is formed of two coextensive layers of material held together by spaced rivets 41 and by grommets 40 through which releasable externally threaded fasteners 40 extend. In between adjacent rivets 41, the two layers are sufficiently flexible to insert a tool bit 42 or other similar items. If the two layers of strap 37 have sufficiently rough surfaces, or are elastic or the like, tool bit 42 will be held by frictional forces and will not fall out inadvertently. A textile webbing is a suitable material for the layers of strap 37, although leather, rubber, and plastic straps are also operable.
Still another optional feature is shown in FIGS. 4 and 5 where the organizer 60' is for a stud gun 50' hand tool. Holster 55' is molded to the shape of stud gun 50', and it has all the previously described features of a supporting strap 26 on which holster 55' is vertically adjustable and a leg encircling strap 32. In this instance there is no provision for a loop holder 34 retaining a chuck key 35, because a stud gun requires no such key. For stud gun 50' there is a need to keep a supply of power loads that can be loaded into stud gun 50' for use when desired. For this purpose there is a channel clip means 43 attached to the outside side wall 23' of holster 55' by releasable fasteners 40 of the same type and location as described above with respect to FIGS. 1-3. Channel clip means 43 is a generally rectangular chute closed on three sides and having an open front slotted portion 57 to permit the wearer's fingers to have ready access to contact a box 48 of power loads to remove same. Channel clip means 43 has an open top end 44 and a bottom end 45 with inturned stop flanges 46 to prevent boxes 48 from sliding out the bottom of channel clip means 43. Generally, channel clip means 43 is about as long as holster 55 so as to provide as much storage capacity for boxes 48 of power loads, which may be needed in different sizes for different jobs. It may be desired to include an elastic band 47 around the outside of channel clip means 43 to squeeze together the portions of the channel bordering on open position 57. Such a squeezing is only needed if the channel clip means does not provide enough frictional forces to keep boxes 48 from inadvertently falling out of the channel.
Another feature of holster 55 (or 55') is its reversibility. In FIGS. 7 and 8 the same holster 55 and its accompanying features supporting strap 26, leg strap 32, key holder 34 and tool bit holder 37 can be worn on the right leg or the left leg as desired. Holster 55 is molded and punched holes and T-nuts 40' are located to make it symmetrical about central plane 58 as shown in FIGS. 2 and 3. Plane 58 is vertical and passes through the vertical centerline of front portion 20 and back portion 21 of holster 55. Holes to match grommets 30, T-nuts 40' and fasteners 40 are identically located and spaced on side walls 22 and 23 so that supporting strap 26 and tool bit strap 37, and channel clip means 43 may be attached to either side of holster 55.
In some instances, e.g., where the hand tool 50 is extraordinarily long, it may be desirable to employ a front opening holster which permits the hand tool 50 to be pushed forward causing side walls 22 and 23 to spread apart along juncture 59 (as shown in dotted lines in FIG. 5) where the forward edges of side walls 22 and 23 join and are held in place by the bias of fastener 51 and tension screw 52. If hand tool 50 is sufficiently short to be withdrawn from holster 55 upwardly through open top 24, it may be preferred not to employ this front opening embodiment, but rather to have a nonopening front wall 20 as shown in solid lines in FIG. 5.
A molded thermoplastic tool bag or a leather or textile (e.g., canvas) tool bag may also be attached to holster 55 at and by fasteners 40, in addition to or in place of tool bit holder 37 or channel clip 43. This is merely to illustrate that any type of container or assistant may be attached via fasteners 40 and still be within the spirit of this invention.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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The organizer includes a molded holster for a hand tool having a piston grip, the holster having a supporting strap for suspending the holster from the waist belt of the wearer at a selected distance below the waist belt. The organizer also has a leg encircling strap to hold the holster snugly against the leg, and having optional attachments for holding a chuck key, a plurality of tool bits, a tool or nail bag, or several boxes of fasteners.
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TECHNICAL FIELD
The invention relates to sealing means for a shaft in a structural body, and more particularly to such a sealing means made from a memory retainable material; forming a gasket seal between itself and the structural body; and having at least one surface distorted and stretched into a tapered configuration and a tension-related sealing association with the shaft, enhanced by the memory of the seal material.
BACKGROUND ART
It is common prior art practice to seal a shaft with a packing arrangement formed by a plurality of stacked V-shaped rings. The V-shaped rings are generally disposed in the packing chamber of a structural body in a circumferentially sealing relationship tot he shaft. Follower rings (also known as adaptor assemblies) are typically employed with the V-shaped rings and are positioned on opposite axial sides of the V-shaped rings. The externally positioned follower ring is urged into axially compressive engagement with the stacked V-shaped rings by a packing gland, with the internally positioned follower rings restrained from axial movement by the bottom of the packing chamber. Axial compression of the V-shaped ring stack tends to radially expand the rings and to assist in maintaining a sealing relationship between the V-shaped rings and the shaft.
Such V-shaped rings have been formed from a wide variety of materials. For example, elastomeric V-shaped rings formed from homogeneous rubbers have been used in many applications where relatively low pressures are encountered and where the fluid media involved does not damage the rubber. Fabric V-shaped rings coated with elastomers are often used on heavy duty equipment or when higher pressures are encountered. When corrosive media is handled, however, the corrosive media will often attack both the rubber and the fabric rings, making them unsuitable for commercial use. Under such conditions, prior art workers have used V-shaped rings of a molded fluoronated hydrocarbon polymer, such as polytetrafluoroethylene. Many fluoronated hydrocarbon polymers, such as polytetrafluoroethylene, are inert to virtually all chemical media and are suitable for use with a wide variety of corrosive fluids. In addition, fluoronated hydrocarbon polymeric V-shaped rings operate successfully through a wide range of temperatures, from approximately -120° F. to about 350° F. Many of the fluoronated hydrocarbon polymers are characterized by extremely low coefficience of friction.
A problem arises form the fact that fluoronated hydrocarbon polymers have a high coefficient of expansion relative to most metals. In addition, when cooled after exposure to elevated temperatures, fluoronated hydrocarbon polymers may shrink to a size which is smaller than their original size. As a result, even when prior art polytetrafluoroethylene packing rings are initially compressed tightly in sealing relationship about a metal shaft in a metal structural body, the sealing relationship may be lost if the system is thermally cycled.
Prior art polytetrafluoroethylene seals have been formed to the desired V-shaped configuration by compressive molding techniques. Such molding techniques, however, require the rings to have a minimum thickness of about 1/8 inch. This thickness requirement, when the rings are stacked in a packing arrangement, limits the minimum stack height requirement and thus limits the number of independent sealing surfaces acting on the shaft and packing chamber sidewall. Furthermore, compressively molded rings are permanently shaped and normally are compressed to form sealing surfaces with the shaft and packing chamber sidewalls.
U.S. Pat. No. 4,512,586 addressed these problems by forming a plurality of packing rings from memory retainable polytetrafluoroethylene. The rings are initially flat and are given a pre-formed V-shaped cross-sectional configuration in a forming dye. The pre-formed V-shaped rings are disposed in aligned relationship in the packing chamber between the cylindrical sidewall thereof and the shaft with the packing ring sidewalls compressed toward each other beyond the pre-formed V-shaped configuration. The memory retainable material is operative to urge the rings toward their original horizontal configuration whereby the sealing relationship between the cylindrical sidewall of the packing chamber and the shaft is enhanced, and is maintained despite thermocycling.
While such dye formed rings, taking advantage of the memory retainable material from which they are made, represent an improvement in the art, it has been found that whenever leakage did occur, it most often occurred between the rings and the cylindrical sidewall of the packing chamber. It has further been found that the memory of most fluoronated hydrocarbon polymers is very good in tension, but not as good in compression.
U.S. Pat. No. 4,333,632 teaches a sealing assembly comprising a plastic diaphragm, a delta ring, a metal diaphragm, and a floating thrust collar. The plastic diaphragm is made of a fluorinated hydrocarbon polymer and has a preformed tapered sealing lip which is deformed into a substantially cylindrical shape by the shaft and delta ring with which it makes a seal. While the seal disclosed in this patent has some tension sealing, the seal area is relatively wide and the seal is basically a compressive seal.
The present invention teaches sealing means made of memory retainable fluoronated hydrocarbon polymer and configured to prevent leakage between the sealing means and the surrounding body by means of a gasket seal. The sealing means of the present invention also provides at least one surface which is distorted and stretched into a tapered configuration and into a tension-related sealing association with the shaft. This tension-related narrow sealing surface is enhanced by the memory of the material of which the sealing means is made and is further enhanced by the pressure of the media. A sealing relationship with the shaft is maintained even in a system subject to thermocycling. It has also been found that when the shaft shifts with respect to the surrounding body due to the media pressure, resulting in misalignment, a tension seal flexes and maintains its seal, while a compression seal would not.
DISCLOSURE OF THE INVENTION
According to the invention there is provided a seal for a shaft in a structural body. The seal is made of memory retainable material and surrounds the shaft, being located between the shaft and the structural body. The seal is configured to form a gasket seal with the structural body. The seal is provided with at least one surface which is distorted and stretched into a tapered configuration and into a tension-related sealing association with the shaft. This tension-related sealing association is further enhanced by the memory of the material from which the seal is made.
In one embodiment of the seal of the present invention, the seal is initially a cylindrical member having an exterior peripheral flange which forms a gasket seal with a shoulder of the shaft-surrounding structural body. The shaft is mounted in the cylindrical seal with a minimal clearance there between. The shaft has an outwardly flared or tapered portion which, when forced into the cylindrical seal, causes a portion of the cylindrical seal to assume a corresponding flare or taper. The tapered portion of the seal is distorted and stretched into a tension-related sealing association with the shaft. This sealing association is enhanced by the memory characteristics of the seal material which urges the tapered portion of the seal toward its original cylindrical configuration.
A second embodiment of the seal of the present invention comprises a cylindrical member of memory retainable material. The second embodiment has an external peripheral flange which forms a gasket seal with the shaft-surrounding structural body. The inside surface of the cylindrical seal is provided with a plurality of horizontal inwardly extending lips in parallel spaced relationship. The free edges of the lips define a central bore of the cylindrical seal which is of lesser diameter than the diameter of the shaft. The shaft is inserted into the seal with special tooling. This causes the sealing lips to be distorted and stretched into a tapered configuration so as to lie at an angle of about 45° to their original horizontal configuration. This again produces for each lip a narrow tension-related sealing association with the shaft which is enhanced by the memory characteristic of the seal material constantly urging the lip toward its original horizontal configuration.
The seals of the present invention are characterized by a low coefficient of friction and are inert to virtually all chemical media. Their sealing relationship with the shaft and the shaft-surrounding structural body is maintained even if the system is thermally cycled. The seals of the present invention may be used individually or in combination. The seals may also be used in combination with a lantern gland, as will be described hereinafter.
While the seals of the present invention may be used in substantially any situation involving a shaft within a surrounding body, for purposes of an exemplary showing they will be described in their application to the actuating shaft of a plug valve. This application of the seals is exemplary only, and is not intended to be limiting. The description which follows sets forth a preferred embodiment of this invention, simply by way of illustration of one of the best modes contemplated for carrying out the invention. It will be apparent that the invention is capable of other different embodiments, and its several details are capable of modifications in various, obvious aspects all without departing from the spirit of the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional elevational view of an exemplary plug valve, the actuating shaft of which is provided with a first embodiment of the seal of the present invention.
FIG. 2 is a cross-sectional view similar to FIG. 1 and illustrating the plug valve provided with the first embodiment of the seal of the present invention together with a second embodiment of the seal of the present invention located in a packing chamber provided with a follower ring and a gland.
FIG. 3 is a cross-sectional elevational view illustrating the second seal embodiment of the present invention initially mounted in the packing chamber.
FIG. 4 is a cross-sectional elevational view illustrating the packing chamber and seal of FIG. 3 mounted on a cylindrical tool, together with a plunger die carrying a transfer tube.
FIG. 5 is a cross-sectional elevational view similar to FIG. 4, but illustrating the plunger having been driven through the seal to the extent that the distorted seal lips engage the periphery of the transfer tube.
FIG. 6 is a cross-sectional elevational view similar to FIG. 3, but illustrating the transfer tube mounted in the seal.
FIG. 7 is a fragmentary cross-sectional elevational view similar to FIG. 6, and illustrating the free end of the valve actuating shaft received within the transfer tube together with a cylindrical tool for driving the seal and packing chamber onto the shaft toward the valve body, to provide the completed structure of FIG. 2.
FIG. 8 is a cross-sectional elevational view illustrating the structure of FIG. 2 provided with a lantern gland.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is first made to FIG. 1 which illustrates a substantially conventional plug valve provided with a first embodiment of the seal of the present invention. The plug valve is generally indicated at 1 and comprises a body 2. The body 2 is provided with an inlet 3 and an outlet 4 with an internal fluid flow passage 5 extending therebetween. The inlet 3 and the outlet 4 are surrounded by flanges 6 and 7, respectively, by which the body 2 may be connected between similarly flanged conduits (not shown) by appropriate fastening means such as bolts or the like (not shown).
Between its inlet 3 and its outlet 4 the valve body 2 has a tapered valve chamber 6. At its lower end (as viewed in FIG. 1) the valve chamber 6 is open and is surrounded by an annular inset shoulder 7. At its upper end, the valve chamber 6 terminates in a tapered passage 8, leading to a cylindrical passage 9 to the exterior of the valve body. The cylindrical passage 9 is also surrounded by an inset shoulder 10.
The valve chamber 6 is adapted to receive a tapered plug 11. It will be noted that the valve chamber 6 and the plug valve 11 extend transversely of and intersect the inner flow passage 5 of the valve body 1. The plug valve 11 has a transverse passage 12. The plug valve 11 is rotatable within valve chamber 6. In one rotative position, the valve passage 12 is aligned with the fluid flow passage 5 of the valve body, allowing fluid flow therethrough. When the plug valve 11 is rotated 90° from the position shown in FIG. 1, its passage 12 will be out of registry with the valve body flow passage 5, effectively closing the valve body passage 5 and precluding fluid flow therethrough. The plug valve sleeve 13 is preferably formed of a plastic material such as fluorinated hydrocarbon or other material inert to process media flowing through the valve. The sleeve 13 has pairs of annular ribs 14-15 and 16-17 formed at its ends and received within annular grooves 18-19 and 20-21 formed in valve body 1. The sleeve 13 is appertured in correspondency with the plug valve 11 so as to permit fluid flow therethrough when the plug valve passage 12 is in registry with the valve body flow passage 5.
The lower end of the valve chamber 6 is closed by a closure cap 22 affixed to valve body 1 by a plurality of bolts (not shown). A resilient diaphragm-like gasket 23 is provided. The periphery of diaphragm 23 forms a gasket seal between the valve body shoulder 7 and cap 22. Centrally of cap 22 there is a bore having a first portion 24 of large diameter and a second threaded portion 25 of smaller diameter. Bore portion 24 contains a plunger 26 having a stem 27 surrounded by Bellville springs 28. The Bellville springs 28 bias the plunger 26 against the diaphragm 23 and the lower end of plug valve 11 to constantly urge the plug valve to its fully seated position within valve chamber 6. The threaded bore portion 25 is adapted to receive a bolt 29 having a lock washer 30. The bolt 29 adjusts the position of plunger 26.
The plug valve 11 is rotated between its open and closed positions by an actuating shaft 31. Actuating shaft 31 terminates at its lower end (as viewed in FIG. 1) in a non-circular stud 32 received within a correspondingly shaped socket 33 formed in the upper end of plug valve 11. The actuating shaft 31 extends through tapered passage 8 and cylindrical passage 9. The upper end of the valve body is provided with a closure cap 34 affixed to the valve body by a plurality of bolts, two of which are shown at 35, threadedly engaged in bores 35a. Closure cap 34 has a central bore 36 formed therein to just nicely receive actuating shaft 31. It will be understood that the free end of actuating shaft 31 may be attached to any appropriate actuating means (not shown) such as a manually rotated wheel or lever, or to the shaft of an appropriate prime mover.
The first embodiment of the seal of the present invention is generally indicated at 37 in FIG. 1. The seal 37 is made of a memory retainable material capable of withstanding temperatures in the range of from about 350° F. to about -120° F. Preferably, the seal 37 is a molded or machined fluorinated hydrocarbon polymer, such as polytetraflouroethylene. Polytetrafluoroethylene has a number of advantages. For example, it is inert to virtually all chemical media and is suitable for use with a very wide range of corrosive fluids. Furthermore, polytetrafluoroethylene, like many fluorinated hydrocarbon polymers, has an extremely low coefficient of friction. As initially molded or machined, the seal 37 has a cylindrical body 38 terminating at one end in a radial flange 39.
It will be noted that the lower end of the main body portion of actuating shaft 31 is flared or tapered, as at 31a. As the actuating shaft 31 is inserted through seal 37, it causes the lower portion 37a of the seal to be distorted and tapered to conform to the tapered portion 31a of actuating shaft 31. The flange 39 of seal 37 is located on shoulder 10. The flange 39 has a thickness dimension slightly greater than the dimension by which shoulder 10 is inset. As a consequence, the flange 39 is compressed when closure plate 34 is mounted on valve body 2 creating a gasket seal. This gasket seal will preclude leakage of fluid along the outside surface of seal 37.
It has been found that the memory of polytetrafluoroethylene and most other fluorinated hydrocarbon polymers is greater in tension than in compression. The distortion of the tapered portion 37a of seal 37 places that portion in tension. Thus, the tapered seal portion 37a is urged tightly against the tapered portion 31a of shaft 31. This is enhanced by the fact that the memory of the seal material seeks to return the tapered seal portion 31a to its original cylindrical configuration. Finally, fluid under pressure between tapered valve body passage 8 and the adjacent tapered portion 31a of seal 37 will also urge the seal tightly against actuating shaft 31.
Fluorinated hydrocarbon polymers have a high coefficient of expansion relative to most metals (about ten times that of the expansion of metal). Further, when cooled after exposure to elevated temperatures, fluorinated hydrocarbon polymers may shrink to a size which is smaller than their original size. In this instance, however, the sealing relationship will not be lost, even if the system is thermally cycled. This is true because the gasket seal of the flange 39 will preclude the leakage of fluid along the outside of seal 37. Both the memory of the seal material and the pressure of fluid against the outside of the tapered seal portion 37a will assure that the seal will be maintained against actuating shaft 31.
As is illustrated in FIG. 1, according to the present invention a standard valve can be furnished with a single seal which, under most circumstances, will suffice. However, when the valve is subjected to severe service (a highly corrosive fluid and/or high pressure and/or severe thermocycling) a second seal can be added to the same valve. The second seal comprises a very specialized packing, next to be described.
Reference is made to FIG. 2 wherein the valve of FIG. 1 is illustrated with appropriate modifications to add the second seal. For this reason, like parts have been given like index numerals.
In FIG. 2, closure plate 34 has been replaced by a packing chamber 40 containing the second seal 41 and an adaptor assembly or follower ring 42. The packing chamber 40 is provided with a gland 43 and the bolts 35 have been replaced by threaded members 44, each provided with a pair of nuts 45 and 46. Each of these elements will be further described hereinafter.
In FIG. 1, actuating shaft 31 is illustrated as being rather short. If required, the actuating shaft 31 can be replaced by an actuating shaft 47. Actuating shaft 47 is identical to actuating shaft 31 with the exception that it is of greater length. Thus, actuating shaft 47 has a flared portion 47a equivalent to the flared portion 31a of shaft 31 and a non-circular stud 48 equivalent to the stud 32 of shaft 31 and receivable in the correspondingly shaped socket 33 formed in the upper end of plug valve 11. It will be understood that if actuating shaft 31 of FIG. 1 had been of sufficient length, then its replacement would not have been necessary.
FIG. 3 illustrates the packing chamber 40 and the second seal 41. The packing chamber 40 comprises a cylindrical body 49 having an annular, radial flange 50. The flange 50 is provided with a plurality of bores 51 adapted to accommodate the threaded members 44 (see FIG. 2).
The cylindrical body 49 of packing chamber 40 has a central bore 52. At its lowermost end (as viewed in FIG. 3) the bore 52 is enlarged as at 52a to form an annular shoulder 53.
The second seal 41 is molded or machined of a fluorinated hydrocarbon polymer such as polytetrafluoroethylene, having the same properties as described with respect to the first seal 37. In FIG. 3, the second seal 41 is illustrated in its as molded or machined condition. The second seal 41 comprises a cylindrical body 54 terminating at its upper end (as viewed in FIG. 3) in a tapered surface 55 extending downwardly and inwardly at an angle of about 45°. At its lower end, the body 54 is provided with an internal tapered flange 56, again sloping downwardly and inwardly at an angle of about 45°. At its lower end, the second seal body 54 is provided with an exterior radial annular flange 57.
The second seal 41 is completed by the provision on the inside surface of its body 54 of a plurality of annular, horizontally oriented, thin flanges 58. The flanges 58 constitute sealing lips. They are in parallel spaced relationship with respect to each other and constitute an integral, one-piece part of the second seal 41. The free annular edges of sealing lips 58 define a central bore in the second seal 41 having a diameter less than the diameter of actuating shaft 47.
The manner in which the second seal 41 and the packing chamber 40 are assembled on the valve 1 will now be described. Referring first to FIG. 3, the body portion 54 of second seal 41 is so sized as to be compressed within the packing chamber bore 52. It will be noted from FIG. 3 that the peripheral flange 57 of second seal 41 is received in the larger diameter bore portion 52a of packing chamber 40 and rests upon shoulder 53. The flange 57 of second seal 41 has a thickness dimension just slightly greater than the dimension by which shoulder 53 is inset from the bottom surface of packing chamber 40.
Reference is now made to FIG. 4. The assembly of the packing chamber 40 and second seal 41 is caused to rest upon the upper end of a simple tool 59 comprising a hollow cylinder. It will be noted that the cylinder tool 59 is of such size that it supports both the body portion 54 of second seal 41 and the packing chamber 40 via seal flange 57. A plunger die 60 is inserted in the central bore of second seal 41, defined by annular lips 58. Plunger die 60 has a bottom surface 61 which rounds into an upwardly and outwardly tapered side portion 62. The plunger die 60 is of circular cross section throughout its length. The tapered side portion 62 terminates in a cylindrical side portion 63 having a diameter slightly larger than the diameter of actuating shaft 47. The plunger die 60 is provided with an upper end 64.
From a point near the junction of tapered side surface 62 and cylindrical side surface 63 of plunger die 60, the plunger die is provided with a reduced diameter 65 which extends to its upper end 64.
Plunger die 60 is preferably made of metal. The reduced diameter 65 receives a transfer tube 66. Transfer tube 66 may be made of metal or plastic. When mounted on the plunger die as shown in FIG. 4, the outside surface of transfer tube 66 is essentially coextensive with the cylindrical surface 63 of the plunger die, having a slightly larger diameter than the actuating shaft 47.
The plunger die 60 is preferably provided with a removable head 67. The removable head 67 is detachably affixed to the upper end 64 of plunger die 60 by any appropriate fastener means (not shown). The head 67 protects not only the upper end 64 of plunger die 60 but also the upper end of transfer tube 66. The head 67 further prevents axial shifting of the transfer tube 66 with respect to the plunger die 60. With the various elements arranged as illustrated in FIG. 4, the plunger die 60 is driven or shoved in the direction of arrow A until the second seal 41 is engaged on transfer tube 66, as shown in FIG. 5. At this point, the head 67 (if used) of the plunger die 60 is removed and the plunger die 60, itself, is withdrawn from transfer tube 66 and the packing chamber 40 is removed from cylinder tool 59. This leaves the structure illustrated in FIG. 6, comprising the packing chamber 40, the second seal 41 and the transfer tube 66. At this stage, the second seal 41 and the packing chamber 40 are ready to be mounted on actuating shaft 47 and valve body 2, respectively.
Comparing FIG. 4 with FIGS. 5 and 6, it will be noted that the downward shifting of the plunger die 60 and transfer tube 66 causes distortion of the second seal lips 58, shifting them downwardly so that instead of being horizontal, the lips 58 are tapered forming an angle of about 45° to the horizontal.
FIG. 7 illustrates the manner in which the assembly of FIG. 6 is mounted on actuating shaft 47 and valve body 2. To this end, a second cylindrical tool 67 is provided. The main portion of tool 67 has an outside diameter greater than the inside diameter of central bore 52 of packing housing 40. Tool 67 has an inside diameter sized to just nicely receive transfer tube 66. Near its lower end, tool 67 has a portion 68 having a reduced outside diameter so sized as to be just nicely received in the central bore 52 of packing housing 40. This forms a shoulder 69 which engages the upper end of the cylindrical body portion 49 of packing chamber 40. The lowermost end of cylindrical tool 67 (as viewed in FIG. 7) tapers inwardly and downwardly as at 70 at an angle of about 45° and is adapted to abut the surface 55 of second seal 41.
It will be remembered that the actuating shaft 47 has an upper portion 47b of reduced diameter forming a shoulder 47c. The outside diameter of actuating shaft portion 47b is sized to be received within transfer tube 66. It will be noted that the outside diameter of the main portion of actuating shaft 47 is coextensive with the slightly larger outside diameter of transfer tube 66.
The lower end of cylindrical tool 67 is inserted in the central bore 52 of packing housing 40 with its surface 70 abutting the surface 55 of second seal 41 and its shoulder 69 abutting the upper end of the packing chamber cylindrical body portion 49. Thereafter, the transfer tube is located on the smaller diameter portion 41b of actuating shaft 47, with the lower end of the transfer tube abutting actuating shaft annular shoulder 47c. The tool 67 is driven or shoved downwardly in the direction of arrow B. The lowermost tapered surface 70 of cylindrical tool 67 applies a downward force on the body portion 54 of second seal 41. The cylindrical tool shoulder 69 similarly applies a force to the cylindrical portion 49 of packing chamber 40 and the second seal flange 57. This causes the second seal 41 to shift downwardly off of the transfer tube 66 and onto the main body portion of actuating shaft 47 until flange 57 of second seal 41 abuts flange 39 of first seal 37. At the same time, the bottom surface of packing chamber 40 abuts or nearly abuts the upper surface of valve body 2, as is shown in FIG. 2.
When the second seal 41 is fully seated (as shown in FIG. 2) and the packing housing 40 lies adjacent valve body 2, the cylindrical tool 67 is removed from the packing housing and the transfer tube, no longer carrying the second seal 41, is removed from the actuating shaft 41.
At this point, the threaded members 44 are inserted through the bores 51 of the packing chamber and are threadedly engaged in the bores 35a of valve body 2. It will be remembered that the annular flange 39 of the first seal 37 is slightly thicker than the inset dimension of shoulder 10. Similarly, the flange 57 of second seal 41 is slightly thicker than the inset dimension of shoulder 53. When nuts 45 are threaded on threaded members 44 and tightened, the first seal flange 39 and the second seal flange 57 will be compressed and will form gasket seals with their respective shoulders 10 and 53. At the same time, the top of valve housing 2 will be abutted by the bottom of packing chamber 40 forming a metal-to-metal seal.
Continuing with FIG. 2, once the packing chamber 40 and second seal 41 have been bolted to the valve body 2, the follower ring 42 is placed over the actuating shaft 47 and into the central bore 52 of the cylindrical portion 49 of packing chamber 40. The follower ring 42 has a downwardly and inwardly sloping bottom surface 42a and an upwardly and inwardly sloping top surface 42b, so as to be substantially triangular in cross-section. The sloping bottom surface 42a of follower ring 42 lies at an angle of about 45° and abuts the upper surface 55 of second seal 41. The upper surface 42b of follower ring 42 also slopes at an angle of about 45°. The structure of FIG. 2 is completed by the provision of gland 43. The gland 43 comprises a cylindrical body 71 provided at its upper end (as viewed in FIG. 2) with a flange 72 containing a plurality of bores 73 to accommodate threaded members 44. The lowermost end of the cylindrical body portion 71 of gland 43 slopes upwardly and inwardly as at 74 at an angle of about 45°. The lowermost end of the cylindrical body portion 71 of gland 43 is inserted in the bore 52 of packing chamber 40 with the gland surface 74 abutting the upper surface 42b of follower ring 42. When the gland 43 is located in place, the nuts 46 are threadedly engaged on threaded members 44 and are tightened to snug the gland against follower ring 42, and follower ring against the body portion 54 of second seal 41. The gland 43 should not be tightened to the extent that it crushes the annular lips 58 of second seal 41.
It will be apparent from the above description and FIG. 2 that the first seal 37 will function in the manner described above. The second seal precludes leakage between itself and packing chamber 40 by virtue of the gasket seal formed between the flange 57 of the second seal and the annular shoulder 53 of packing chamber 40.
It will be remembered that the sealing lips 58 of second seal 41 have been distorted and stretched from a substantially horizontal position to a downwardly sloping tapered position (as viewed in FIG. 2) at an angularity of about 45°. As a result, the individual lips are urged into a tension-related association with actuating shaft 47. Thus, there is a plurality of sealing surfaces in tension on the shaft. The individual lips 58 are additionally urged in sealing relationship against the actuating shaft 47 by virtue of the memory of the material from which the second seal is made, this memory constantly urging the individual lips toward their original horizontal configuration.
It will be apparent from FIGS. 6, 7 and 2 that the slot between the lowermost lip 58 and the inclined lower surface 56 of second seal 41 is open to any leakage which might be present. As a result, fluid under pressure within this slot will urge the lowermost lip even tighter against the actuating shaft 47. Should the pressurized leakage enter others of the slots between the lips 58 of second seal 41, the pressurized fluid will assist in urging the adjacent lips against the actuating shaft 47.
From the above explanation, it will be apparent that both the first and second seals prevent leakage between themselves and the surrounding valve body 2 and packing chamber 40 by means of gasket seals. Leakage between the first and second seals 37 and 41 and the adjacent acuating shaft 47 is precluded by a tapered tension-related sealing contact between the seals and the shaft, this relationship being enhanced by the memory of the material from which the seals are made, and further enhanced by the pressure of the media.
In instances where leakage is extremely critical, the follower ring 42 of FIG. 2 can be replaced by a lantern gland. Such a lantern gland is illustrated in FIG. 8. Since substantially all of the remaining parts of FIG. 8 are identical to those of FIG. 7, like parts have been given like index numerals. The lantern gland is generally indicated at 75 and comprises a cylindrical body just nicely received between packing chamber 40' and actuating shaft 47. The lantern gland has an upper surface (as viewed in FIG. 8) which slopes upwardly and inwardly at about 45° and is in abutting relationship with the lowermost sloped surface 74 of gland 43. The lantern gland 75 has a lower surface (as viewed in FIG. 8) which slopes downwardly and inwardly at about 45° and is in abutting relationship with the uppermost surface 55 of second seal 41. The inner and outer surfaces of lantern gland 75 are provided with annular grooves 78 and 79, respectively. The grooves 78 and 79 are joined together by a plurality of evenly spaced passages, two of which are shown at 80.
The packing chamber 40' differs from packing chamber 40 of FIG. 2 only in that its cylindrical body portion 49' is slightly longer, to accommodate the lantern gland, and is provided with an inlet 81 communicating with the exterior slot 78 of lantern gland 75. The inlet 81 is internally threaded and is adapted to receive a fitting connected to a source of inert fluid (liquid or gas) having a pressure equal to or greater than the pressure of the flow of media through valve 1. This assures that there cannot be any leakage of media. The use of a lantern gland, per se, is well-known in the art.
Modifications may be made in the invention without departing from the spirit of it. For example, while the second seal is described as used in conjunction with the first seal, it will be appreciated by one skilled in the art that the second seal could be used alone. Under these circumstances, the first seal 37 would be eliminated and a simple bushing substituted therefore. Alternatively, the valve passage 9 could be made of such diameter as to just nicely receive the main body portion of actuating shaft 47. Furthermore, the shoulder 10 of the valve body 2 would be eliminated and the top surface of the valve body would be made co-planar throughout, so as to be abutted by the flange 57 of second seal 41. When used alone, or in conjunction with a lantern gland, the second seal 1 would function in the same manner described above.
As used herein and in the claims, such words as "top", "bottom", "horizontal", "upper", "lower", "upwardly", "downwardly", and the like are used in conjunction with the drawings for purposes of clarity. It will be understood by one skilled in the art that the valve 1 could be mounted and used in any orientation required by the piping of which it forms a part.
The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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A seal for a shaft in a structural body. The seal is configured to surround the shaft within said structural body. The seal has a flange making a gasket seal with the structural body. The seal has at least one portion distorted and stretched into a tapered configuration and into a tension-related sealing association with the shaft. The seal is made of a memory-retainable material. This memory urges the distorted and stretched tapered portion towards its original configuration, thereby enhancing the sealing association with the shaft.
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TECHNICAL FIELD
The present invention relates to the technical field of illumination, ventilation and air purification, and more particularly to a light-pipe system through which light and air can be transferred into an indoor room for illumination and air exchange and the indoor air can be purified by irradiating of the light conducted from the light-pipe.
BACKGROUND OF THE INVENTION
1. Cross-Related Applications
This application claims priority from Chinese Patent Application Serial Nos. 200410029945.2 filed Apr. 6, 2004 and 200410086705.6 filed Oct. 29, 2004, the disclosures of which are incorporated herein by reference.
2. Background Art
It is known to conduct or distribute air either in natural flow or mechanical flow in order to ventilate rooms of a building. It is also known to conduct or distribute light, as daylight or artificial light, for instance, to use daylight for illuminating large rooms.
A light-pipe is simply an empty tube along which light can travel into the interior of a building or other dark spaces. A coating on the internal surface of the light-pipe is composed of highly reflective material, which has reflectance greater than 95%. The light-pipe uses the principle of high efficiency reflection to transmit the light to the other end. Research on light-pipes started in 1880 in Russia, but they weren't put into mass production until 100 years later. At that time, the internal coating reflectivity was around 0.85. At the end of 1970s, a Canadian scholar put forward a method using the isosceles triangle prism with apex angle 90 as the film. The transmission efficiency was highly improved but costs were too great. Nowadays, the majority of commercially available light-pipe films are from 3M company and their film thickness is only 0.5mm.
The integration of light-pipe and ventilation technology is an original innovation in the light-pipe technology field. It can provide not only illumination but also ventilation, thus to improve the fresh air in buildings. U.S. Pat. No. 6,141,645 disclosed a skylight system which includes a skylight opening, a ventilator opening and an artificial lighting fixture at the roof of a room. Through three separate systems, it can realize the sun lighting, ventilation and the artificial lighting simultaneously. But this system is too large and complex.
In addition, U.S. Pat. No. 5,988,843 discloses a method and device for conducting/distributing air and light, particularly in a building or the like. The air and light are conducted along the same transport path. It also has an artificial lighting fixture in the light-pipe. Although this invention is structural simpler than that disclosed in U.S. Pat. No. 6,141,645, the light and air are conducted along the same transport path. Thus, after a considerable period of time, the dust will deposit in the duct, which will surely affect the transmission efficiency of light. So, it needs routine cleaning and thus increases maintenance cost.
There are no known reports about a light-pipe system integrated with photocatalytic air purification and ventilation. This invention not only can realize lighting and ventilation, but also can purify the indoor air. At the same time, the structural design of the light-pipe system is simple, can be easily installed and doesn't need periodic maintenance.
SUMMARY OF THE INVENTION
In order to overcome the drawbacks noted above, this invention uses two coaxial ducts. The interior conduit only transmits the light and the air flows through the annular passage formed between ventilation stack and light-pipe. More importantly, this invention uses a nanometer photocatalyst film which is coated on the outside surface of the emitter to purify the indoor air. The object of this invention is to realize lighting, ventilation and photocatalytic indoor air purification in buildings. Many measures are adopted in the present invention in order to achieve the above object. In one embodiment, the present invention provides a light-pipe system for use in the ceiling of a room in a structure having a roof.
According to the present invention, air and light are conducted along two different transport paths. The path for light, that is a light-pipe, is laid in the center of the path for air coaxially. Light is conducted into the interior of a building along the light-pipe, whereas, the air is flowed through the annular passage formed between the ventilation stack and light-pipe. The light-pipe comprises three components, that is:
(i) an outside collector (usually on the roof), generally a clear dome that removes UV radiation and acts as a cap to prevent dust and water from entering the pipe; (ii) the light-pipe itself; (iii) an emitter or luminaire that releases the light into the interior. The nanometer photocatalyst is coated on the outer surface of the emitter of the light-pipe to purify the indoor air under the illumination of transported light from the light-pipe.
The light source for the light-pipe may be any one of sunlight, artificial light, light storage material, the mixture of sunlight and artificial light, the mixture of sunlight and light storage materials or the mixture of sunlight, light storage materials and artificial light.
In a further embodiment of the invention, the light-pipe and the ventilation stack can be located on different axes, the light and the air is conducted through their own channels.
The air duct may be the building ventilation wall. Air can be moved naturally and/or is transported mechanically. A sunlight collector may be installed on the outside collector of light-pipe, or a sun tracker can be mounted on the said sunlight collector.
The photocatalyst film, loaded on the outer surface of the emitter, is an immersion coating, physical coating, or a mixture of an immersion coating and physical coating, the material of which can be anyone of the following, that is nanometer TiO2, nanometer modified TiO2, nanometer modified meso-pore TiO2, nanometer titanium free composite oxide or other semiconductor material.
The photocatalyst film can contain the absorptive material, which can absorb the polluted gas.
In another embodiment of the invention, the air and light may enter a building through separate ports of air and light, the air is conducted in a transport direction from indoor to outdoor, or from outer door to indoor, or mixture of both
Other objects and features of the invention will be apparent from a description of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various embodiments, features and advances of the present invention will be understood more completely hereinafter as a result of a detailed description thereof in which reference will be made to the following drawings:
FIG. 1 is a full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the ceiling of a room;
FIG. 2 is a full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the ceiling of multi-floors of a building;
FIG. 3 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the ceiling of a room;
FIG. 4 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the ceiling of multi-floors of a building;
FIG. 5 is a full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the sidewall of a room;
FIG. 6 is a full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the sidewall of multi-floors of a building;
FIG. 7 is another full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the sidewall of a room;
FIG. 8 is another full section view of light-pipe system with structure for natural ventilation and photocatalytic air purification mounted on the sidewall of multi-floors of a building;
FIG. 9 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of a room;
FIG. 10 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of multi-floors of a building;
FIG. 11 is a full section view of slot type light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of a room;
FIG. 12 is a full section view of slot type light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of multi-floors of a building;
FIG. 13 is a full section view of light-pipe system with structure for mechanical ventilation and photocatalytic air purification mounted on the ceiling of a room;
FIG. 14 is a full section view of light-pipe system with structure for mechanical ventilation and photocatalytic air purification mounted on the ceiling of multi-floors of a building;
FIG. 15 is a full section view of light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the ceiling of a room;
FIG. 16 is a full section view of light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the ceiling of multi-floors of a building;
FIG. 17 is a full section view of light-pipe system with structure for mechanical ventilation and photocatalytic air purification mounted on the sidewall of a room;
FIG. 18 is a full section view of light-pipe system with structure for mechanical ventilation and photocatalytic air purification mounted on the sidewall of multi-floors of a building;
FIG. 19 is a full section view of light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of a room;
FIG. 20 is a full section view of light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of multi-floors of a building;
FIG. 21 is a full section view of slot type light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of a room;
FIG. 22 is a full section view of slot type light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of multi-floors of a building.
FIG. 23 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification and artificial lighting mounted on the sidewall of multi-floors of a building;
FIG. 24 is a full section view of slot type light-pipe system with structure for mechanical ventilation, photocatalytic air purification and artificial lighting mounted on the ceiling of multi-floors of a building;
FIG. 25 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification, artificial lighting and light storage material lighting mounted on the ceiling of a room;
FIG. 26 is another full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification, artificial lighting and light storage material lighting mounted on the ceiling of a room; and
FIG. 27 is a full section view of light-pipe system with structure for natural ventilation, photocatalytic air purification, artificial lighting mounted on the ceiling of a room, of which the sunlight collector and sun tracer are connected on the light-pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
FIG. 1 shows a building 1 which has at least one room 2 with a roof 3 . The light-pipe system 4 for natural ventilation and photocatalytic air purification is installed on the roof 3 of room 2 . The light-pipe system 4 comprises a light-pipe device and ventilation stack 8 , of which the light-pipe device includes outer light collector 5 for collecting light, light-pipe 6 itself for conducting light and emitter 7 fitted to the bottom of light-pipe 6 for diffusing light and preventing the dust from entering into the interior of the light-pipe 6 . The sunlight 22 collected by the light collector 5 of light-pipe 6 is conducted into the interior of building 1 . The natural ventilation is achieved along ventilation passage 9 through air port 23 as a result of the temperature difference between indoors and outdoors or the pressure difference due to wind flow around light-pipe outlet. In order to prevent or increase the wind effect, ventilation terminals 11 are used. The nanometer photocatalyst TiO2 12 is coated on the surface of emitter 7 of light-pipe 6 . Under the illumination of transport light from the light-pipe, the indoor air can be purified. In this application, the directional arrow 10 on a linear course depicts the direction of airflow. The arrows 13 depicting the light are not uniformly curved.
This light-pipe system 4 can realize day-lighting, natural ventilation and air purification simultaneously.
Embodiment 2
FIG. 2 shows a building 1 having several rooms 2 with a roof 3 . The light-pipe system 4 for natural ventilation and photocatalytic air purification is installed on the roof 3 of room 2 . Each room 2 has a horizontal light-pipe 6 connected with vertical light-pipe 6 in the region of its ceiling. The individual horizontal light-pipes 6 are connected to each other by vertical light-pipe 6 . Light from the sun 22 passes through the light collector 5 and enters the vertical light-pipe 6 . Light is directed into the horizontal light-pipe 6 where it then emerges through light ports (emitter fitted to the light ports) 7 . The air port 23 takes up exhaust air, i.e., the room air of the room 2 passes into the corresponding horizontal air passage 9 within wall 8 and, then passes out of the room 2 from ventilation terminals 11 via the central vertical air passage 9 through chimney-like action. The nanometer photocatalyst TiO2 12 is coated on the surface of emitter 7 of light-pipes 6 . Under the illumination of light conducted by light-pipe, the indoor air can be purified. A hinged mirror 15 is arranged in the horizontal light-pipes 6 to distribute the light homogeneously. This light-pipe system 4 can realize day-lighting, natural ventilation and air purification in multi-floors of a building simultaneously.
Embodiment 3
FIG. 3 shows a building 1 , at least having a room 2 with a roof 3 . The light-pipe system 4 for natural ventilation and photocatalytic air purification installed on the roof 3 of room 2 in a manner similar to FIG. 2 . The only difference is that artificial lights 14 are installed on the two ends of horizontal light-pipe 6 . The light source of light-pipe 6 can be daylight or/and artificial light. The light-pipe system can conduct daylight, artificial lighting, natural ventilation and air purification.
Embodiment 4
FIG. 4 shows the light-pipe system 4 , which is similar to that of FIG. 3 . The only difference is that this system can be fitted to multi-floors of buildings.
Embodiment 5
FIG. 5 shows a building 1 , at least having a room 2 with a roof 3 . The light-pipe system 4 for natural ventilation and photocatalytic air purification is installed on the sidewall 16 of room 2 . The sunlight from sun 22 collected by the light collector 5 enters the horizontal light-pipe 6 and passes into room 2 through light ports (emitter fitted to the light ports) 7 . The exhaust air, i.e., the room air of the room 2 is taken into air duct 9 through air port 23 and is passed out the room 2 through ventilation terminals 11 . The nanometer photocatalyst (modified TiO2) 12 is coated on the surface of the emitter 7 of light-pipe 6 . Under the illumination of light conducted by light-pipe, the indoor air can be purified.
Embodiment 6
FIG. 6 shows the light-pipe system 4 , which is similar to that of FIG. 5 . The only difference is that this system 4 can be fitted to multi-floors of a building 1 .
Embodiment 7
FIG. 7 shows the light-pipe system 4 , which is similar to that of FIG. 5 . The only difference is that the ventilation terminal 11 is located on the opposite sidewall 16 of room 2 .
Embodiment 8
FIG. 8 shows the light-pipe system 4 , which is similar to that of FIG. 7 . The only difference is that the system 4 can be fitted to multi-floors of a building 1 .
Embodiment 9
FIG. 9 shows the light-pipe system 4 , which is similar to that of FIG. 5 . The only difference is that an artificial light is provided at the other end of light-pipe 6 , so that room 2 can be provided with daylight, artificial light or with a mixture of both.
Embodiment 10
FIG. 10 shows the light-pipe system 4 , which is similar to that of FIG. 9 . The only difference is that the system 4 can be fitted to multi-floors of buildings.
Embodiment 11
FIG. 11 shows the light-pipe system 4 , which is similar to that of FIG. 9 . The only difference is that the light-pipe 6 is slot type. The exhaust air, i.e., the room air of room 2 is taken into air duct 9 through air port 23 and is passed out of room 2 through ventilation terminals 11 . The nanometer photocatalyst (modified nanometer meso-pore TiO2) 12 is coated on the surface of the slot type emitter 7 of light-pipe 6 . Under the illumination of light conducted by the light-pipe, the indoor air can be purified.
Embodiment 12
FIG. 12 shows the light-pipe system 4 , which is similar to that of FIG. 11 . The only difference is that the system 4 can be fitted to multi-floors of buildings.
Embodiment 13
FIG. 13 shows a building 1 , at least having a room 2 with a roof 3 , the light-pipe system 4 for ventilation and photocatalytic air purification is installed on the ceiling 3 of room 2 . The sunlight from sun 22 collected by the outer collector 5 of light-pipe 6 is conducted into the horizontal light-pipe 6 and then enters the interior of room 2 through light ports (emitter) 7 . A hinged mirror 15 is arranged in the horizontal light-pipe 6 to distribute the light. The indoor exhaust air can be removed from room 2 by separate fan 17 communicating through an exhaust duct 8 . Outdoor air can be introduced into the interior of room 2 through inlet duct 8 by fan 18 . The air flows through the dust filter 19 to arrive at the interior of the room. The modified nanometer meso-pore photocatalyst TiO2 12 is coated on the surface of emitter 7 . Under the illumination of light conducted by the light-pipe, the indoor air can be purified. This light-pipe system 4 can realize the day-lighting, mechanical ventilation and air purification simultaneously.
Embodiment 14
FIG. 14 shows the light-pipe system 4 , which is similar to that of FIG. 13 . The only difference is that the system 4 can be fitted to multi-floors of buildings.
Embodiment 15
FIG. 15 shows the light-pipe system 4 , which is similar to that of FIG. 13 . The only difference is that the artificial lights 14 are installed at both ends of light-pipe 6 , so that the room 2 can be provided with daylight, artificial light or with a mixture of both.
Embodiment 16
FIG. 16 shows the light-pipe system 4 , which is similar to that of FIG. 15 . The only difference is that the system 4 can be fitted to multi-floors of buildings.
Embodiment 17
FIG. 17 shows the light-pipe system 4 , which is similar to that of FIG. 13 . The only difference is that the light-pipe is installed on the sidewall 16 of room 2 .
Embodiment 18
FIG. 18 shows the light-pipe system 4 , which is similar to that of FIG. 17 . The only difference is that the system 4 can be fitted to multi-floors of buildings.
Embodiment 19
FIG. 19 shows the light-pipe system 4 , which is similar to that of FIG. 17 . The only difference is that the artificial light 14 is installed at the other end of light-pipe 6 , so that the room 2 can be provided with daylight, artificial light or with a mixture of both.
Embodiment 20
FIG. 20 shows the light-pipe system 4 , which is similar to that of FIG. 19 . The only difference is that the system 4 can be fitted to multi-floors of a building 1 .
Embodiment 21
FIG. 21 shows the light-pipe system 4 , which is similar to that of FIG. 19 . The only difference is the light-pipe is a slot type.
Embodiment 22
FIG. 22 shows the light-pipe system 4 , which is similar to that of FIG. 21 . The only difference is that the system 4 can be fitted to multi-floors of a building 1 .
Embodiment 23
FIG. 23 shows a building 1 , at least having a room 2 with a roof 3 . The light-pipe system 4 for natural ventilation and photocatalytic air purification is installed on the roof 3 of room 2 . The indoor lighting is realized by the artificial light source 14 through the slot type light-pipe 6 . The nanometer photocatalyst (titanium free composite oxide) 12 is coated on the surface of slot type emitter 7 of light-pipe 6 . Under the illumination of light conducted by light-pipe, the indoor air can be purified. The indoor air, preferably with natural movement, passes out of the room through air duct 8 , so that air exchange from indoor to outdoor can be realized. This light-pipe system can provide artificial lighting, photocatalytic air purification and natural ventilation.
Embodiment 24
FIG. 24 shows the light-pipe system 4 , which is similar to that of FIG. 23 . The only difference is that air exchange is realized through mechanical ventilation.
Embodiment 25
FIG. 25 shows a light-pipe system 4 , which can be any one of the systems shown in FIGS. 1 to 24 . The only difference is that the light storage material 20 is used as the light source of light-pipe system 4 . The light storage material 20 can store the light under the exposure of the daylight from sun 20 , and then release the light slowly at night. At night, the light released from light storage material 20 can be collected by light collector 21 , and then is conducted to the collector 5 of light-pipe 6 . The light-pipe system 4 thus lights the building along the light-pipe by daylight from sun 22 in daytime and by light storage material 22 at night. FIG. 25 shows the system similar to that of FIG. 3 , but which adds light storage material 20 and light collector 21 . This light-pipe system can provide daylight, artificial light 14 , and light storage material 20 or a mixture of them.
Embodiment 26
FIG. 26 shows the light-pipe system 4 , which is similar to that of FIG. 25 . The only difference is that the light from the light storage material 20 is collected by light collector 21 and then is sent into the light-pipe 6 directly. In the daytime, the light from sun 22 is collected by collector 5 of vertical light-pipe 6 and then is transferred into the room 2 through horizontal light-pipe 6 and light ports (emitter is fitted to the light port) 7 . At night, the light from light storage material 20 can illuminate the room 2 . The nanometer photocatalyst is coated on the surface emitter 7 . Under the illumination of light from light-pipe the indoor air can be purified. The light source of light-pipe system can be daylight, artificial light 14 , light storage material 20 or with a mixture of them.
Embodiment 27
FIG. 27 shows the light-pipe system 4 , which is similar to that of FIG. 25 . The only difference is that the sunlight collector 25 and sun tracer 24 are adopted to improve light transport. Sun tracer 24 can track the sun all day so that the collected light can reach an optimum.
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The invention relates to a light-pipe system for conducting/distributing light and air, which can also purify indoor air, particularly in a building, or the like. The light-pipe system includes a light-pipe for conducting light and having a clear top dome mounted at the top of the light-pipe to let in sunlight but keep out dust, rain and UV. An emitter fitted to the bottom of light-pipe improves the light distribution into the room, and a ventilation stack laid around the light-pipe coaxially/or non-coaxially, and a photocatalyst film (e.g. Nanometer TiO2) coated on the outer surface of the emitter for purifying indoor air under the illumination of light from light-pipe. The air and light are conducted separately along two different transport paths. The light-pipe system can provide illumination, ventilation and air purification simultaneously. The light source may be daylight, artificial light, light storage material or a mixture of them. Air can be moved naturally and/or is transported mechanically. Mirrors in the light-pipe may be used to control brightness and distribution.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from Japanese Patent Application No. 2012-168220 filed on Jul. 30, 2012, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a technology for printing by allocating a plurality of images on one surface of a sheet.
[0004] 2. Description of the Related Art
[0005] A so-called “N in 1” printing in which a plurality of images is printed upon allocating on one surface of a sheet has hitherto been known. Generally, in the N in 1 printing, a setting of an allocation number which is the number of images to be allocated on one surface of a sheet is received by a user, and the number of images corresponding to the allocation number which has been received, are allocated on one surface of the sheet. However, when the number of images according to the allocation number which has been set by the user are allocated, sometimes a wasteful blank space is formed on a sheet.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a technology which uses effectively a sheet without making a size of an image smaller as compared to a size of the image in a case that the images are allocated according to an allocation number which has been set by a user in an N in 1 printing.
[0007] According to an object of the present invention, there is provided a non-transitory computer-readable medium storing computer-executable instructions that, when executed by a processor, cause an information processing apparatus to: perform a first receiving process for receiving a setting of a first allocation number, which is the number of images to be allocated on one surface of a sheet; perform a size determining process for determining a size of an allocation area which is to be allocated to one image on the sheet, based on the first allocation number which has been received in the first receiving process; perform a judging process for judging whether it is possible to arrange, on the one surface of the sheet, allocation areas each of which has the size determined in the size determining process, according to a second allocation number which is greater than the first allocation number; and perform a guiding process for guiding that it is possible to allocate the images according to the second allocation number while maintaining the size of the allocation area determined in the size determining process for each of the images, in a case that it is judged in the judging process that it is possible to arrange the allocation areas according to the second allocation number.
[0008] As the instructions are executed by the processor of the information processing apparatus, the user who has been informed that it is possible to allocate the images according to the second allocation number which is greater than the first allocation number, by resetting the allocation number from the first allocation number to the second allocation number, is able to allocate on one sheet the number of images greater than the first allocation number, with the size of the images is maintained to be same as in a case that the images had been allocated with the first allocation number which was set in the beginning. Therefore, according to the computer-readable storage medium in which the instructions are stored, in the N in 1 printing, it is possible to use a sheet effectively without making the size of images smaller as compared to a case in which the images are allocated according to an allocation number which has been set by the user.
[0009] A technology disclosed in the present patent specification enables to realize by various modes such as an information processing apparatus, an information processing system, a print control apparatus, a print control method, and a recording medium in which a print-control computer program has been recorded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram showing in a simplified form, an electrical configuration of a PC (personal computer) according to a first embodiment.
[0011] FIG. 2 is a schematic diagram for explaining an N in 1 printing.
[0012] FIG. 3 is a schematic diagram showing a print setting screen.
[0013] FIG. 4 is a schematic diagram showing a paper in which allocation areas are arranged according to 6 in 1.
[0014] FIG. 5 is a schematic diagram showing a paper in which the allocation areas are arranged according to 8 in 1.
[0015] FIG. 6 is a schematic diagram showing a paper in which the allocation areas are arranged according to 9 in 1.
[0016] FIG. 7 is a schematic diagram showing a layout screen.
[0017] FIGS. 8A and 8B show a flowchart of a print control process.
[0018] FIG. 9 is a flowchart of a maximum-number calculation process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0019] A first embodiment of the present invention will be described below while referring to diagrams from FIG. 1 to FIG. 9 .
<Electrical Configuration of PC>
[0020] To start with, an electrical configuration of a personal computer (hereinafter, referred to as a “PC”) 1 as an information processing apparatus and a print control apparatus according to the first embodiment will be described below by referring to FIG. 1 . The PC 1 includes a CPU (central processing unit) 10 , a ROM (read only memory) 11 , a RAM (random access memory) 12 , a display section 13 , an operating section 14 , a storage section 15 , and a communication interface section 16 .
[0021] The CPU 10 controls each section of the PC 1 by executing computer programs which have been stored in the ROM 11 and the storage section 15 . Data and computer programs to be executed by the CPU 10 are stored in the ROM 11 . The RAM 12 is utilized as a main storage device for executing various processes by the CPU 10 . The CPU 10 is an example of a processing section.
[0022] The display section 13 includes a display unit such as a liquid-crystal display, and a display drive circuit which drives the display unit. The display section 13 is an example of a guiding section. The operating section 14 includes a keyboard, a mouse, and an interface to which the keyboard and the mouse are to be connected.
[0023] The storage section 15 is a unit which stores various data and computer programs by using a non-volatile memory such as a hard disc and a flash memory. The storage section 15 has an operating system (hereinafter, referred to as “OS”) 31 , application programs (hereinafter, referred to as “applications”) 32 , and printer driver programs (hereinafter, referred to as “printer driver”) 33 which control a printer 2 . The printer driver 33 is an example of a print control program.
[0024] The communication interface section 16 is an interface for communicating with an external apparatus such as the printer 2 , via a communication network 5 such as the Internet and the LAN (Local Area Network). The communication interface section 16 may have an arrangement of being connected to the printer 2 via a USB (Universal Serial Bus) or a parallel line. Moreover, the communication interface section 16 may be a communication interface section which communicates with an external apparatus by wired communication or may be a communication interface section which communicates with an external apparatus by wireless communication. The printer 2 is an apparatus which prints an image on a sheet such as a printing paper (hereinafter, referred to as a “paper”) by an electrophotography or by an ink jet method.
<N in 1 Printing>
[0025] Next, an N in 1 printing will be described below by referring to FIG. 2 . The printer driver 33 is arranged to be capable of executing the N in 1 printing. The N in 1 printing means printing upon allocating one or more than one images on one paper. “N” in “N in 1” indicates an allocation number which is the number of images to be allocated on one sheet.
[0026] FIG. 2 shows cases in which the printing has been carried out according to 1 in 1, 2 in 1, 4 in 1, 9 in 1, and 16 in 1. The allocation numbers which can be set are not restricted to the abovementioned numbers, and the user is able to setting arbitrarily other allocation numbers such as 6 in 1 and 8 in 1.
[0027] A rectangular area 41 on each paper M indicates an allocation area on which a respective image is to be allocated. In FIG. 2 , reference numerals of some of the allocation areas are omitted. In the N in 1 printing, N number of allocation areas 41 are arranged on one surface of a paper, and sizes of all the N number of allocation areas 41 are same. An image is allocated upon being reduced to be accommodated in the allocation area 41 . An aspect ratio of the allocation area 41 is same as an aspect ratio of a printable area of the paper M. Here, the printable area corresponds to an area after excluding an area of a blank space (margin) on which the image is not to be printed, from the paper M. The aspect ratio of the allocation area 41 may be same as an aspect ratio of the paper M, or an arrangement may be made such that the aspect ratio of the allocation area 41 is to be specified by a user.
[0028] In FIG. 2 , a case in which the allocation area 41 is arranged in a portrait orientation has been shown. However, a setting of as to whether the allocation area 41 is to be arranged in a portrait orientation or in a landscape orientation can be carried out by the user as an orientation of image, on a print setting screen 60 (refer to FIG. 3 ) which will be described later. Therefore, even when the direction of the paper M is in the portrait orientation, sometimes the allocation area 41 is arranged in the landscape orientation.
[0029] For a combination of the image direction (direction of allocation area) and the allocation number, the orientation of the paper has been associated with in advance. In an example shown in FIG. 2 , the landscape orientation (width>height) has been associated with a combination of an image in the portrait orientation (height>width) and 2 in 1 print, as an orientation of paper. Moreover, the portrait orientation has been associated with a combination of an image in the portrait orientation and the allocation number other than 2, as the orientation of paper. Although is not shown in FIG. 2 , the portrait orientation has been associated with a combination of an image in the landscape orientation and 2 in 1 print, as the orientation of paper.
[0030] Similarly, for the other allocation numbers, an arrangement is to be made such that the orientation of paper has been associated with in advance for the combinations of the orientation of image and the allocation number. In the example shown in FIG. 2 , in a case of arranging an image in the portrait orientation by 6 in 1 print or by 8 in 1 print, the landscape orientation is let to be associated with as the orientation of paper. An arrangement may be made such that, the orientation of paper can be set by the user irrespective of the orientation of image and the allocation number.
[0031] Moreover, in the combinations of the orientation of image and the allocation number, the number of rows (lines) and the number of columns (hereinafter, expressed by “number of rows×number of columns”) at the time of allocating the image to the paper M are also associated with in advance. For instance, in a case of arranging images in the portrait orientation by 2 in 1, 1×2 is associated with as the number of rows and the number of columns, in a case of arranging an image in the portrait orientation by 4 in 1, 2×2 is associated with as the number of rows and the number of columns, and in a case of arranging an image in the portrait orientation by 9 in 1, 3×3 is associated with as the number of rows and the number of columns.
<Print Setting Screen>
[0032] Next, the print setting screen 60 which is displayed by the printer driver 33 will be described below by referring to FIG. 3 . The user, by clicking a property button 51 upon selecting a printer on a print screen displayed by the application 32 , is capable of giving an instruction to a printer driver which controls the printer which has been selected, to display the print setting screen 60 . In FIG. 3 , an example in which a “printer A” has been selected, and the instruction for displaying the print setting screen 60 has been given, is shown.
[0033] As the instruction is given for the display of the print setting screen 60 , a printer driver which controls the “printer A”, or in other words, the printer driver 33 displays the print setting screen 60 on the display section 13 . In the print setting screen 60 of the example shown in FIG. 3 , it is possible to set setting values of print setting items such as a paper size 61 , an image orientation 62 , a print layout 63 , “notify optimum layout” 64 , and a paper feeding tray 65 .
[0034] The paper size 61 is an item for setting a size of a paper on which an image is to be printed. The user, by clicking a button 61 a , is able to select a fixed size which has been registered in advance, such as A3 (297 mm×420 mm), A4 (210 mm×297 mm), and B5 (182 mm×257 mm) in a pull-down menu which is displayed, and is also able to input an arbitrary size. In a case of inputting the arbitrary size, the user inputs a horizontal size and a vertical size of the paper in the units of millimeters such as 300 mm×200 mm. The image orientation 62 is an item for setting an orientation of the allocation area mentioned above (refer to FIG. 2 ).
[0035] The print layout 63 is an item for setting the allocation number. The user is able to select the allocation numbers such as 1 in 1, 2 in 1, 4 in 1, 9 in 1, and 16 in 1 which have been registered in advance, on a pull-down menu which is displayed by clicking a button 63 a , and is also able to input an arbitrary allocation number such as 6 in 1. In the description that follows, the allocation which has been set in the print layout 63 will be called as a first allocation. A process in which the printer driver 33 displays the print setting screen 60 , and receives a setting of the first allocation is an example of a first receiving process and a receiving process.
[0036] The “notify optimum layout” 64 is an item for the user to set as to whether or not to inform the user about a case in which it is possible to allocate the number of images on one surface of a paper, larger than a first allocation number while maintaining a size of an image in a case in which an image is allocated on the one surface of the paper of a size set by the paper size 61 according to the first allocation number. A process in which the printer driver 33 displays the print setting screen 60 , and receives a setting of the “notify optimum layout” 64 is an example of a second receiving process.
[0037] As the user clicks an OK button 66 on the print setting screen 60 , the screen returns to a print screen 50 after the printer driver 33 has updated a print condition of default stored in the RAM 12 to a set value which had been set on the print setting screen 60 . Whereas, when a cancel button 67 has been clicked, the screen returns to the print screen 50 after the printer driver 33 has discarded the set value which had been set. As the user gives an instruction for printing, on the print screen 50 , an image to be printed is output to the printer driver 33 from the application 32 via the OS 31 .
<Second Allocation Number>
[0038] Next, a second allocation number will be described below by referring to FIG. 4 , FIG. 5 , and FIG. 6 . The second allocation number is an allocation number which is higher than the first allocation number which has been set on the print setting screen 60 , and is an allocation number which enables to allocate the number of images larger than the first allocation number on one surface of the paper, with the size of an image maintained to be same as in a case in which the image has been allocated according to the first allocation number on the one surface of the paper of a size which has been set by the paper size 61 .
[0039] For instance, FIG. 4 shows a case in which 6 in 1 has been set as the first allocation number on the print setting screen 1 . By 6 in 1 being set in the example shown in FIG. 4 , a large blank space is formed on the paper M. In a case in which a large blank space is formed on the paper in such manner, sometimes, by narrowing a distance between the adjacent allocation areas 41 , it is possible to arrange the number of areas 41 larger than the first allocation number with the size of the allocation areas 41 maintained to be same as it has been.
[0040] In a case of the example shown in FIG. 4 for instance, by narrowing the distance between the adjacent allocation areas 41 , it is possible to arrange the allocation areas 41 according to 8 in 1 shown in FIG. 5 . In this case, 8 in 1 corresponds to the second allocation number. Moreover, 7 in 1 is also possible, and here, the largest allocation number from among the plurality of allocation numbers is to be called as the second allocation number.
[0041] Incidentally, the orientation of both the paper M shown in FIG. 4 and the paper M shown in FIG. 5 is the landscape orientation. Whereas, by letting the orientation of the paper M shown in FIG. 6 to be the portrait orientation, sometimes, even larger second allocation number does exist. By letting the orientation of the paper M to be the portrait orientation in an example shown in FIG. 6 , the allocation areas 41 are arranged according to 9 in 1 with the size of the allocation areas 41 maintained to be same as it has been. Moreover, arrangement according to 7 in 1 and an arrangement according to 8 in 1 are also possible. However, the largest allocation number being 9 in 1, the second allocation number with the orientation of the paper let to be the portrait orientation becomes 9 in 1.
[0042] In other words, in the examples shown in the abovementioned FIG. 4 , FIG. 5 , and FIG. 6 , since the second allocation number when the paper M is let to be in the landscape orientation is 8 in 1, and the second allocation when the paper M is let to be in the portrait orientation is 9 in 1, it means that the plurality of second allocation numbers exists.
<Print Control Process by Printer Driver>
[0043] As an image to be printed is outputted from the application 32 via the OS 31 , the printer driver 33 executes a print control process which is a process for making the printer 2 print out the image which has been outputted. The print control process is executed based on print conditions which have been stored in the RAM 12 .
[0044] Incidentally, as it has been mentioned above, sometimes, the second allocation number does exist with respect to the first allocation number. When an image is allocated according to the second allocation number, it is possible to allocate larger number of images without making a size of the images smaller as compared to case in which the images had been allocated according to the first allocation number. Therefore, in a case in which a set value of the “notify optimum layout” 64 of the print conditions is ON, the printer driver 33 , in the print control process, makes a judgment of whether or not there exists the second allocation number. Moreover, in a case in which the second allocation number does exist, the printer driver 33 informs the user by displaying a layout screen 70 which will be described later, on the display section 13 , that it is possible to allocate the images according to the second allocation number with the size of the images being maintained to be same as a size in a case in which the images had been allocated according to the first allocation number.
<Layout Screen>
[0045] The layout screen 70 will be described below by referring to FIG. 7 . For instance, in a case in which the first allocation number is 6 in 1, let the second allocation number when the paper is let to be in the landscape orientation be 8 in 1, and the second allocation number when the paper is let to be in the portrait orientation be 9 in 1. In this case, as shown in FIG. 7 , a layout 71 in which the allocation areas are arranged according to 6 in 1 on a paper in the landscape orientation, a layout 72 in which the allocation areas are arranged according to 8 in 1 on a paper in the landscape orientation, and a layout 73 in which the allocation areas are arranged according to 9 in 1 on a paper in the portrait orientation are displayed on the layout screen 70 . The size of the papers on which the layouts are displayed is the same. Moreover, the size of the allocation areas displayed in the layouts is also the same. Accordingly, it can be understood that it is possible to allocate the larger number of images on one surface of the paper of the size set by the user, with the size of the image maintained to be same as the size when the images had been allocated according to the first allocation number.
[0046] Moreover, radio buttons 75 which correspond to respective layouts are displayed on the layout screen 70 . The user, by putting any of the radio buttons 75 ON, is able to select the layout corresponding to the radio button 75 which has been pressed. A process in which the printer driver displays the layout screen 70 on the display section 13 is an example of a guiding process and a selection process.
<Print Control Process by Printer Driver>
[0047] A print control process by the printer driver 33 will be described below concretely by referring to FIG. 8 . At step S 101 , the CPU 10 which executes the printer driver 33 (hereinafter, to as the “printer driver 33 ”) executes an allocation-area size determining process. The allocation-area size determining process is a process for determining the size of the allocation area per image on a paper of the size which has been set, based on the first allocation number. The allocation-area size determining process will be described later.
[0048] At step S 102 , the printer driver 33 makes a judgment of whether or not a set value of the “notify optimum layout” 64 is ON. In a case in which the set value is ON, the process advances to step S 103 , and in a case in which the set value is OFF, the process advances to step S 116 . At step S 103 , the printer driver 33 executes a maximum-number calculation process for the orientation of paper which has been associated with the combination of the orientation of the image and the first allocation number. The maximum-number calculation process is a process of calculating the maximum number of the allocation areas which can be arranged with the size of the allocation area maintained to be same as the size of the allocation area determined at step S 101 . The maximum-number calculation process will be described later. In the following description, the maximum number which has been calculated at step S 103 will be referred to as S 1 .
[0049] At step S 104 , the printer driver 33 executes the maximum-number calculation process for the orientation of paper which has not been associated with the combination of the orientation of image and the first allocation number. The orientation of paper which has not been associated with the combination of the orientation of image and the first allocation number means the portrait orientation when the orientation of paper which has been associated with the combination of the orientation of image and the first allocation number is the landscape orientation, and means the landscape orientation when the orientation of paper which has been associated with the combination of the orientation of image and the allocation number is the portrait orientation. In the following description, the maximum-number which has been calculated at step S 104 will be referred to as S 2 .
[0050] At step S 105 , the printer driver 33 makes a judgment of whether or not the maximum number S 1 which has been calculated at step S 103 is larger than the first allocation number. In a case in which the maximum number S 1 is larger than the first allocation number, the process advances to step S 106 , and in a case in which the maximum number is same as or smaller than the first allocation number, the process advances to step S 107 .
[0051] At step S 106 , the printer driver 33 generates a layout image which indicates a layout in which the allocation areas are arranged according to the maximum number S 1 , on a paper of the size which has been set, and having an orientation which has been associated with the combination of the orientation of image and the first allocation number. At step S 107 , the printer driver 33 makes a judgment of whether or not the maximum number S 2 which has been calculated at step S 104 is larger than the first allocation number. In a case in which the maximum number S 2 is larger than the first allocation number, the process advances to step S 108 , and in a case in which the maximum number S 2 is same as or smaller than the first allocation number, the process advances to step S 109 .
[0052] At step S 108 , the printer driver 33 generates a layout image which indicates a layout in which the allocation areas are arranged according to the maximum number S 2 , on a paper of the size which has been set, and having an orientation which has not been associated with the combination of the orientation of image and the first allocation number. At step S 109 , the printer driver 33 makes a judgment of whether or not at least one of the maximum number S 1 and the maximum number S 2 is larger than the first allocation number. In a case in which at least one of the maximum number S 1 and the maximum number S 2 is larger than the first allocation number, the process advances to step S 110 , and in a case in which at least one of the maximum number S 1 and the maximum number S 2 is same as or smaller than the allocation number, the process advances to step S 116 . Step S 109 is an example of a judging process.
[0053] At step S 110 , the printer driver 33 generates a layout image which indicates a layout in which the allocation areas are arranged according to the first allocation number, on a paper of the size which has been set, and having an orientation which has been associated with the combination of the orientation of image and the first allocation number. At step S 111 , the printer driver 33 displays the layout screen 70 on the display section 13 , and displays layout images which have been generated at steps S 106 , S 108 , and S 110 , on the layout screen 70 . The printer driver 33 waits till the OK button 76 is clicked on the layout screen 70 , and as the OK button 76 is clicked, the process advances to step S 112 .
[0054] At step S 112 , the printer driver 33 makes a judgment of whether or not the allocation number has been changed. Concretely, the printer driver 33 , in a case in which “not to be changed” has been selected on the layout screen 70 , makes a judgment that the allocation number has not been changed, and in a case in which a layout 1 or a layout 2 has been selected, makes a judgment that the allocation number has been changed. In a case in which the allocation number has been changed, the printer driver 33 allows the process to advance to step S 113 , and in a case in which the allocation number has not been changed, the printer driver 33 allows the process to advance to step S 116 .
[0055] At step S 113 , the printer driver 33 updates the first allocation number to an allocation number corresponding to the layout which has been selected on the layout screen 70 . Step S 113 is an example of an updating process. At step S 114 , the printer driver 33 makes a judgment of whether the layout which has been selected on the layout screen 70 is the layout 1 or the layout 2 . In other words, the printer driver 33 makes a judgment of whether or not the setting of the orientation of paper has been changed. In a case in which the layout selected on the layout screen 70 is the layout 2 , or in other words, in a case in which the setting of the orientation of paper has been changed, the process advances to step S 115 . In a case in which the layout selected on the layout screen 70 is the layout 1 , or in other words, in a case in which the setting of the orientation of paper orientation has not been changed, the process advances to step S 116 . Concretely, when the orientation which has been associated with the combination of the orientation of image and the first allocation number is the landscape orientation, the printer driver 33 updates the orientation to the portrait orientation, and when the orientation which has been associated with the combination of the orientation of image and the first allocation number is the portrait orientation, the printer driver 33 updates the orientation to the landscape orientation.
[0056] At step S 116 , the printer driver 33 generates print data and transmits the print data which has been generated to the printer 2 . For generating the print data, when the allocation number has not been updated at step S 112 , the printer driver 33 allocates images according to the first allocation number on a paper having the orientation which has been associated with the combination of the orientation of image and the first allocation number, or on a paper having the orientation updated at step S 114 , and when the allocation number has been updated at step S 112 , the printer driver 33 allocates images according to the second allocation number updated, on the paper having the orientation which has been associated with the combination of the orientation of image and the first allocation number, or on the paper having the orientation updated at step S 114 . Thereafter, the printer driver 33 terminates the print control process.
<Allocation-Area Size Determining Process>
[0057] Next, the allocation-area size determining process which is executed at step S 101 will be described below by referring to FIG. 4 . The size (width X×height Y) of the allocation area 41 is determined by the first allocation number, a paper width Sw, a paper height Sh, an upper blank-space width Mh 1 , a lower blank-space width Mh 2 , a left blank-space width Mw 1 , a right blank-space width Mw 2 , the orientation of image (portrait orientation in FIG. 4 ), the number of rows and the number of columns C×D of image, the minimum blank-space width Wm in a horizontal direction between the adjacent allocation areas, and the minimum blank-space width Hm in a vertical direction between the adjacent allocation areas.
[0058] The first allocation number from among the abovementioned values and the orientation of image are to be set on the print setting screen 60 . The paper width Sw and the paper height Sh are determined from a paper size which has been set on the print setting screen 60 . The upper blank-space width Mh 1 , the lower blank-space width Mh 2 , the left blank-space width Mw 1 , the right blank-space width Mw 2 , the minimum blank space width Wm in the horizontal direction, and the minimum blank-space width Hm in the vertical direction may have been fixed and set in advance or, an arrangement may be made such that the user can set on the print setting screen 60 .
[0059] The orientation of paper and the number of rows and the number of columns C×D being associated with the combination of the orientation of image and the allocation number, are determined when the orientation of image and the first allocation number are determined. In FIG. 4 , a case in which the orientation of image is the portrait orientation, the first allocation number is 6 in 1, the orientation of paper which has been associated with the combination of the orientation of image and the first allocation number is the landscape orientation, and the number of rows and the number of columns C×D is 2×3, is shown. Moreover, as the paper width Sw, the paper height Sh, the upper blank-space width Mh 1 , the lower blank-space width Mh 2 , the left blank-space width Mw 1 , and the right blank-space width Mw 2 are determined, a width W and a height H of a printable area R obtained by excluding the upper blank-space width Mh 1 , the lower blank-space width Mh 2 , the left blank-space width Mw 1 , and the right blank-space width Mw 2 from the paper, are determined.
[0060] In determination of the size (width X×height Y) of the allocation area 41 , first of all, the width X is determined without taking into consideration the height Y. The width X without taking the height Y into consideration is to be calculated by the following expression 1.
[0000] X =( W−Wm ×( D− 1))/ D Expression 1
[0061] Since an aspect ratio of the allocation area 41 in a case in which the orientation of the allocation area 41 and the orientation of the printable area R, are same, and an aspect ratio of the printable area R, are same, the height Y of the allocation area 41 in the example shown in FIG. 4 is to be calculated by the following expression 2.
[0000] Y=X ×( H/W ) Expression 2
[0062] When the allocation areas 41 are arranged on an upper side and a lower side with the number of rows C, letting the height Y calculated by expression 2 to be a height of the allocation area 41 , a distance P from a lower side of the allocation area 41 at the lowest stage up to an upper side of the allocation area 41 at the uppermost stage is expressed by the following expression 3.
[0000] P=Y×C+Hm ×( C− 1) Expression 3
[0063] In a case in which the distance P is not more than a height H of the printable area, the X and Y mentioned above become the width and the height respectively of the allocation area 41 . However, as mentioned above, since the width X of the allocation area 41 is a width which has been determined without taking into consideration the height Y of the allocation area 41 , there are cases in which the distance P is larger than the height H of the printable area. The distance P is larger than the height H of the printable area means that the allocation area is not accommodated in the printable area R. Therefore, in that case, the height Y of the allocation area 41 is to be determined by the following expression 4.
[0000] Y =( H−Hm ×( C− 1))/ C Expression 4
[0064] In this case, in the example shown in FIG. 4 , the width X of the allocation area 41 is determined by the following expression 5.
[0000] X=Y ×( W/H ) Expression 5
[0065] In a case of the example shown in FIG. 4 , since the distance P becomes larger than the height H of the printable area when the width X is determined by expression 1, the height Y and the width X are to be calculated by expression 4 and expression 5.
<Maximum-Number Calculation Process>
[0066] Next, the maximum-number calculation process which is executed at step S 103 and step S 104 will be described below by referring to FIG. 9 . Here, to start with, a flowchart of the maximum-number calculation process will be described, and the maximum-number calculation process will be described thereafter by citing a concrete example.
[0067] At step S 201 , the printer driver 33 calculates the maximum value of n (integer) which satisfies the following expression 6.
[0000] X×n+Wm ×( n− 1)≦ W Expression 6
[0068] At step S 202 , the printer driver 33 calculates the maximum value of m (integer) which satisfies the following expression 7.
[0000] Y×m+Hm ×( m− 1)≦ H Expression 7
[0069] At step S 203 , the printer driver 33 calculates the maximum number of allocation areas which can be arranged, from the following expression 8.
[0000] maximum number=maximum value of n ×maximum value of m Expression 8
[0070] Next, the abovementioned maximum-number calculation process will be described below by citing a concrete example. Let the values in FIG. 4 be the values shown below for example.
[0071] width X of allocation area=55 mm
[0000] height Y of allocation area=90 mm
width W of printable area=311 mm
height H of printable area=190 mm
minimum blank-space width Wm in horizontal direction=10 mm
minimum blank-space width Hm in vertical direction=10 mm
[0072] In a case in which the maximum-number calculation process has been called up from step S 103 , when the abovementioned values are substituted in expression 6, the expression becomes expression 9 as follows.
[0000] 55 ×n+ 10×( n− 1)≦311 n≦ 4.93 Expression 9
[0000] In other words, the maximum value of n which satisfies the abovementioned expression 6 becomes 4.
[0073] Moreover, when the values are substituted in expression 7, the expression becomes expression 10 as follows.
[0000] 90 ×m+ 10×( m− 1)≦190 m≦ 2.00 Expression 10
[0000] In other words, the maximum value of m which satisfies expression 7 becomes 2. Therefore, in a case in which the maximum-number calculation process has been called up, the maximum number of allocation areas 41 which can be arranged becomes 8 (=4×2).
[0074] A case in which the maximum-number calculation process has been called up from step S 104 will be described below. In a case of being called up from step S 104 , the orientation of paper M is inverted from the portrait orientation to the landscape orientation (and vice versa). However, since the orientation of image, or in other words, the orientation of the allocation area 41 is not inverted even when the orientation of the paper M is inverted, the width X of the allocation area 41 is 55 as it has been, and the height Y of the allocation area 41 is 90 as it has been. Consequently, when the abovementioned values are substituted in expression 6, the expression becomes expression 11 as follows.
[0000] 55 ×n+ 10×( n− 1)≦190 n≦ 3.08 Expression 11
[0000] In other words, the maximum value of n which satisfies expression 6 becomes 3.
[0075] Moreover, when the values are substituted in expression 7, the expression becomes expression 12 as follows.
[0000] 90 ×m+ 10×( m− 1)≦311 m≦ 3.21 Expression 12
[0000] In other words, the maximum value of m which satisfies expression 7 becomes 3. Therefore, in a case in which the maximum-number calculation process has been called up, the maximum number of allocation areas 41 which can be arranged becomes 9 (=3×3).
Effects of Embodiment
[0076] According to the printer driver 33 according to the first embodiment described heretofore, by the user who has been informed by the layout screen 70 that it is possible to allocate images according to the second allocation number, is able to allocate the number of images larger than the first allocation number on one surface of the sheet, with the size of the images maintained to be same as in a case in which the images are allocated according to the first allocation number on one surface of the sheet, by selecting the second allocation number on the layout screen 70 . Therefore, according to the printer driver 33 , in N in 1 printing, it is possible to use the paper effectively without making the size of the image smaller as compared to the case in which the images are allocated according to the allocation number which has been set by the user on the print setting screen 60 .
[0077] Furthermore, according to the printer driver 33 , for each of the case in which the paper is let to be in the landscape orientation and the case in which the paper is let to be in the portrait orientation, a judgment of whether or not it is possible to arrange the allocation areas according to the second allocation number is made. Accordingly, even when it is not possible to arrange the allocation areas according to the second allocation number in the case in which the paper is let to be in the landscape orientation, in the case in which it is possible to arrange the allocation areas according to the second allocation number in the case in which the paper is let to be in the portrait orientation, since the user has been informed that it is possible to allocate the images according to the second allocation number, it is possible to use the paper effectively.
[0078] Furthermore, according to the printer driver 33 , since the layout in which the allocation areas are arranged according to the second allocation number is displayed on the layout screen 70 , the user is able to check the layout in which the allocation areas are arranged according to the second allocation number. Accordingly, the user is able to judge more easily whether to allocate the images according to the first allocation number or to allocate the images according to the second allocation number.
[0079] Furthermore, according to the printer driver 33 , in the case in which the second allocation number has been selected on the layout screen 70 , since the first allocation number is updated to the second allocation number, the user does not have to reset the allocation number upon returning to the print setting screen 60 . Accordingly, convenience of the user is enhanced.
[0080] Furthermore, according to the printer driver 33 , in the case in which there exists the plurality of second allocation numbers, since the user is made to select one of the first allocation number and the plurality of the second allocation numbers, the user is able to select the allocation number from among the first allocation number and the plurality of the second allocation numbers.
[0081] It is possible that among users, there might be a user who desires that the images be allocated according to the first allocation number which the user has set on the print setting screen, contrarily, feels it bothersome when informed that it is possible to allocate the images according to the second allocation number. According to the printer driver 33 , in the case in which the set value of the “notify optimum layout” 64 is OFF, the layout screen 70 is not displayed. Therefore, the user who feels it bothersome when informed that it is possible to allocate the images according to the second allocation number is able to make an arrangement that the above-mentioned information is not provided, by putting the set value of the “notify optimum layout” 64 OFF.
Second Embodiment
[0082] Next, a second embodiment of the present invention will be described below. In the abovementioned first embodiment, the description has been made by citing an example of the case of making the judgment of whether or not it is possible to arrange according to the second allocation number for the case of letting the paper to be in the landscape orientation and the case of letting the paper to be in the portrait orientation. Whereas, a judgment of whether or not it is possible to arrange according to the second allocation number only for the orientation of paper which has been associated with the combination of any one orientation of image which has been set on the print setting screen 60 out of the landscape orientation and the portrait orientation, and the first allocation number, may be made.
[0083] A flowchart of a print control process according to the second embodiment being practically the same as the flowchart shown in FIG. 8 except for steps S 104 , S 107 , and S 108 in the flowchart shown in FIG. 8 are not executed, and only the maximum number S 1 is used for judgment at step S 109 , the repetitive description is omitted.
[0084] According to the printer driver 33 according to the abovementioned second embodiment, the judgment of whether or not it is possible to arrange the allocation areas according to the second allocation number is made only for the orientation of paper which has been set on the print setting screen 60 . For instance, let us assume that the user has set an allocation number for which the landscape orientation has been associated with as the orientation of paper on the print setting screen 60 . In this case, let us assume that it is not possible to arrange the allocation areas according to the second allocation number when the paper is let to be in the landscape orientation, and let us assume that it is possible to arrange the allocation areas according to the second allocation number when the paper is let to be in the portrait orientation. In this case, as the user has set the allocation number for which the landscape orientation has been associated with as the orientation of paper, even when it is possible to allocate images according to the second allocation number when the orientation is let to be the portrait orientation, there is a possibility that the user is not willing to do so. According to the printer driver 33 according to the second embodiment, it is possible to make an arrangement such that no image is printed on a paper having an orientation which is not desired by the user.
Other Embodiments
[0085] The present invention is not restricted to the embodiments which have been explained by the abovementioned description and the diagrams, and embodiments such as the following embodiments are also to be included in the scope of the present invention.
[0086] In the embodiments described heretofore, a case of informing the user by displaying on the layout screen 70 that it is possible to allocate images according to the second allocation number with the size of the images maintained to be same as the size when the image had been allocated according to the first allocation number, has been described. However, it is possible to inform the user by various methods. For example, the user may be informed by an audio.
[0087] In the embodiments described heretofore, the description has been made by citing an example of the case of displaying the layout image in which the allocation areas have been arranged according to the second allocation number on the layout screen 70 . However, the second allocation number may be displayed by characters instead of the layout image.
[0088] Moreover, the second allocation number may not be informed to the user necessarily by the layout screen 70 . For example, the user may only be notified that it is possible to allocate the number of images larger than the first allocation number with the size of images maintained to be same as in the case when the images had been allocated according to the first allocation number, and the second allocation number may not be informed to the user.
[0089] In the embodiments described heretofore, the description has been made by citing an example of the case in which the user is able to carry out setting of whether or not to make a judgment of whether or not the second allocation number exists, by setting the set value of the “notify optimum layout” 64 . However, an arrangement may be made such that the judgment of whether or not the second allocation number exists is made all the time, without providing the item “notify optimum layout” 64 on the print setting screen 60 .
[0090] In the embodiments described heretofore, the description has been made by citing an example of the case in which the layout screen 70 has been displayed in the print control process. However, the layout screen 70 may be called up from the print setting screen 60 . For instance, a judgment of whether or not the second allocation number exists may be made when the OK button 66 has been clicked on the print setting screen 60 . Moreover, in a case in which the second allocation number does exist, the layout screen 70 may be displayed. In this case, as the user selects a layout on the layout screen 70 , the screen may return to the print screen 50 , or an arrangement may be made such that the layout cannot be selected on the layout screen 70 , and as the OK button 66 is clicked, the screen returns to the print setting screen 60 , and the first allocation number is to be reset on the print setting screen 60 .
[0091] In the embodiments described heretofore, the description has been made by citing an example of the case in which the allocation numbers are set directly such as 2 in 1 and 4 in 1 as the first allocation number. However, the first allocation number may be set by setting the number of rows and the number of columns for example.
[0092] In the embodiments described heretofore, the description has been made by citing an example of the PC 1 as an information processing apparatus and a print control apparatus. However, the information processing apparatus and the print control apparatus may be a portable telephone or may be a portable information terminal.
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A non-transitory computer-readable medium stores computer-executable instructions. When the instructions are executed by a processor, the instructions cause an information processing apparatus, to perform: a first receiving process for receiving a setting of a first allocation number; a size determining process for determining a size of an allocation area which is to be allocated to one image on the sheet; a judging process for judging whether it is possible to arrange the allocation areas of the size determined in the size determining process, according to a second allocation number which is greater than the first allocation number; and a guiding process for guiding that it is possible to allocate the image according to the second allocation number while maintaining the size of the allocation area determined in the size determining process for each of the images.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to German patent application number DE 102010049960.9, filed Oct. 28, 2010 which is incorporated by reference in its entirety.
TECHNICAL FIELD
The present disclosure relates to a thermoform packaging machine as well as to a method of operating a thermoform packaging machine for punching out strip cuts.
BACKGROUND
In thermoform packaging machines, a trough is normally formed in a bottom film/foil in a forming station, the trough being then filled with a product and sealed with a top film in an airtight manner in a sealing station under vacuum and/or a modified atmosphere. The packages produced in this way constitute a compound which is interconnected through the bottom film and are conveyed through the thermoform packaging machine by means of clamp chains provided on both sides of the film. For separating the individual packages from the compound of bottom and top films, a combination comprising a cross cutting station and a subsequent longitudinal cutting station may be provided. In the cross cutting station the compound of bottom and top films is cut transversely to the conveying direction, or strip cuts are punched out if radii should be necessary on the edges of the packages. In this case, the knife may punch out the strip cuts from above, which means that the strip cuts will drop. If there should not be sufficient space for a unit for collecting the strip cuts within the machine frame or for removing them from the machine frame, the punching tool may punch out the strip cuts from below in an upward direction. These strip cuts will then be pushed further up in a receptacle after each step and can finally be removed in one go. In high-performance machines, the receptacles are very high so that they need not be emptied constantly. The strip cuts are here pushed over a projection which extends above a film conveying plane and on which part of the strip cut punched out last rests with its edge thus preventing the strip cuts stacked thereabove from dropping into the cross cutting station and on the packages to be cut. In the latter case malfunctions would be caused in the thermoform packaging machine.
Especially if the strip cuts in question are comparatively thin or not flexurally rigid, there will be a high risk that the weight of the stacked strip cuts cannot be held by the lowermost supported strip cut.
SUMMARY
An object of the present disclosure is to provide a thermoform packaging machine and a method of operating the same, by means of which the above described drawbacks can be eliminated.
The thermoform packaging machine is characterized in that it comprises at least one cross cutting station and a longitudinal cutting station, said cross cutting station including a punching device so as to cut out a strip cut from a bottom film and/or a top film by means of a punching tool, said punching device being preferably oriented substantially transversely to a conveying direction and including a receptacle for receiving therein the strip cut above the bottom film and/or the top film. The cross cutting station is provided with at least one slide so as to support part of the strip cuts located in the receptacle and above the slide. Preferably, the slide is arranged as closely as possible above the conveying plane of the bottom film. Such a slide and its position guarantee that the strip cuts resting on the slide will not press on the strip cuts located therebelow. Since only a small number of strip cuts is disposed between the conveying plane of the bottom film and the slide, said strip cuts can be supported by a projection provided in the receptacle due their low own weight and, in the case of thin films, in spite of their lack of flexural rigidity.
The slide is adapted to be moved in the receptacle preferably in a plane substantially parallel to a conveying plane of the bottom film, so as to guarantee that the slide can reliably be inserted between two strip cuts.
Preferably, the punching device comprises holding elements so as to support a plurality of strip cuts located above the conveying plane of the bottom film and below the slide. By means of such holding elements individual strip cuts can be supported, and this will reduce still further the weight on the lowermost strip cut, which is the strip cut that has been cut out last. The strip cut that has been cut out last and the strip cuts located thereabove are prevented from dropping.
According to a preferred embodiment, the holding elements are sawtooth-shaped, on the one hand for providing a support for at least part of the strip cuts and, on the other hand, for allowing the strip cuts to be easily pushed further up past the projections of the holding elements. The holding elements have a plurality of horizontal projections on different levels between which a bevel is disposed.
The slide preferably has a beveled (inclined) leading edge, so that insertion of the slide between two superimposed strip cuts will be guaranteed. The slide can be implemented as a flat plate or in the form of a rake or a fork.
Preferably, the slide is adapted to be driven by means of a pneumatic drive, e.g. a pneumatic cylinder, or an electric drive, preferably a servo motor or a solenoid, so as to guarantee a fast movement and exact positioning of the slide relative to the strip cuts.
A method according to the present disclosure, used for operating a thermoform packaging machine, is so conceived that it comprises at least one cross cutting station and a longitudinal cutting station, said cross cutting station including a punching device so as to cut out a strip cut from a bottom film and/or a top film by means of a punching tool, and it is so conceived that a slide is moved away from the strip cuts prior to or during a punching operation, a further strip cut is pushed upwards, and the slide is then moved to a position between two neighboring and superimposed strip cuts so as to support the strip cuts located above the slide. It is thus guaranteed that the slide movement is executed as long as a stack of strip cuts is at rest.
Preferably, the movement of the slide is executed by means of a controller, since the controller is in the possession of all information on the processes taking place in the packaging machine and, in particular, on the sensors and actuators of the cross cutting station and is therefore able to guarantee an efficient and process-reliable sequence of operations.
Preferably, the slide is moved out of a stack of strip cuts in a receptacle before the punching tool starts the punching operation or the punching tool comes into contact with the bottom film or the conveyance of the bottom film and the top film into the cross cutting station has been finished.
The slide is preferably moved into the stack of strip cuts in the receptacle before the punching tool is moved downwards again after the punching operation, so as to support all the strip cuts positioned above the slide and relieve the strip cuts positioned therebelow.
In the following, an advantageous embodiment of the thermoform packaging machine according to the present disclosure and of the method according to the present disclosure will be explained in more detail with reference to the below drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a thermoform packaging machine according to the present disclosure;
FIG. 2 is a schematic view of a cross cutting station;
FIG. 3 is a schematic view into the upper area of a cross cutting station; and
FIG. 4 is a top view of the cross cutting station.
DETAILED DESCRIPTION
Components corresponding to one another are normally designated by the same reference numerals throughout the figures.
FIG. 1 shows in a schematic view a packaging machine according to the present disclosure in the form of a thermoform packaging machine 1 . The thermoform packaging machine 1 comprises a forming station 2 , a sealing station 3 , a cross cutting station 4 and a longitudinal cutting station 5 , which are arranged on a machine frame 6 in this sequence in a working direction R. On the input side, the machine frame 6 has provided thereon a supply roll 7 from which a bottom film/foil 8 is unwound. In the area of the sealing station 3 a material storage unit 9 is provided, from which a top film 10 is unwound. On the output side, a discharge unit 13 in the form of a conveyor belt is provided on the packaging machine, said discharge unit 13 being used for removing finished packages 21 which have been separated from one another. In addition, the packaging machine 1 is provided with a feed unit, which is not shown, said feed unit gripping the bottom film 8 and advancing it clockwise in the working direction R in a main work cycle. The feed unit may be realized e.g. by laterally arranged conveyor chains and convey the bottom film 8 in a conveying plane E.
In the embodiment shown, the forming station 2 is implemented as a thermoforming station in which containers 14 are formed in the bottom film 8 by thermoforming. The forming station 2 can be configured such that several containers are formed side by side in a direction perpendicular to the working direction R. An infeed line 15 is provided downstream of the forming station 2 when seen in the working direction R. On said infeed line 15 the containers 14 formed in the bottom film 8 are filled with products 16 .
The sealing station 3 is provided with a closable chamber 17 in which the atmosphere in the container 14 can be replaced by a substitute gas or a substitute gas mixture, e.g. by means of gas flushing, before said container 14 is sealed.
The cross cutting station 4 is configured as a strip punch, which cuts through the bottom film 8 and the top film 10 in a direction transversely to the working direction R between neighboring containers 14 . The cross cutting station 4 operates such that the bottom film 8 is not cut through across its whole width, but remains uncut at least in a boundary area and between two neighboring containers 14 . The containers 14 can thus be advanced by the feed unit in a controlled manner.
In the embodiment shown, the longitudinal cutting station 5 is configured as a knife assembly by means of which the bottom film 8 and the top film 10 are cut through between neighboring containers 14 and at the lateral edge of the bottom film 8 so that individual packages 21 are obtained downstream of the longitudinal cutting station 5 .
The thermoform packaging machine 1 is additionally provided with a controller 18 . This controller 18 has the function of controlling and supervising the processes taking place in the packaging machine 1 . A display device 19 provided with control elements 20 is used for making the processes in the thermoform packaging machine 1 visible to and for influencing them through an operator.
The general mode of operation of the packaging machine 1 is briefly described hereinbelow.
The bottom film 8 is unwound from the supply roll 7 and conveyed into the forming station 2 by means of the feed unit. In the forming station 2 , containers 14 are formed in the bottom film 8 by means of thermoforming. The containers 14 , together with the bottom film portion extending therearound, are advanced in a main work cycle to the infeed line 15 where they are filled with a product 16 .
Subsequently, the filled containers 14 , together with the bottom film portion extending therearound, are advanced into the sealing station 3 by means of the feed unit in said main work cycle. After having been sealed onto the bottom film 8 , the top film 10 is advanced along with the feed movement of the bottom film 8 . In the course of this movement, the top film 10 is unwound from the material storage unit 9 . Due to the sealing of the top film 10 onto the containers 14 , sealed packages 21 are produced.
FIG. 2 shows a cross cutting station 4 with a punching device 22 which, by means of a pneumatic drive 23 , moves a punching tool 24 upwards against the bottom film 8 and the top film 10 , which are not shown, and, in so doing, cuts out a strip cut 25 (cf. FIG. 4 ) from the compound consisting of said bottom film 8 and said top film 10 . During the continued upward movement, the strip cut 25 is advanced to such an extent that it will be supported by holding elements 26 so as to prevent it from dropping.
In the subsequent main work cycles, further strip cuts 25 are pushed upwards into a receptacle 27 . As soon as the stack of strip cuts 25 has reached a certain height in the upper area of the receptacle 27 , the uppermost strip cuts 25 will laterally drop onto a discharger 28 and can subsequently be supplied to a collecting unit.
FIG. 3 shows two slides 29 which have the shape of a rake or a fork and which are adapted to be moved within the receptacle 27 by means of pneumatic cylinders 30 in the direction of a stack of strip cuts 25 , which is not shown, and back again into the opposite direction. The stack of strip cuts 25 is guided by guide means 31 such that the position of the individual strip cuts 25 is retained in the transverse and in the longitudinal direction. The holding elements 26 are provided with sawtooth-shaped projections 32 , which hold a boundary area of a strip cut 25 so as to prevent the latter from dropping back into the punching device 22 while the punching tool 24 is moved in a downward return movement to a parking position. In the subsequent main work cycle, the next strip cut 25 is pushed upwards and, during this upward movement, it pushes the preceding strip cut 25 further up by a distance corresponding to one projection 32 on the holding elements 26 . The horizontal projections 32 are disposed on the holding element 26 on different levels.
In FIG. 4 the slides 29 are shown at two positions. The slide 29 located on the left, when seen in a top view, occupies a position outside of the stack of strip cuts 25 , and the slide 29 shown on the right occupies the position at which it is moved between two strip cuts 25 of said stack and supports consequently the strip cuts 25 located thereabove such that they are prevented from dropping. The slides 29 are preferably moved in synchronism. The movement of the slides 29 into the stack of strip cuts 25 takes place as soon as the punching tool 24 has finished the punching operation at the uppermost position. As soon as the slides 29 have been moved in and support the upper part of the stack, the punching tool 24 moves downwards. The slides 29 are arranged in or on the receptacle 27 directly above the punching device 22 so that only a small number of strip cuts 25 will be located between the conveying plane E of the bottom film 8 and the slides 29 .
The slides 29 are preferably provided with a bevel or inclination in the front portion 31 thereof. This bevel may also be provided on the upper and lower surfaces of the slide 29 . The slides 29 need not be provided in common on the same side; also a variant comprising opposed slides 29 is imaginable. These slides 29 can then be moved into one another in the form of rakes. Also a further variant is imaginable, in the case of which one or a plurality of slides 29 are not movable in the conveying direction of the bottom film 8 but orthogonally to or at an oblique angle to said conveying direction.
The cross cutting station 4 may be arranged as a single or as an additional cross cutting station 4 between the forming station 2 and the sealing station 3 so as to cut (only) the bottom film 8 . Likewise, it is imaginable to dispose the cross cutting station 4 or an additional cross cutting station 4 between the material storage unit 9 and the sealing station 3 so as to cut (only) the top film 10 .
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
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A thermoform packaging machine comprising at least one cross cutting station that includes a punching device for cutting out strip cuts from a packaging film. The thermoform packaging machine also includes a receptacle for receiving a stack of a plurality of the strip cuts and a slide element for supporting the weight of the stack during operation of the punching device. The slide may be position to be inserted between two adjacent strip cuts in the stack in the receptacle. A method of operating such a thermoform packaging machine is also described.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to swimming pool covers for in-ground, interior pools.
2. Description of the Prior Art
Swimming pool covers that will lift out of position have been known in the prior art. U.S. Pat. No. 3,566,420, issued to Peterson et al. on Mar. 2, 1971 comprises a combination pool cover and submergible dressing room. The cover is raised up and down with hydraulic cylinders that are embedded in the walls of the pool, and that a hand crank arrangement using pulleys can be used in place of the hydraulic cylinders to raise and lower the cover. In any event, however, it includes a dome type roof for shedding rain, but with the moving mechanism recessed below the level of the ground.
U.S. Pat. No. 4,078,293, issued to Aine on Mar. 14, 1978 shows a rigid swimming pool cover that is made out of suitable material and fits against the edges of the pool to provide a shield for keeping debris and the like out of the pool. Several variations of the pool cover are shown, and each shows a type of a foam material. This too is for outdoor pools, and deals with the forming of the cover. A lifting mechanism for the cover is shown in FIG. 4 of the patent which comprises a type of a drive including a chain that will move a column upwardly to lift the cover.
Ceilings which raise and lower are shown in U.S. Pat. No. 4,006,567, issued Feb. 8, 1977 to Flannery wherein a false ceiling is supported in a parallel spaced relationship to the floor and can be moved up and down by operating electric motors. It is used for varying the height of the ceiling, but not for covering any pool.
U.S. Pat. No. 4,037,385 also shows a portable room that has a movable ceiling or cover for this room that can be raised and lowered once the partitions forming the room are in place.
U.S. Pat. No. 4,135,259, issued Jan. 23, 1979 to Scardenzan shows a deck structure that is used as a pool cover and is disclosed as being capable of supporting weight. It can serve as a deck in either the open or closed positions. Linkages are used for supporting the cover and a hydraulic cylinder is actuated for pivoting the linkage to raise and lower the cover.
U.S. Pat. No. 3,114,153, issued Dec. 17, 1963 to Pierson, and U.S. Pat. No. 3,118,148, issued Jan. 21, 1964 to Taylor et al. show combination devices that can be swimming pools or bomb shelters and have covers. U.S. Pat. No. 3,114,153 shows a cover that is used for supporting weight and which rolls into place on rollers. In other words it is offset laterally when it is in its open position oncovering the pool or shelter. U.S. Pat. No. 3,118,148 shows a cover that is folded in sections like a "accordian".
U.S. Pat. No. 3,091,777, issued to Pearlson on June 4, 1963 shows a swimming pool cover that is submerged, and comes up from the bottom of the pool so that during use it forms the bottom of the pool, and U.S. Pat. No. 4,106,134, issued to Schiron et al. on Aug. 15, 1978 also shows a false bottom or floor that lifts up to form a type of a cover, and during use is at the bottom of the pool.
SUMMARY OF THE INVENTION
A swimming pool cover for an indoor swimming pool has an upper surface which is flush with the floor surface of the room in which the swimming pool is placed, and which can be raised through a suitable mechanism to a position wherein it is substantially above the pool so the pool can be used. The pool cover is sturdy enough to provide a floor surface when in place covering the pool, so that the room can be used for normal use such as recreation room for a dance floor or the like.
The lifting apparatus includes a winch that operate cables to raise and lower the pool cover. The pool cover is guided by suitable upright guides that stabilize the cover and prevent it from twisting or swaying, and further include safety latches that prevent falling of the cover unless it is desired that such reverse movement be permitted (when the cover is lowered). Mechanical latches are used so that during the raising if a cable breaks it would not cause any damage. Upon raising the pool cover to the desired height, the latches can be used for holding the cover in place and then when the pool cover is to be lowered, the cover may first be raised to a full height where the one set of latches is disabled, after which the pool cover can be lowered, without the latches engaging.
The lift cables also are connected to the pool cover through spring loaded safety catches which are held disengaged when the cables are under tension, but as soon as tension is gone the latches will engage to prevent accidental dropping of the pool cover.
During the lowering operation the main latches are disengaged, but, during that time the operators and others will be out of the way because the pool is going to be covered, and the cable tension sensitive latches are still operable. When the pool cover is fully lowered the latch is reset mechanically so that it will be operable the next time the pool cover is raised.
The floor is made so that it is rigid enough to provide adequate suport, and because it is guided into position it fits easily within the recess. The vertical guides also reduce any tendency of the unit to twist or spin, thereby reducing the likelihood of any component failure during the raising and lowering operations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a home having a room in which an in-ground indoor pool is placed, and which has a pool cover made according to the present invention installed therein;
FIG. 2 is a vertical sectional end view of the room showing the swimming pool cover of FIG. 1;
FIG. 3 is a sectional view taken along the same lines as FIG. 2 showing the swimming pool cover in a raised position;
FIG. 4 is a fragmentary enlarged perspective view of an upright guide column made according to the present invention used for guiding and restraining the swimming pool cover as it is moved between its working and raised positions;
FIG. 5 is a side sectional view showing a housing used for guiding the swimming pool cover in a vertical guide;
FIG. 6 is a sectional view taken as on line 6--6 in FIG. 5;
FIG. 7 is a side elevational view showing a mechanism for disengaging a safety latch at the upper end of the movement of the swimming pool cover where it is;
FIG. 8 is a sectional view taken generally along line 8--8 in FIG. 7; and
FIG. 9 is a side sectional view showing a lower reset plate for the safety latch of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of illustration, a house or building indicated generally at 10 is constructed to have a room 11 with enclosing walls 12 and 13 and a roof structure 14. The room further has a floor 15, surrounding an in-ground, indoor swimming pool the upper portions of which are shown at 17 in FIGS. 2 and 3.
The pool as shown is generally rectangular in plan view, and is spaced inwardly from the side walls 12 so that the floor 15 forms a perimeter around the pool 17.
As shown, the floor 15 has a recess indicated at 20 formed around the perimeter of the pool 17. The recess defines a perimeter support surface 19 around the pool. A pool cover indicated at 25 is made so that when it is resting on the support surface 19 of the recess 20 it overlies the pool 17, and the upper surface of the floor layer 26 of the pool cover lies flush with the surface of floor 15. The pool cover is made to have adequate strength to support people on the top so that the pool cover, when in place, permits use of the room 11 defined by the walls 12 and the end walls 13 for a recreation room or for other uses. The upper surface 26 of the pool cover can be covered with the same floor covering as the rest of the floor.
The raising and lowering of the pool cover 25 is guided by a plurality of upright guide columns indicated generally at 27 which are placed at the sides of the pool. As shown, these upright guide columns 27 are fixed with respect to the floor 15 and extend upwardly to be attached to a ceiling indicated generally at 30 which is immediately below the rafters 31 forming the roof structure of the room.
The upright guide columns 27 pass through an opening in the pool cover 25 at the corners, and suitable framing is made in the cover member 25 so that the upright columns act as guides for the cover. The means for lifting and lowering the pool cover are attached to the cover at these locations as well. The columns 27 also provide means for mounting safety devices to prevent accidental dropping of the cover.
In FIGS. 4, 5 and 6, a typical pool cover support and guide assembly is shown at 32. The swimming pool cover 25 is made up of a plurality of cross beams 35, which are spaced at regular intervals along the length of the cover and which extend across and are supported on the recess surface. A floor material layer 26 is supported on the beams 35. In the region of the upright supports there are braces or cross members 36 attached to two cross beams to form a guide assembly boxing in the respective upright columns 27. The cross members 36,36 are placed on opposite sides of the upright support 27 and the cross members 35 extend along the other sides of the column. The members 36,36 closely slidably fit along the sides of the upright guide columns 27, and as shown the guides 27 each comprise a first upright channel member 38, and a second channel member 39 that have their legs facing the legs of the other channel and spaced from the other legs to define a longitudinally (vertically) extending slot 40. The guides do not have to be channels, but the guide slot 40 provides a space in which a retainer arm 42 moves for guide and restraint. The retainer arm 42 is fixed suitably, such as by welding, to the cross members 36,36 and extends parallel to the members 35,35. The cross member 42 is a rectangular shaped bar as shown in FIG. 7, and fits within the slot 40 in a suitable manner.
The cross members 36,36 also support end guide walls 44,44 that are on opposite sides of the upright beams and parallel to cross member 42. A guide arm 42A extends from member 42 on the respective interior of the upright columns 27. Suitable low friction guide strips 45A are provided on the surfaces of the walls 44 which face the respective upright guide columns 27 and on the end of guide arm 42A, in suitable location for guiding the pool cover 25 along the respective upright column 27 to provide anti-friction or low friction bearing surfaces for the two sliding parts.
As shown in FIGS. 5 and 6, the cross member 42 is used for supporting a cable control housing 45. The housing 45 comprises a pair of spaced apart plates 46,46 that are fixed to the cross member 42 in a suitable manner and these plates in turn have a cross member 50 at the upper end thereof which is welded to the plates. A lift cable 51 is passed through the cross member 50 and is connected to a bell crank 47 for providing the lifting and lowering cable attachment for the swimming pool cover.
The bell crank 47 is pivoted on a shaft 48 which is mounted on side plates 46 and the bell crank is positioned between the plates 46. The bell crank has a safety latch dog or leg 49 that extends downwardly. The cable 51 is suitably connected to the other leg 47A of the bell crank 47 and when the cable 51 is under tension the leg 47A will butt on plate 50 to lift the housing 45 and thus the pool cover. A spring mounting plate 52 is fixed to plates 46 and plate 52 has a pin 52A mounting a compression spring 53 which mounts over a pin 49A of leg 49 and acts to urge the leg 49 toward an upright ratchet rack 61 attached to the guide column 27. The spring 53 is compressed by the cable tension and when lifting the pool cover the bell crank is mechanically stopped by plate 50 with the latch leg 49 held away from the ratchet rack 61.
The lower portions of the plates 46 are used for mounting a separate safety catch assembly indicated generally at 55. A suitable cross shaft 56 is coupled between the plates 46 and mounts a relatively wide dog member 57 that is spring loaded with a tension spring 58, attached to a pin 59 attached to one of the side plates 46. A pin 60 is also fixed to the dog 57. The pins 59 and 60 extend laterally of plates 46, as shown in FIG. 8 and as shown in FIG. 5 the pins 59 and 60 are positioned so that when the dog 57 is normally urged toward the rack 61 that has rack teeth 62 defined therein. A separate rack 61 is fixed to and extends the full length of each of the guide columns 27, and as tension is placed on the cables (each of the guide columns 27 has the cable housing and cable therein) and as the pool cover is raised, the dog 57 will ratchet up the teeth 62 until it is reset to permit reverse movement, as will be explained.
Each cable 51 in each of the guide columns, extends upwardly through the column and is mounted over a suitable pulley indicated at 63 rotatably mounted at the upper ends of each of the respective upright guide columns. The pulleys 63 can be mounted in any conventional manner, and usually are rotatably mounted on the upper ends of the guide columns. If desired the pulleys 63 can even be mounted to the rafters of the home in which the swimming pool cover is used.
Each of the pulleys 63, in turn, guides its respective cable 51 to a horizontal length that extends to selected winch drums, indicated in FIG. 1 generally at 65. The winch drum 65 (there can be two or four as desired, just so the cables are wound up evenly) is driven from a motor-gear reducer unit indicated generally at 66 of a conventional design that can be powered from a suitable switch, for example a switch indicated at 67 on the wall of the room in which the pool cover 25 is used.
By driving the motor 66, the shaft 68 will be rotated to rotate the winch drums 65 and wind up the cables onto the winch drums, or unwind them depending on the direction of rotation of the motor 66. The cables 51 from two pulleys 63 on the same side of the pool may be combined into a single cable leading to the winch drums.
Suitable gear reduction can be achieved by using a four hundred to one gear reducer for the motor 66 and directly driving the winch shafts. If additional reduction is required, jack shafts can be used for obtaining the necessary speed reduction to insure that the cables will be winched up or down evenly, and under adequate power.
As shown in FIGS. 7, 8 and 9, the safety latch mechanism 55 can be reset in two different positions as the spring 58 tends to go over center with respect to the axis of the pivot of the dog 57.
In its working position as shown in FIG. 5, the spring 58 is past the center of the axis of pin 56 so that the lower end of the dog is urged against the rack teeth 62, and it will remain in this position until the pool cover is desired to be lowered. Then the pool cover is raised all the way up to adjacent its uppermost position where a pivoting dog member indicated generally at 70 (FIGS. 7 and 8), which is mounted on a pivot pin 71 supported on the rack on one end and on one of the side walls of the upright guide member 27 at the other end, will be engaged by the outer end of laterally extending pin 60, which is the pin that carries one end of the spring 58 for the latch dog 57. As the swimming pool cover is lifted, the pin 60 will engage the lower end of dog 70 as shown in dotted lines in FIG. 7, and the dog 70 will pivot about the pin 71, moving pin 60 outwardly and forcing the latch dog 57 to pivot outwardly as indicated by the arrow 75, until the spring 58 goes over center with respect to the axis of the shaft 56, at which time the latch dog will be pivoted in the same direction of arrow 75 by the spring 58. A stop 76 may be provided, or the dog 57 can pivot until spring 58 loses its tension. The spring 58 can be selected in length so that the latch dog will not move a substantial distance. The latch dog is held out of the way of the ratchet teeth on the rack 61, and in a position where it will permit the swimming pool cover to be lowered by reverse operation of the winch.
It should be noted that safety switches can be provided so that when the carriage for the cables reaches the uppermost position the winch motor will be shut off automatically when the switch is engaged. This can be ordinary limit switch of suitable design.
The swimming pool cover 25 can be therefore lowered after the latches 57 have been disabled. Tension will be carried on the cables 51 from the load of the pool cover as the pool cover is lowered. The bell crank 47 and dog 49 thereof will continue to clear the ratchet teeth 62 unless the pool cover hangs up or a cable 51 breaks.
In order to make the safety latch assembly 55 operable again and reset dog 57, when the swimming pool cover 25 is near its lowermost position with the upper surface thereof flush with the floor, an actuator plate shown in FIG. 9 at 78 is provided in each of the guide columns 27 and the latch dogs 57 will engage and slide along the plates 78 to a position wherein the spring 58 will go over center again, urging the latch dog 57 toward the rack 61 and teeth 62 so that as the swimming pool cover is again lifted the safety latch will be operable.
The swimming pool cover assembly 25 has a waterproof lower liner 80 on its under surface that prevents moisture from being evaporated into the room air, and also preferably the liner 80 on the bottom surface of the swimming pool cover would be mildew resistant to reduce any problems with fungus.
The individual guide columns that are spaced, and preferably at the sides of the swimming pool cover provide adequate protection against swaying and catching, and stabilize the swimming pool cover during its movement. A gasket 81 (FIG. 3) may be suitably placed around the support surface of the recess to prevent moisture from escaping when the cover is closed. The liner used on the bottom of the pool cover also adequately blocks moisture passage when it rests on the surface defining the recess 20 around the pool, so a gasket is not normally needed.
It should also be noted that while I beams are shown for forming the pool cover support member, trusses of suitable design and strength also can be used.
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 swimming pool cover for an indoor pool which is designed to cover an in-ground pool that is positioned below floor level in a manner so that it provides a support floor when in place that is merely a continuation of the existing floor and which can be raised up vertically when the pool is to be used and become a false ceiling. The cover is provided with vertical guides that prevent it from twisting or coming out of proper orientation, and the guides have safety ratchets that prevent the pool cover from accidentally lowering. The hoist mechanism is stored out of sight in a crawl space or attic above the normal ceiling and operates through cables and pulleys for positively moving the pool cover between its raised and lowered position so that the pool, when covered, provides floor space for a recreation room or party room and also tends to seal the water surface to prevent excessive moisture from escaping into the room.
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This is a continuation of copending application Ser. No. 624,334 filed on Dec. 7, 1990, now abandoned.
BACKGROUND TO THE INVENTION
This invention relates to a method and means for separating materials.
Mining operations almost invariably involve the extraction of valuable minerals which exist in very small quantities in the mined rock. This is particularly so in the case of valuable metals such as gold and silver.
It is therefore considered that it would be advantageous to have a method and means whereby non-magnetic, electrically conductive materials such as gold and silver can be separated from other materials.
SUMMARY OF THE INVENTION
The invention provides a method of separating particulate material according to the electrical conductivity of the particles of the material, the method comprising irradiating the particles with microwave or radio frequency electromagnetic radiation and subjecting the irradiated particles to a magnetic field so that eddy currents induced in the particles by the electromagnetic radiation interact with the magnetic field to cause movements, dependent upon electrical conductivity, of electrically conductive particles.
The particles are preferably irradiated with microwave radiation having a frequency in the range 10 9 Hz to 3×10 11 Hz, or by radio wave radiation having a frequency in the range 10 4 Hz to 10 9 Hz.
The magnetic field may be a moving or stationary field. In addition, the magnetic field may have a constant or varying intensity.
In one version of the invention, the particles are passed through a microwave chamber in which they are irradiated with microwave radiation and in which they are subjected to the magnetic field. In another version of the invention, the particles are held in suspension in a liquid and are subjected to microwave irradiation and the magnetic field while so suspended.
The method of the invention can be used to separate gold particles from other particles.
The invention also provides an apparatus for separating particulate material according to the electrical conductivities of the particles of the material, the apparatus comprising means for irradiating the particles with microwave or radio frequency electromagnetic radiation and means for subjecting the irradiated particles to a magnetic field so that eddy currents induced in the particles by the electromagnetic radiation interact with the magnetic field to cause movements of electrically conductive particles dependent on their conductivities.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 shows a diagrammatic side view illustrating a first embodiment of the invention; and
FIG. 2 shows a diagrammatic plan view of a second embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows an apparatus 10 which illustrates the principles of the method of the invention. The Figure illustrates a microwave chamber 12 in which is mounted a microwave generator 14 for generating microwaves having a frequency in the range 10 9 Hz to 3×10 11 Hz.
A glass dish 16 is placed on a conductive shielding plate 18 in the chamber 12 and contains an aqueous colloidal suspension 19 of fine gold particles together with other non-magnetic, non-conductive particles.
A permanent magnet 20 is placed beneath the conductive plate 18 and means (not shown) are provided for moving the magnet in the direction of the arrow 22 in FIG. 1. The magnetic field lines associated with the magnet 20 are vertical in FIG. 1.
With the microwave generator in operation, the magnet is caused to move in the direction of the arrow 22. The microwaves induce eddy currents in the gold particles in suspension. Such eddy currents interact with the moving magnetic field and give rise to an electromotive force which in this case urges the gold particles to move to the right in FIG. 1, i.e. in the same direction as the magnet moves.
No eddy currents are induced in the non-conductive particles which are also in suspension with the gold particles, and such particles remain in their original positions in the suspension. Thus a separation of the gold particles from the non-conductive particles is achieved.
The extent to which conductive particles are moved by the interaction of the induced eddy currents and the moving magnetic field is dependent, inter alia, on the conductivity of those particles. It will be appreciated that particles with lower electrical conductivities such as, say, aluminum particles will be moved to a lesser extent than highly conductive particles such as gold particles. Thus it is not only possible to achieve a separation between conductive and non-conductive particles, but it is also possible to achieve a separation between particles of different electrical conductivity. In cases where it is desired to achieve the latter kind of separation with an apparatus such as that of FIG. 1, the particles of different conductivities will be grouped, after a period of time, in different zones of the dish 16.
In cases where it is desired to separate one particular kind of particle, such as gold particles, from other particles, the microwave frequency will be chosen to induce eddy currents of the desired magnitude in the desired particles so that the movement of those particles can be predicted and the desired particles recovered apart from other particles. In other words, the desired particles will be specifically targeted. On the other hand, where it is desired to make a general discrimination between various particle types having different thermal conductivities, a non-specific microwave frequency may be used to cause differing degrees of movement of the various particle types.
An apparatus such as that of FIG. 1 can be of practical benefit in assay procedures where it is desired, for instance, to determine the gold content of an ore sample. In such a case, the gold fraction is recovered and a computation may be made of the gold content of the sample as a whole.
In the high throughput apparatus 30 depicted diagrammatically in plan view in FIG. 2, milled and crushed ore particles 32 are fed onto an endless conveyor belt 34. The ore particles 32 contain a low concentration of small particles of valuable electrically conductive material, such as gold, which are to be separated from other non-conductive material or less conductive materials in the mass of ore particles.
During their travel on the belt, the particles pass through a microwave chamber 40 in which they are subjected to microwave radiation having a frequency in the range 10 9 Hz to 3×10 11 Hz. While being irradiated the particles pass between magnets 36 (only one visible in FIG. 2) located above and below the belt 34. The magnets may be shielded from the microwaves by plates similar to the plate 18 of FIG. 1. The field lines associated with the magnets are perpendicular to the belt, i.e. into the plane of the paper in FIG. 2.
As illustrated, the magnets 36 are arranged at 45° to the direction of belt movement, indicated by the arrows 38. Thus the magnetic field itself is at 45° to the direction of movement of the belt and particles.
The incident microwave radiation induces eddy currents in conductive particles. These eddy currents interact with the applied magnetic field to produce forces which tend to move the conductive particles sideways off the belt. The exact frequency of the microwaves is chosen to produce eddy currents of sufficient magnitude in small conductive particles for the resultant electromotive force to be great enough to cause the relevant particles to fall sideways off the belt.
The remaining particles, which are either non-conductive or less conductive than the particles which it is desired to separate are not moved off the belt and continue moving on the belt. Such particles are discharged over the discharge end of the belt for collection separately from those particles moved sideways off the belt.
The magnets 36 seen in FIG. 2 may be arranged to move in a direction at right angles to the direction of movement of the belt up and down as viewed in FIG. 2. Also, there can be a number of magnets 36 arranged side-by-side to produce a "sweeping" magnetic field acting on the particles. A sweeping electromotive force, resulting from the interaction of the eddy currents with the magnetic fields of the various magnets moves the relevant particles progressively in a sideways direction off the belt.
In cases such as that exemplified in FIG. 2, it will be appreciated that the physical nature of the particles, in addition to their conductivities, will also determine the extent to which they are moved. For instance, a lighter particle may be moved more easily than a heavier particle, even though the latter particle may have a higher conductivity than the former. Such factors will of course have to be taken into account in the design of a particular particle separation installation.
As indicated previously, the invention is not limited to the use of microwave frequency electrmagnetic radiation. Radio frequency electromagnetic radiation, in the frequency range 10 4 Hz to 10 9 Hz can also be used.
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Non-magnetic, conductive particles are separated from one another on the basis of their respective electrical conductivities. This is achieved by irradiating the particles with microwave or radio frequency electromagnetic radiation and simultaneously subjecting the particles to a magnetic field. The eddy currents induced in the particles by the electromagnetic irradiation interact with the magnetic field to cause movements of the particles which are dependent on their conductivities.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application 60/978,203 filed on Oct. 8, 2007.
BACKGROUND
1. Field of the Invention
The present invention relates to the field of electrical connectors and more particularly to electrical feedthroughs for downhole packers.
2. Background Information
Numerous applications involve the use of electrical connectors. High power connectors are used in applications including subsea connections, and in submersible pump connections in both water wells and oil wells. The size, weight, and orientation of the cables and connectors induce mechanical loads on connector components that make reliable mechanical and electrical connection difficult. In addition, the physical environment may include high temperature, high pressure, and abrasive and/or corrosive liquids and gases.
Packers may be used in downhole applications to seal off separate producing zones. Electrical cables may be run through packers to power downhole equipment, for example, electric submersible pumps, downhole electric actuators, and downhole electronics and sensors. In some applications, a through-packer penetrator may be used that has an electrical cable with a connector on each end. Such configurations require a special packer and may be very costly. Alternatively, cables may be vertically spliced together. Splicing operations in the field may take an inordinate amount of time and result in a less reliable connection.
SUMMARY
In one aspect of the present invention, an apparatus for providing electrical power through a downhole packer comprises a riser nipple engagingly insertable in a passage in the packer; a sleeve surrounding a portion of the riser nipple and slidingly moveable between a cable assembly position and an operational position enabling connection of a cable extending through the packer and the sleeve to an electrical connector; and a retaining nut engageable with the riser nipple capturing the sleeve in the operational position when the retaining nut is engaged with the riser nipple.
In another aspect, a method for providing electrical power through a downhole packer comprises engagingly inserting a riser nipple in a passage of the downhole packer; sliding a sleeve surrounding the riser nipple into a cable assembly position; connecting a cable extending through the packer and the sleeve to an electrical connector; sliding the sleeve to an operational position; and engaging a lock nut with the riser nipple to retain the sleeve in the operational position.
In yet another aspect, an apparatus comprises a submersible pump in a wellbore; a cable having an electrical conductor in electrical communication with the submersible pump; an electrical feedthrough assembly enabling passage of the electrical conductor through a packer in the wellbore; and a gripping contact assembly engaging the electrical conductor conducting electrical power to the submersible pump.
Non-limiting examples of certain aspects of the invention have been summarized here rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions they represent to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter.
BRIEF DESCRIPTION OF THE FIGURES
For a detailed understanding of the present invention, references should be made to the following detailed description of the exemplary embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
FIG. 1 shows an exploded view of a connector contact assembly according to one illustrative embodiment of the present invention;
FIG. 2 shows an assembled view of the elements of FIG. 1 ;
FIG. 3 shows a portion of a contact receptacle according to one illustrative embodiment of the present invention;
FIG. 4A shows an end view of a gripping contact according to one illustrative embodiment of the present invention;
FIG. 4B shows a cross-section view along section line A-A of FIG. 4A ;
FIG. 5 shows a non-limiting example of a portion of a connector assembly according to one illustrative embodiment of the present invention;
FIG. 6 shows a non-limiting example of a connector utilizing a contact assembly of one embodiment of the present invention to connect power to a submersible pump;
FIG. 7 shows an example of an electrical feedthrough used in a downhole submersible pump application; and
FIG. 8 shows an enlarged view of the example electrical feedthrough of FIG. 7 .
DETAILED DESCRIPTION
The following description presents non-limiting examples of embodiments of the present invention. Refer now to FIGS. 1-4B . FIG. 1 shows an exploded view of a connector contact assembly 5 according to one illustrative embodiment of the present invention. As shown in FIG. 1 , a cable 40 has an electrical conductor 45 therein. Electrical conductor 45 may be a solid conductor, or, alternatively, a stranded conductor.
A gripping contact 15 has a cavity 16 sized to accept electrical conductor 45 . In one embodiment, the inner diameter of cavity 16 is a substantially a zero clearance fit with the outer diameter of electrical conductor 45 . Gripping contact 15 (see also FIGS. 4A and 4B ) comprises a plurality of gripping fingers 20 with an outer surface 25 having a substantially conical shape. As seen, in FIG. 4B , the conical surface 25 is defined by the angle β. In one embodiment, angle β is about 6°. Alternatively, angle β may be in the range of about 2° to about 10°. The internal surface 21 of fingers 20 substantially defines cavity 16 . While shown in FIG. 4A as comprising four fingers, any number of fingers may be used and are intended to be encompassed by the present disclosure. In one embodiment, the internal surface 21 of fingers 20 may be substantially smooth. Alternatively, in another embodiment, the internal surface 21 of fingers 20 may have a raised pattern (not shown) formed on surface 21 . Such a pattern may include, but is not limited to: a thread form, a tooth form, a knurling form, and any other raised pattern form used for gripping electrical conductor 45 .
On an opposite end of gripping contact 15 , an integral body 27 has an internally threaded bore 35 . Gripping contact 15 may be made out of an electrically conductive metal. Examples of such an electrically conductive metal include, but are not limited to: gold, silver, copper, copper alloys, aluminum, aluminum alloys, brass, bronze, and any other suitable electrically conducting metal. The surfaces 25 and 21 of fingers 20 may be plated with a suitable electrically conductive material to reduce galling and/or wear of the gripping fingers 20 . Any suitable plating may be used including, but not limited to: chrome plating, nickel plating, gold plating, and silver plating.
A contact receptacle 10 (see FIGS. 1-3 ), has an internal conical surface 26 having an angle α where α≦β. In one embodiment, α is on the order of 1.0° smaller than β. Alternatively, α may be smaller than β from about 0.5° to about 1.5°. The difference in angles ensures that fingers 20 of gripping contact 15 are forced to collapse around and compress electrical conductor 45 , as shown in FIGS. 1 and 2 , when gripping contact 15 is urged axially into contact receptacle 10 . Contact receptacle 10 may be made from any of the materials as described previously for gripping contact 15 . Similarly, contact receptacle 10 may be plated by any of the platings discussed previously with respect to gripping contact 15 .
As shown in FIGS. 1 and 2 , threaded element 30 engages threads 35 in gripping contact 15 and, under tension, reacts against shoulder 31 in contact receptacle 10 such that gripping contact 15 is axially urged into contact receptacle 10 . This motion causes interaction between outer surface 25 and inner surface 26 such that fingers 20 of gripping contact 15 are forced to collapse around and compress electrical conductor 45 along substantially the length of the extension of electrical conductor 45 into gripping contact 15 . The use of threaded element 30 provides a substantially repeatable force urging gripping contact 15 into contact receptacle 10 , thereby providing a repeatable holding force between electrical contact 45 and connector contact assembly. In addition, the substantially repeatable axial holding force provides a repeatable electrical contact between fingers 20 of gripping contact 15 and both electrical conductor 45 and contact receptacle 10 . Threaded element 30 may be a suitably sized threaded fastener that may be commercially available. Alternatively, threaded element 30 may be designed for this particular application using techniques known in the art.
FIG. 5 depicts a non-limiting example of a portion of a connector assembly 100 according to one illustrative embodiment of the present invention. Connector assembly 100 may be a power connector for use in connecting a power source to a submersible pump in a well. Alternatively, connector assembly 100 may be a sub-sea connector. As shown in FIG. 5 , a multi-conductor armored cable assembly 41 has at least one insulated cable 40 with an internal electrical conductor 45 . Armored cable assembly 41 is connected to connector assembly 100 by cable adapter 101 . Crossover 102 connects cable adapter 101 to lower housing 103 .
It will be appreciated by one skilled in the art that the portion of connector assembly 100 shown in FIG. 5 may be immersed in a high pressure fluid such as, for example, a wellbore fluid. To seal high pressure fluid from the internal electrical connections, cable 40 is inserted through seal 120 . Seal 120 is an elastomer seal that is compressed around the insulation of cable 40 to preclude passage of fluid toward the electrical contacts 15 and 10 . Seal 120 is held in place by follower 130 . Seal 120 may be made of a suitable elastomer. Suitable elastomers include but are not limited to, natural rubber, synthetic rubber, fluoroelastomers, perfluoroelastomers, ethylene propylene diene rubber, and any other suitable elastomer.
Connector contact assembly 5 is inserted into an insulator 110 that is located above seal 120 . As shown, connector contact assembly 5 comprises gripping contact 15 assembled in contact receptacle 10 and held in place by threaded element 30 . To better facilitate field assembly, insulator 110 is located in lower housing 103 and upper housing 104 that are connected through coupling nut 140 and shoulder nut 135 acting against shoulder 145 . Insulator 110 may be a thermoplastic suitable for the particular environment encountered. Examples of such a thermoplastic include, but are not limited to, a polyetheretherketone material and a glass-filled polyetheretherketone material. Gripping contact 15 is in engaged contact, both mechanically and electrically with electrical conductor 45 . Connector assembly 5 conducts an electrical power signal to contact 105 which is electrically conducted to a surface power control system. One skilled in the art will appreciate that the connector assembly 5 and its components may be appropriately scaled to fit different size electrical conductors without undue experimentation.
One non-limiting example of an application of the present invention is shown in FIG. 6 . In FIG. 6 , a well 200 comprises a string of surface pipe 212 cemented in the upper portion of a bore hole 214 which extends into the earth to a location adjacent and usually below a subterranean oil productive formation (not shown). A wellhead 216 attaches to the surface pipe 212 . A set of slips 218 suspends a casing string 220 inside the bore hole 214 which is also cemented in place. A casing head 222 connects to the upper end of the casing string 220 and includes a tubing hanger 224 .
A tubing string 226 is suspended from the tubing hanger 224 and extends downwardly inside the casing string 220 to a location adjacent the productive formation. An electrically powered submersible pump 228 , of any suitable type, on the lower end of the tubing string 226 pumps oil or an oil-water mixture from the inside of the casing string 220 upwardly through the tubing string 226 .
Electric power is delivered to the downhole pump 228 through an armored cable 234 connected to a motor 236 comprising part of the submersible pump 228 . The cable 234 extends upwardly in the well 200 to a connector 100 of the present invention located immediately below the tubing hanger 224 . The connector 100 is secured to a mandrel or feed through socket 240 extending through the hanger 224 , seal assembly 230 and flange 232 . The connector 100 employs a contact assembly as described previously. In one embodiment, a pig tail connector 242 attaches the mandrel 240 to a power cable 244 extending to a source of power at the surface.
FIG. 7 shows an example of a downhole pump application where a packer is located uphole of the pump. Electrical submersible pump 228 is powered by electric motor 236 and is located proximate a producing formation 341 . Reservoir fluid 340 enters pump 228 and is forced up tubing string 226 to a surface system, for example, wellhead 216 in FIG. 6 for distribution to surface storage and/or processing systems (not shown). Packer 310 is located uphole of pump 228 and may be expanded to seal off the volume of borehole 214 above packer 310 to the volume below packer 310 . Packer 310 seals against tubing string 226 where the tubing string passes through packer 310 .
Armored electrical cable 41 extends from motor 236 upward and through a passage 350 through packer 310 . Cable 41 extends through packer feedthrough assembly 300 and may be electrically connected to electrical connector 400 which may be an electrical connector as described above in FIGS. 1-5 . Alternatively, cable 41 may be electrically connected to any suitable electrical connector adapted to interface with feedthrough assembly 300 . Electrical connector 400 may facilitate electrical connection to a suitable power and/or control system (not shown) at the surface.
FIG. 8 shows an enlarged view of the example electrical feedthrough of FIG. 7 . As shown in FIG. 7 , electrical feedthrough assembly 300 comprises riser nipple 320 , sliding sleeve 315 , and retaining nut 325 . Riser nipple 320 comprises a lower end having thread 322 formed thereon, and an upper end having an upset 316 formed thereon. Threads 322 on the lower end of riser nipple 320 are engageably inserted into threads 323 formed in a sleeve formed in packer 310 . The outer diameter of the upset 316 on riser nipple 320 fits closely in the inner diameter of sliding sleeve 315 such that elastomer seal 326 substantially excludes wellbore fluids from entering the clearance gap between the outer diameter of upset 316 and the inner diameter of sliding sleeve 315 . Sliding sleeve 315 has a shoulder section 317 on a lower end thereof. Retaining nut 325 has thread 318 formed on an inner diameter thereof. In an operational position, retaining nut 325 is threaded onto threads 319 on an outer diameter of riser nipple 320 such that retaining nut 325 captures shoulder section 317 of sliding sleeve 315 against upset 316 of riser nipple 320 .
In a cable assembly position, sliding sleeve 315 has an open upper end. Retaining nut 325 is unthreaded from riser nipple 320 and moved to position 325 ′ shown in FIG. 8 . Likewise, sliding sleeve 315 is moved down to position 315 ′. In this configuration, a sufficient length of cable 41 is exposed above packer 310 to allow the cable to be stripped and dressed for connection of conductor 45 of each individual cable element 40 to a suitable contact receptacle, for example, gripping contact assembly 5 of FIG. 1 . Gripping contact assembly 5 may then assembled in connector 400 , which in one embodiment is similar to connector 100 shown in FIG. 5 . Alternatively, any suitable connector may be used.
Upon connection of conductors 45 to a suitable connector 400 , sliding sleeve 315 is raised to the upper operational position and connected to connector 400 , for example, at threaded connection 321 . Retaining nut 325 is moved upward and threaded onto riser nipple 320 by engaging threads 318 and 319 . Retaining nut 325 forces shoulder section 317 of sliding sleeve 315 against upset 316 of riser nipple 320 thereby capturing sliding sleeve 315 in the operational position. The packer electrical feedthrough and method of assembly described herein is intended to provide a substantial reduction in assembly time of a field connection while also providing enhanced reliability over spliced connections.
While the foregoing disclosure is directed to the non-limiting embodiments of the invention, various modifications will be apparent to those skilled in the art. It is intended that all variations within the scope of the appended claims be embraced by the foregoing disclosure.
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An apparatus for providing electrical power through a downhole packer comprises a riser nipple engagingly insertable in a passage in the packer; a sleeve surrounding a portion of the riser nipple and slidingly moveable between a cable assembly position and an operational position enabling connection of a cable extending through the packer and the sleeve to an electrical connector; and a retaining nut engageable with the riser nipple capturing the sleeve in the operational position when the retaining nut is engaged with the riser nipple.
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BACKGROUND OF THE INVENTION
Material handling implements of the type under consideration have been in existance for many years. These implements normally incorporate a vehicle that has a pair of lift arms pivoted at one end on a support portion of the vehicle. A material handling unit, such as a bucket, is pivotally supported on the opposite end of the respective lift arms. The lift arms, which define a boom, are raised and lowered with respect to the vehicle by a pair of fluid rams while the bucket or unit is pivoted on the end of the boom by a single or a pair of fluid rams.
In normal operation of this unit, the boom is placed in a lowered position and the bucket is positioned to have the lower edge or wall generally flat with respect to the ground and the vehicle is driven forwardly to fill the bucket. After the bucket is filled, it is tilted or rolled back with respect to the boom to maintain the contents within the bucket as it is raised to a position enabling dumping of the bucket to transfer the contents to some other location. As the boom is being raised, it is necessary for the bucket to be pivoted with respect to the boom to maintain the bucket in a generally level position and prevent spilling of the contents.
In small compact units of this type, one of the problems encountered is the fact that the bucket is in close proximity above the operator when the boom is in the fully raised position. This presents a considerable hazard if the operator should inadvertently engage the control lever to tilt the bucket rearwardly and possibly spill the contents onto the operator.
To alleviate this problem, many types of mechanisms have been proposed for preventing rearward tilting of the bucket when the boom is in the fully raised position. One type of mechanism incorporates a hydraulic system which prevents rearward pivoting of the bucket when the boom is in the fully raised position. Other types include elaborate mechanical linkages between the bucket and the boom and the boom and/or vehicle.
One of the problems encountered with most of the prior art devices that prevent tilting or "rollback" in the fully raised position is that the operator in many instances is not capable of manually overriding the system should the need arise. There are many instances in which the bucket should be tilted rearwardly in the fully raised position and other times when it is essential that such movement be precluded. Thus, many operators disconnect the entire rollback mechanisms so that the unit is capable of being operated as desired. This of course, is extremely hazardous and can result in serious injury to the operator and damage to the vehicle.
SUMMARY OF THE INVENTION
According to the present invention, a simple and inexpensive mechanism for preventing "rollback" of the bucket with respect to the boom in a raised position incorporates an additional mechanism which allows the operator to manually override the system. The manual override requires an additional manipulation of the control lever so that the operator must be fully cognizant of what he is doing thereby eliminating inadvertent "rollback38 of the bucket in the raised position.
More specifically, the invention is incorporated into a vehicle having a boom pivotally supported at one end with hydraulic means for raising and lowering the boom. A material handling unit is pivotally supported on the free end of the boom and is moved by hydaulic means which includes a lever pivoted about an axis in opposite directions to pivot the unit on the boom.
According to the invention, the vehicle incorporates position defining means adjacent the lever and the position defining means includes an abutment that is disposed in the pivotal path of movement of the lever to prevent actuation of the lever in one direction when the boom is in a fully raised position. The anti-rollback mechanism also incorporates a mechanism for allowing the lever to be moved relative to the abutment to accommodate manual override of the anti-rollback mechanism.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side elevation view of a material handling implement having the present invention incorporated therein;
FIG. 2 is an enlarged view, as viewed along line 2--2 of FIG. 1, showing the anti-rollback mechanism;
FIG. 3 is a end view of the mechanism as viewed along line 3--3 of FIG. 2; and
FIG. 4 is a enlarged exploded view of the anti-rollback mechanism.
DETAILED DESCRIPTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as a exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.
FIG. 1 of the drawings indicates a material handling implement generally designated by the reference numeral 10 and including a vehicle 12 having a pair of vertical fixed supports 14 thereon (one being shown) and located on opposite sides of an operator's compartment 16. A pair of lift arms 18, which define a boom, are pivotally supported at one end by pins 20 on the vertically extending fixed supports 14. Boom 18 is adapted to be pivoted about pins 20 through a fluid ram 22 interposed between support 14 and boom 18.
A material handling unit 24, such as a bucket, is pivotally supported on the outer end of boom or lift arms 18 through pivot pins 26. Material handling unit or bucket 24 is pivoted about the outer end of boom 18 by hydaulic means including a fluid ram 30 and a linkage 32 interposed between boom 18 and bucket 24. The hydraulic circuit (the details of which are not shown) also incorporates a manual control lever 34 pivoted about a fixed pivot axis in the operator's compartment for the vehicle. Control lever 34 is pivoted in a counterclockwise direction as viewed in FIG. 1 to pivot the bucket 24 in a clockwise direction with respect to pivot pin 26 while pivotal movement of the lever 34 in a clockwise direction will pivot bucket 24 in a counterclockwise direction, as is well known in the art.
The details of the position defining means and its interrelationship with control lever 34 are shown in FIGS. 2, 3 and 4 and will be described before the overall operation is considered.
As shown in FIG. 2, position defining means includes a shaft 40 having an arm 42 fixedly secured to one end thereof and extending radially therefrom. Shaft 40 is rotatably supported in a bushing 44 that is fixed to body 16 and has a rigid reinforcing plate 46 adjacent an opposite end thereof with a collar 48 welded thereto. A spring clip 50 is received into a groove 51 on shaft 40 to position the shaft with respect to collar 44.
The opposite end of shaft 40 has a second collar 52 secured thereto with collar 52 having an enlarged portion 54 (FIG. 3) extending radially therefrom, for a purpose that will be described later. Collar 52 is preferably secured to the end of shaft 40 by a roll pin 56.
As most clearly shown in FIG. 2, control lever 34 is rotatably supported on shaft 40 and has a clevis portion 60 at the lower end thereof. Clevis portion 60 supports a link 62 through a clevis pin 64 and the opposite end of link 62 is adapted to be connected to the control spool (not shown) of a valve that is actuated in opposite directions from a neutral position to supply hydraulic fluid to opposite ends of fluid ram 30 and pivot the bucket 24 with respect to boom 18. Control lever 34 is normally biased to a first position by a coil spring or biasing means 70 interposed between spring clip 50 and an adjacent surface of the portion of the control lever which is rotatably supported on shaft 40. Thus, biasing means 70 normally biases control lever 34 into engagement with collar 52. It will also be noted in FIG. 3 that clevis portion 60 of lever 34 has an axial extension 72 which is in circumferential alignment with abutment 54.
Referring now to FIGS. 1 and 4, it will be noted that arm 42 on the end of shaft 40 has an elongated slot 80 defined therein. Slot 80 receives a pin or bolt 82 that is secured to the lower surface of boom 18 through a bracket 84. Thus, the rotated position of shaft 40 within hub or collar 44 defines the position of boom 18 with respect to vehicle 12.
As will now be appreciated, shaft 40, arm 42 and collar 52 will be moved in response to movement of boom 18 with respect to vehicle 12 and thus define position defining means adjcent lever 34 which defines the position of boom or lift arms 18 on vehicle 12. The abutment 54, which is located in the path of movement of control lever 34, defines the position of the boom with respect to the vehicle.
Assuming that the lift arms or boom are in a fully raised position with respect to vehicle 12, as shown in phantom line position in FIG. 1, position defining means which includes abutment 54, shaft 40 and arm 42 will be in the position illustrated in FIG. 3. In this position, abutment 54 is almost in contact with extension 72 that forms part of control lever 34. This means that the control lever cannot be rotated in a clockwise direction, as viewed in FIG. 3, thereby preventing the bucket from being inadvertently pivoted in a counterclockwise direction, as viewed in FIG. 1. This eliminates the possibility of having the operator inadvertently dump the contents of the bucket over the rear edge thereof. However, should the operator desire to manually override the mechanism, it is only necessary for him to grasp control lever 34 and shift the lever to the left as viewed in FIG. 2 to a position where rigid extension 72 no longer is in alignment with abutment 54. At this point in time, the operator can move control lever in a clockwise direction, as viewed in FIG. 3, and thereby cause the bucket 24 to be pivoted in a counterclockwise direction as viewed in FIG. 1. While control lever 34 is in such actuated position, it will be appreciated that extension 72 will be biased into engagement with the end of abutment 54. If the operator then subsequently pivots the control lever in the opposite direction, when the control lever reaches the neutral position, as illustrated in FIG. 3, the bias of spring 70 will automatically return the control lever to the position indicated in FIG. 2.
Summarizing the above, it will be appreciated that abutment 54 of position defining means is positioned as a function of the position of boom 18 with respect to vehicle 12 and in the fully raised position of boom 18, abutment 54 cooperates with lever 34, more specifically extension 72, to prevent actuation of the lever in one direction. The spring 70 defines means that accommodates relative movement between lever 34 and abutment 54 to allow pivotal movement of the lever in this same direction after the lever has been shifted axially with respect to shaft 40, which defines the pivot axis for the lever.
As can be seen from the above description, the present invention provides a simple and inexpensive mechanism for normally preventing rolling back of the bucket when it is in the fully raised position but will automatically allow the operator to manually override this function at times when the need arises.
While a specific embodiment of the invention has been shown and described, numerous modifications are apparent. For example, the bolt 82 and slot 80 arrangement for causing arm 42 to move as a function of boom 18 could readily be changed. For example, arm 42 could normally be biased into engagement with boom 18 so that arm 42 and subsequently abutment 54 would still be positioned as a function of boom 18. Also abutment 54 could readily be an integral extension on shaft 40.
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An anti-rollback mechanism for a material handling implement including a unit pivotally mounted on the outer end of the boom of a vehicle is disclosed herein. The anti-rollback mechanism includes a member that is moved with the boom to indicate the position of the boom and prevent actuation of a manual control lever that forms part of the hydraulic circuit for pivoting the unit on the boom. The anti-rollback mechanism incorporates a manual override to allow the operator to tilt the unit on the boom even though the boom is in the completely raised position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to schemes for modifying and expanding the functionality of websites.
[0003] 2. Background
[0004] Third party software applications or add-ons have been developed to enhance website functionality and enhance website management. To deploy such third party applications it is necessary to integrate the website with the applications by placing additional lines of code into the website source code. The process of integrating (or linking) third party software applications with a website may be thought of as “application enabling” of the website.
[0005] In today's online commerce and technology environments, there is a great need for application enabling of websites in a non-programming manner, to enable the reuse of third party developed, specialized components that will increase the capabilities and efficiencies of websites, while at the same time reducing the development cost and time needed for implementation.
[0006] Some examples of third party web applications include website optimization solutions, web analytics, advertisement, and web content management solutions that enable more effective website management. Similarly, there are reusable components that enable shopping cart functionality, news section management, and other website functionalities that may be handled by third party web applications.
[0007] Prior art approaches to application enabling of websites include manual source code changes in conjunction with third party software installation, proxy server based enabling, and automated source code changes as further described below.
[0008] Application enabling by manual source code change involves inserting additional lines of code into website source code, which additional lines initialize the execution of the third party applications. This requires a breadth of technical and programming language knowledge, thereby limiting the distribution and use of third party developed web applications to a relatively small number of organizations that have know-how and operational setup needed to effectively carry out such projects. The main difficulties of this approach stem form website source code being often poorly documented, as well as poorly structured, so that even seasoned website programmers may have difficulty creating modifications. Even where appropriately qualified individuals are involved in the website modification process, the tedious nature of the exercise can lead to errors and mistakes, and is also time-consuming.
[0009] Application enabling by proxy server for the website optimization and visitor tracking is described in U.S. Patent Application Publication Number 20060271671A1, for example. In that reference, the website optimization application is executed through a modification module that changes website content and tracks website visitors' behavior. This method replaces the complexity of the website source code manipulation in the manual approach with another complicated task of creating (“wiring”) the modification module. Further, the method also requires the involvement of skilled technical resources, creating another impediment to mass adoption.
[0010] Another approach for website application enabling is discussed in U.S. patent application Ser. No. 11/729,569 filed Mar. 29, 2007 by Buchs, et al., and assigned to Hiconversion, Inc., the assignee of the present letters patent, for “Method and Apparatus for Application Enabling of Websites.” This approach automates the process of source code changes through the use of visual tools that have the ability to acquire end-user input about location on the live web page, and the type of functionality that will be added to that location. It further has the ability to merge that input with the third party installation code that will be inserted into the website source code for application enabling. Also, this approach eliminates technical complexity, and makes it possible for a great number of organizations to take the advantage of third party web applications.
SUMMARY OF THE INVENTION
[0011] The invention is a new method and system that enables web operators to application enable their website without the need to perform website source code manipulation. The key aspect of the present-inventive approach is the ability to completely abstract or virtualize the website application enabling data set with the associated capability to perform “just in time” website application enabling when a web page is requested by an end-user device. This general virtual application enabling approach is very flexible, as it supports simultaneous enabling of multiple applications with the freedom to perform the just in time application enabling action either on the end user side (end-user device) or on the server side (such as web server, proxy server, etc.).
[0012] A method and system are provided for using live website pages in combination with a graphical user interface (GUI) during the application enabling setup process. This enables a non-technical user to define the particular locations on the website where the application enabling will occur, and also to specify the enabling functionality to be performed in accordance with the third party application characteristics and specifications. An application enabling setup package is generated at the end of the setup phase.
[0013] The website application enabling is performed by an enabling module in combination with application specific enabling agents and an enabling setup package file. The enabling agents can execute-either on the end-user side or on the server side (web server, proxy server, etc.). The actual enabling can be performed virtually without changes in the website source code, or alternatively in “real” manner through automatic manipulations of the website source code.
[0014] The innovative method and system leverages visual input information provided by the user, and maps that information to the end user or website source code elements and locations. As result, the present-inventive method and system enable virtual (i.e., just in time) code manipulation in accordance with end-user input and specific application requirements. Once implemented, the present invention provides web operators with the ability to add, change, or remove web applications without the need to disturb the existing website setup or source code.
[0015] The present invention provides a novel method of application enabling of a web page that at least includes: a) via a end-user device, connecting to a website targeted for application enabling; b) generating end-user device compliant code for rendering of a web page on the end-user device; c) rendering a web page on the end-user device; d) providing locations on a rendered web page designated for virtual website application enabling; e) automatically mapping locations selected in element d) into corresponding locations in the end-user or website source code; f) providing application enabling code to be inserted at the locations identified in element e) or other general website code locations; g) generating and managing a virtual application enabling setup package adapted to store application enabling information generated in elements d), e), and f); and h) virtually (i.e., just in time) generating the application enabled end-user code in accordance with the information and directions contained in the application enabling setup package.
[0016] The present invention also provides a system for virtual application enabling of a web page that at least includes: an end-user device, adapted to connect to a website targeted for application enabling, and to render a web page associated with the website; a graphical user interface (GUI), adapted to provide visual location or component selection on a rendered web page; a code mapper, adapted to automatically map locations selected by the GUI into corresponding locations in the end-user code or website source code; a setup agent adapted to generate a virtual application enabling setup package, the virtual application enabling setup package at least including application enabling instructions, programming code, and data; and a just-in-time end-user code generator adapted to generate application enabled end-user code.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0017] Features and advantages of the present invention will become apparent to those skilled in the art from the description below, with reference to the following drawing figures, in which:
[0018] FIG. 1 is a schematic diagram of a prior art system for web page delivery and rendering on an end-user device;
[0019] FIG. 2 is schematic diagram of an example of browser-compliant end-user code generated in response to an end-user request to view a selected web page;
[0020] FIG. 3 is a general diagram of the present-inventive virtual web application enabling system;
[0021] FIG. 4 is an alternate embodiment of the present-inventive virtual web application enabling system;
[0022] FIG. 5 is a flowchart illustrating one possible approach to a third party website application enabling setup process;
[0023] FIG. 6 is a flowchart illustrating one possible process for the virtual application enabling of a website;
[0024] FIG. 7 is a more specific flowchart of a method adapted to carry out the present-inventive website virtual application enabling process; and
[0025] FIG. 8 is a schematic diagram of a general system capable of implementing the present-inventive website virtual application enabling process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] FIG. 1 illustrates the general architecture of a system 100 capable of delivering web pages through interaction with an end-user web browser. The website and the associated web pages are formed by executing website source code represented by the number 110 , as will be appreciated by those skilled in the art. A web server 120 runs the website code 110 using one or more operating systems, which may include such popular operating systems as Linux®, Unix®, Windows®, Vista®, and others.
[0027] The system includes additional servers necessary for carrying out the website functions, including for example, a database server 140 , an application server 144 , a file server 150 , and other resources and applications symbolically represented by the number 148 . Each one of the servers can use a different operating system. In accordance with World Wide Web protocols, one or more end-user computers or devices 160 are used to access the website via an Internet connection 164 . A web browser which may be installed on the device 160 allows web pages to be viewed by a user upon being rendered by the browser.
[0028] A process of web page rendering for viewing in the end-user web browser is further described with reference to FIG. 2 . The website server 220 transforms the website source code 110 into a corresponding end-user code 270 which complies with web browser requirements. The source code 110 may comprise several components programmed in different programming languages. Such programming languages include, but are not limited to, JAVA, Hypertext Markup Language (HTML), JSP, ASP, PHP, PYTHON, and many others. These components provide the desired website functionality through the use of the system described in FIG. 1 .
[0029] After the transformation by the web server, end user code that complies with World Wide Web conventions might have some components that are exactly the same, while other components may look significantly different than the website source code. For example, the components 2 and 4 ( 214 and 218 ) of the source code which are written in HTML, remain in HTML in the end-user code as the corresponding components 2 and 4 ( 274 and 278 ). However, the browser in the example is incapable of executing code written in PYTHON, which is why the web server will process PYTHON code and transform a component 3 ( 216 ) of the source code to, for example, browser readable content in the end-user code (new component 3 , numbered 276 ). Similarly, the component 5 ( 219 ) written in Server JAVA language is also converted to browser readable HTML content (new component 5 , numbered 279 ).
[0030] The web server can successfully perform transformation of the source code for the purpose of rendering of a web page in the end-user web browser described in FIG. 2 only in concert with the entire system described in the FIG. 2 . If any system component is missing, the web page might not render correctly, if at all. Therefore, for any visual application enabling method to work, the access to a correctly rendered web page is essential. The system described in the FIG. 1 can be replicated on a case by case basis, but this is not practical or economical in any mass web application enabling scenario.
[0031] Any change to the website source code requires republishing of the code on the web server. Since multiple individuals may be involved in the process, and assuming that a particular application such as web analytics requires frequent changes, a complicated operational situation can arise with considerable delays and lost time.
[0032] In accordance with the present-inventive system 300 as illustrated by FIG. 3 , one or more end-user computers or devices 310 are used to modify the functionality of a website via an Internet connection 311 .
[0033] The present-inventive website application enabling method and system can be carried out via an application enabling solution directly installed on a customer website end-user server 340 , or alternatively, the method and system can be carried out using an application service provider (ASP) approach. The application enabling solution may even be provisioned to use the end-user device in the implementation process.
[0034] The important feature of the present invention is the ability of end-users to perform application enabling setup steps through a visual graphical user interface (GUI) that renders a current live web page which has been delivered via a customer's website infrastructure 320 . A setup enabling module 360 , which is shown as part of an enabling website 350 in the example, activates a visual editing GUI on the end-user web browser 310 . The GUI allows the end-user to navigate the web page rendered on the end-user computer, and further allows the end-user to perform web application enabling and selections in a “what you see is what you get” fashion, without direct access or knowledge of the programming source code or requirements of a specific application being enabled on the website. In addition the GUI enables the end-user to perform application enabling of specific configuration and provisioning actions. For website optimization applications, as an example, the same GUI interface can be used to create or edit new section variations that will participate in the optimization experiment.
[0035] The present invention also includes a setup agent 361 , which is a computer application containing application-specific setup requirements and information, such as the installation options, and scripts needed for insertion into the website source code (symbolically numbered 330 ) to enable that specific application on the website, etc.
[0036] The selections and actions made by the end-user are automatically recorded and saved in a setup package module 362 , which encapsulates all application enabling settings, and in essence creates a virtual abstraction of the enabling requirements. For example, the end-user can perform application enabling of a web page by highlighting (tagging) in some fashion, the portion of the rendered web page where application enabling will be physically applied. A “mouse” or other pointing device can be used for highlighting, and other highlighting approaches can also be used, such as “pop-up” displays. The term “visual tagging” is used here to denote that the web page locations of interest are “tagged” and made visible to the user and the corresponding locations of the end user code are automatically recorded.
[0037] Another critical feature of the invention is virtual (i.e., just in time) application enabling performed by an enabling module 363 . The enabling module 363 utilizes the functions of one or more enabling agents 364 and a setup package 362 which is performed through an enabling module 363 , which enabling module uses one or more enabling agents 364 and a setup package 362 . The specific details of the virtual enabling process will be further described infra, with reference to FIGS. 5-7 .
[0038] The enabling agents can be application specific, or a combination that supports enabling of multiple web applications. For example, one can imagine a Google™ AdWords® enabling agent that simultaneously supports enabling of both Website Analytics and Website Optimizer applications. The actual enabling can be executed on either the client side or the server (e.g., enabling web server 365 ) side.
[0039] FIG. 4 further describes possible virtual application enabling implementation embodiments. The virtual website application enabling can be performed on the end-user device 410 , a website server 420 , or on the proxy server 430 . The actual application enabling is performed from the enabling website 440 via a communication link 450 . As previously mentioned, there are many possible implementation combinations that might place different enabling elements within the end-user website infrastructure or service provider infrastructure. The communication link is represented by a dotted line in the figure to illustrate the temporary nature of the application enabling procedure.
[0040] If application enabling is performed via the end-user device 410 , then during the preparation for rendering of the end user code 412 , a call to the enabling module 442 is made. Based on the unique web page identification and associated enabling setup package 446 (in case of multiple applications it will be multiple packages) the enabling module activates one or more of the enabling agents 444 that will in turn execute virtual web application enabling.
[0041] Similarly, if the application enabling is performed on the web server side, the web server will, during the website source code processing, make a call to the enabling module that initializes virtual application enabling. In both cases (i.e., end-user device or server side enabling) the link or call to the application enabling module is made possible via a program placed into website source code during the one time setup procedure. It is critical to note that this one time setup provides a generic, non-application specific website application enabling capability. This one time intervention will enable all future virtual application enabling by many different applications performed in many different locations of a website.
[0042] Website application enabling on the proxy server 430 eliminates a need for the initial setup and additional program lines into the website source code. Instead, the proxy module 432 activates the enabling module, and based on the web page identity, activates the appropriate application enabling processes.
[0043] The setup process 500 of the present-inventive website virtual application enabling method is illustrated in FIG. 5 . In the example given, the application enabling setup process is used to create setup information necessary to enable a website optimization solution. Recall that this method is not limited to website optimization solutions, but is also applicable to many other website applications.
[0044] As shown in FIG. 5 , the website application enabling process 500 begins with Step 502 , followed by the project setup (Step 504 ). In the latter step, the end-user defines the identity, scope, and participants in the web application enabling project. For example, in a website analytics case, the end-user can name the website optimization experiment, define the pages, sections, variations, and goals associated with the experiment, and define contributors to this project, such as the designer, manager, etc. This step also generically includes security and authorization to ensure that website optimization is performed only by those who have been granted system access.
[0045] The setup module is initialized and the setup agent is acquired in Step 506 . The setup module is generic and applicable to every setup project, but the agents are application specific. Each agent contains the application specific setup information, requirements, and application enabling code that will be used in the visual setup step ( 508 ). For example, in the case of the setup agent that supports Google's Website Optimizer, the agent requires the end user to define sections, enter variations, and define conversion goals.
[0046] Beginning with Step 508 , the visual setup steps of the application enabling process are performed, as more fully illustrated in FIG. 6 .
[0047] Turning to FIG. 6 , the first step in the visual setup process after the start ( 602 ) is to prepare the end-user code (Step 604 ). In this step the program launches an end-user device browser session with the rendered web page in conjunction with a graphical user interface (GUI) application.
[0048] Visual interaction between the end-user and the rendered web page is performed in Step 606 via the GUI. The use of the GUI facilitates the user's visual identification of the areas or aspects of the web page that will participate in the web application enabling, together with application enabling functionality that will be placed in that area of the rendered web page.
[0049] The mapping step ( 608 ) acquires end-user visual GUI input and automatically identifies corresponding locations or areas of the end-user code that are selected for participation in the application enabling. If necessary, the mapping process will expand into identifying locations and areas in the website source code that are selected to participate in the application enabling. The mapping between end-user code and website source code, as described in FIG. 2 , is a non-trivial exercise which can be accomplished via specialized algorithms that are not part of the description of this Letters Patent. Also, the mapping results can be further processed by the GUI interface to identify areas of the web page that can be application enabled or areas of the web page that might have some application enabling issues, or not capable of being enabled.
[0050] In Step 610 the web page location information along with associated application enabling code and functions are packaged into a setup package designed to support the virtual enabling process. The setup package that supports the virtual application enabling process may be in the form of an accessible and modifiable stored file.
[0051] After the last step ( 612 ) of visual set up, the virtual application enabling process returns to the steps illustrated in FIG. 5 , beginning with Step 510 . Step 512 activates a setup package. If this is the first time that a virtualized application enabling process is used there might be a need for insertion of additional program code into website source code as described in connection with FIG. 4 . Step 514 performs on-going maintenance of the setup package in accordance with requirements dictated by the web application provider. Programs and third party applications that are no longer relevant or needed are uninstalled in Step 516 . The process ends at Step 518 .
[0052] The algorithm 700 in FIG. 7 summarizes the virtual application enabling process. After the beginning (Step 702 ) of the virtual application enabling process, the enabling module is started in Step 704 . The enabling module assigns enabling agents and setup packages to a uniquely identified web page. Step 706 loads the enabling agents and setup package to a component that will actually execute the enabling action, as it was further described in connection with FIG. 4 . In step 708 the enabling agent(s) perform virtual application enabling functionality and dynamically alter the end-user code. This modified code will be made available to the end-user device in the step 710 . The virtual enabling process ends in step 712 .
[0053] One embodiment 800 of a system capable of implementing the present-inventive website application enabling process is illustrated in FIG. 8 . The system components may be in modular software form, with the exception of components such as an Internet connection labeled 810 . These components may also be primarily included as part of a toolkit installed on the end-user computer or the end-user web server system. Alternatively, the primary components of the present-inventive website application enabling process can reside on third party owned computing infrastructure designed to provide on-demand web application enabling services through remote access for authorized end-users.
[0054] An end-user device 820 renders a web page based upon the information received from the website targeted by the web application enabling solution via the connection 810 . A graphical user interface (GUI) 830 enables visual application enabling setup and maintenance. A setup agent 840 provides application specific setup actions and is designed to generate a setup package 844 . The setup package is managed through its lifecycle via a setup package manager 846 .
[0055] The application enabling is managed through an enabling module 850 , which uses application specific enabling agents 852 and a setup package to virtually application enable a website. As result of the application enabling, a just-in-time code generator 860 generates a real-time version of the application enabled end-user code. Code generation is carried out via a code mapper 862 .
[0056] A website source provider 870 is optionally employed if a user desires to make permanent application enabling changes in the website source code. This module enables import and code processing capabilities. Additionally, a new code publisher 872 and code remover 874 are used to perform automated publishing of the new source code, or removal of the application enabling code from the source code.
[0057] Variations and modifications of the present invention are possible, given the above description. However, all variations and modifications which are obvious to those skilled in the art to which the present invention pertains are considered to be within the scope of the protection granted by this Letters Patent.
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A novel method of virtual application enabling of a web site at least includes: a) via a end-user device, connecting to a website targeted for application enabling; b) generating end-user device compliant code for rendering of a web page on the end-user device; c) rendering a web page on the end-user device; d) providing locations on a rendered web page designated for virtual website application enabling; e) automatically mapping locations selected in element d) into corresponding locations in the end-user or website source code; f) providing application enabling code to be inserted at the locations identified in element e) or other general website code locations; g) generating and managing a virtual application enabling setup package adapted to store application enabling information generated in elements d), e), and f); and h) virtually (i.e., just in time) generating the application enabled end-user code in accordance with the information and directions contained in the application enabling setup package.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Italian Application No. PD2000A 000091, filed Apr. 13, 2000, and WIPO Application No. PCT/EP01/04050, filed Apr. 9, 2001. The present application also claims priority to the U.S. application Ser. No. 10/009,482, filed Dec. 13, 2001. The contents of these applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a breathable shoe.
[0004] 2. Discussion of the Background
[0005] It is known that a shoe, in order to be comfortable, must ensure proper exchange of heat and water vapor between the microclimate inside the shoe and the external one.
[0006] This exchange of heat and water vapor, however, must not compromise in any way the impermeableness of the shoe to external humidity or water.
[0007] Currently commercially available shoes entrust this exchange of heat and water vapor substantially to the upper or to the sole.
[0008] As regards the upper, shoes which are perforated and/or provided with linings made of a breathable and waterproof material are currently commercially available.
[0009] In some models, some parts of the upper can be replaced with materials which are indeed waterproof and breathable at the same time.
[0010] In rubber soles, many solutions have been proposed in order to solve the problem of the lack of breathability which is inherent in the characteristics of the material.
[0011] One of these solutions, disclosed in Italian patent No. 1232798, consists in dividing the sole into two layers with through holes and in interposing a breathable waterproof membrane which is joined perimetrically and hermetically to the two layers.
[0012] Variations of this solution occur in subsequent patents, all of which are in any case focused on dividing the sole into two layers in order to stop external water and dirt in a region which is as close as possible to the surface that makes contact with the ground.
[0013] This entails manufacturing complications and in particular prevents the provision of particularly thin soles.
[0014] In other cases, such as for example in European patent No. 275644, the entire sole is provided with through holes and is joined at the top with an upper having a bottom surface, which is entirely made of a waterproof breathable material (film of polytetrafluoroethylene porous foam) with the interposition of a protective layer made of porous material.
[0015] This structure is adapted for shoes whose upper is not provided with the classic methods, such as the ones known as “Strobel”, “ideal welt” or “pre-assembled”.
[0016] European patent No. 103601 also discloses a sole in which delimited regions are completely crossed through their thickness by holes and in which, in an upward region, a waterproof and breathable membrane is in contact with a substrate made of soft perforated material on which the foot rests; this solution is substantially equivalent to the preceding one and makes it impossible to apply classic methods.
[0017] The sole is monolithic with the upper and the entire assembly is made of plastic and is therefore not breathable.
[0018] The regions with holes are separate from the rest and are constituted by removable disks.
[0019] Substantially the same situation is proposed by French patent No. 1228239, which discloses a shoe with a sole and an upper made of the same waterproof but non-breathable (plastic) material, provided with through holes (in both the sole and the upper) and, inside the upper, a bootie made of waterproof and breathable material.
[0020] There is also an insole inside the bootie which is made of felt or similar material.
SUMMARY OF THE INVENTION
[0021] The aim of the present invention is to provide a shoe with a waterproof and breathable sole which can be manufactured with the above cited classic methods (modified appropriately) and is simpler than the ones known in the state of the art.
[0022] Within this aim, an object of the present invention is to provide a breathable shoe whose structure entails absolutely no constraints as regards styling and aesthetic research, allowing the greatest freedom to shoe shapes and types.
[0023] Another object of the present invention is to provide a breathable shoe which is meant for both day-to-day use and for sports use.
[0024] Another object of the present invention is to provide a breathable shoe whose cost is competitive with respect to the costs of known shoes.
[0025] In accordance with the invention, there is provided a breathable shoe and a method for manufacturing a breathable shoe as defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Further characteristics and advantages of the present invention will become better apparent from the description of three embodiments thereof, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
[0027] FIG. 1 is a cross-section view of a shoe according to the invention in the assembled condition, in a first embodiment;
[0028] FIG. 2 is a cross-section view of the shoe of FIG. 1 prior to final assembly;
[0029] FIG. 3 is a cross-section view of the sole of a shoe according to the invention in a second embodiment thereof;
[0030] FIG. 4 is a cross-section view of the sole of a shoe according to the invention in a third embodiment thereof;
[0031] FIG. 5 is a cross-section view of a shoe according to the invention in the assembled condition, in a fourth embodiment thereof;
[0032] FIG. 6 is a cross-section view of the shoe of FIG. 5 prior to final assembly;
[0033] FIG. 7 is a cross-section view of a shoe according to the invention in the assembled condition, in a fifth embodiment thereof;
[0034] FIG. 8 is a cross-section view of the shoe of FIG. 7 prior to final assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] With particular reference to FIGS. 1 and 2 , a breathable shoe according to the invention comprises, in this case, an assembly 10 which wraps around the foot insertion region and is in turn composed of an upper 11 which is breathable (for example made of natural leather without sealing pigments) and is associated with a breathable or perforated lining 12 (made for example of Cambrelle).
[0036] The lining 12 is associated with the upper 11 by spot-gluing, so as to not compromise breathability through said upper.
[0037] The assembly 10 furthermore comprises a breathable or perforated insole 13 which is joined, by means of stitched seams 13 a, to the edges of said upper 11 according to the manufacturing method commonly known as “Strobel” or “ideal welt”, so as to form a sack into which the assembly last, not shown in the figures, is to be inserted.
[0038] The insole 13 can be made of a material which is breathable (for example natural leather) or perforated, with an optional heel seat lining made of soft leather with absorbent rubber latex.
[0039] A membrane 14 made of a breathable and waterproof material, optionally coupled (so as to withstand hydrolysis without compromising breathability) to a supporting mesh 15 made of synthetic material, is associated with said insole 13 for example by spot gluing.
[0040] Preferably, the mesh 15 lies below the membrane 14 .
[0041] The membrane 14 can be of the type that is commercially available and commonly known by the trade-name Gore-Tex.
[0042] A sole 16 , formed by a single block of elastomer with through holes 16 a through its thickness, is joined to said upper for example by gluing (with hydrolysis-resistant adhesives) or high-frequency welding along a perimetric band and is sealed perimetrically with respect to said membrane 14 .
[0043] As an alternative, direct injection of the sole 16 on the upper 11 can be provided.
[0044] A protective element 17 made of a material which is hydrolysis-resistant, water-repellent, breathable or perforated is associated below said membrane 14 by spot gluing, for example by adopting a commercially available adhesive which is resistant to hydrolysis (of the kind commonly known as “hot-melt” or calendered-powder systems).
[0045] The protective element 17 can be conveniently made of a material which is water-repellent and capable of drying rapidly, such as for example non-woven fabric or needled cloth.
[0046] As an alternative, it is possible to provide a Kevlar or filtering fabric. Conveniently, the edge 18 of the protective element 17 lies inside the edge 19 of the membrane 14 in order to allow to form a seal with the sole 16 .
[0047] As an alternative, the edge 19 of the membrane 14 can be folded around the edge 18 of the protective element 17 , or said protective element could be thinned at the edge (if it has the same perimeter as the membrane 14 ) so as to allow the penetration of the sealing adhesive between the membrane 14 and the sole 16 .
[0048] The protective element 17 protects the membrane 14 from external impacts or foreign objects which might penetrate through the holes provided in the sole 16 .
[0049] A breathable or perforated inner sole 20 completes the shoe.
[0050] The shoe is manufactured by associating the membrane 14 and the protective element 17 with the assembly 10 , which is constituted by the upper 11 and the insole 13 (fitted on the last), and subsequently joining the sole 16 .
[0051] As an alternative, the membrane 14 can be joined to the sole 16 first and then the composite element can be associated with the assembly 10 .
[0052] The shoe according to the invention, as shown by the description of this first embodiment, is entirely breathable, any non-breathable regions being limited substantially to the perimetric regions of the sole, which must in any case ensure a good seal with respect to external moisture and water.
[0053] With particular reference to FIG. 3 , in a second embodiment the shoe differs from the preceding case in that the protective element, now designated by the reference numeral 117 , is sandwiched between two components 116 a and 116 b (which are mutually joined hermetically) into which the sole 116 is divided, each component having through holes 116 c and 116 d.
[0054] This is done if the thickness of the sole 116 is so great that it is difficult to clean it of any mud or dirt which might penetrate.
[0055] Being blocked by the protective element 117 , in this case, the dirt can be released purely by virtue of the flexing of the sole, designated by the reference numeral 116 .
[0056] The part above the protective element 117 of the sole 116 can act as an air chamber which increases comfort by absorbing any unevenness of the ground and increasing the ventilation of the membrane so as to rapidly dry its lower surface, when it is wet, in order to increase its breathability.
[0057] With particular reference to FIG. 4 , a shoe according to the invention, in a third embodiment, differs from the preceding cases in that the sole, now designated by the reference numeral 216 , has in its upper part a hollow region 220 which is delimited perimetrically by a border 221 .
[0058] Dome-shaped protrusions 222 protrude from said hollow region 220 , are uniformly distributed and advantageously reach the same height as said border 221 .
[0059] Holes 223 or channels are provided in said border and connect the region 220 to the outside.
[0060] Each one of said holes 223 is inclined with respect to the ground contact plane, so that the outward part is lower than the inward part (this is done to avoid stagnation).
[0061] The holes 223 can furthermore be provided with one-way valves, not shown in the figures (which allow only air to flow outward).
[0062] With particular reference to FIGS. 5 and 6 , a breathable shoe according to the invention, in a fourth embodiment, comprises in this case an assembly 310 composed of a tubular upper 311 which is breathable (for example made of natural leather without sealing pigments) which is associated with a breathable or perforated lining 312 (made for example of Cambrelle).
[0063] The lining 312 is associated with the upper 311 by spot gluing, so as to not compromise breathability through said upper.
[0064] A membrane 314 made of breathable and waterproof material, optionally coupled (so as to withstand hydrolysis without compromising breathability) to a supporting mesh 315 made of synthetic material, is associated with the lower part of the upper 311 , for example by spot gluing.
[0065] A sole 316 made of a single block of elastomer with through holes 316 a through its thickness is joined to said upper 311 , for example by gluing (with hydrolysis-resistant adhesives) or high-frequency welding along a perimetric band and is sealed perimetrically to said membrane 314 .
[0066] As an alternative, it is possible to provide for the direct injection of the sole 316 over the upper 311 .
[0067] A protective element 317 made of a material which is resistant to hydrolysis, water-repellent, breathable or perforated is associated below said membrane 314 by spot gluing, for example by adopting a commercially available adhesive which is resistant to hydrolysis (of the type commonly known as “hot-melt” or calendered-powder systems).
[0068] Conveniently, the edge 318 of the protective element 317 is internal to the edge 319 of the membrane 314 in order to allow to form a seal with the sole 316 .
[0069] As an alternative, the edge 319 of the membrane 314 can be folded around the edge 318 of the protective element 317 or said protective element could be thinned at its edge (if it has the same perimeter as the membrane 314 ) until it allows the sealing adhesive to penetrate between the membrane 314 and the sole 316 .
[0070] The protective element 317 protects the membrane 314 against external impacts or foreign objects which might penetrate through the holes provided in the sole 316 .
[0071] As an alternative, the protective element 317 can be arranged as in the second embodiment.
[0072] In another alternative, the sole 316 can be provided as in the third embodiment.
[0073] The shoe is manufactured by associating the membrane 314 and the protective element 317 with the assembly 310 , which is fitted on the last, and subsequently joining the sole 316 .
[0074] As an alternative, the membrane 314 can be joined to the sole 316 first and then the composite element can be associated with the assembly 310 .
[0075] With particular reference to FIGS. 7 and 8 , a breathable shoe according to the invention in a fifth embodiment comprises, in this case, an assembly 410 which wraps around the foot insertion region and is in turn composed of an upper 411 which is breathable (for example made of natural leather without sealing pigments) and is associated with a breathable or perforated lining 412 (made for example of Cambrelle).
[0076] The lining 412 is associated with the upper 411 by spot gluing, so as not to compromise breathability through said upper.
[0077] The assembly 410 furthermore comprises an assembly insole 413 which is breathable or perforated and below which the edges of said upper 411 are folded and glued (a manufacturing method known as “pre-assembled” or “AGO”), so as to form a sack in which the assembly last, not shown in the figures, is to be inserted.
[0078] The insole 413 can be made of breathable material (for example natural leather) or perforated material, with an optional heel seat lining made of soft leather with absorbent rubber latex.
[0079] The assembly 410 also comprises a breathable or perforated filler layer 413 a (made for example of felt) which is surrounded by the folded edges of the upper 411 .
[0080] A membrane 414 made of waterproof and breathable material, optionally coupled (so as to withstand hydrolysis without compromising breathability) to a supporting mesh 415 made of synthetic material, is associated with said filler layer 413 a for example by spot gluing.
[0081] The mesh 415 is preferably in an upward region with respect to the membrane 414 .
[0082] The membrane 414 can be of the commercially available type commonly known by the trade-name Gore-Tex.
[0083] A sole 416 formed by a single block of elastomer with through holes 416 a through its thickness is joined to said upper for example by gluing (with hydrolysis-resistant adhesives) or high-frequency welding along a perimetric band and is sealed perimetrically with respect to said membrane 414 .
[0084] As an alternative, it is possible to provide for the direct injection of the sole 416 on the upper 411 .
[0085] A protective element 417 made of hydrolysis-resistant, water-repellent, breathable or perforated material is associated below said membrane 414 by spot gluing, for example by adopting a commercially available adhesive which is resistant to hydrolysis (the type commonly known as “hot-melt” or calendered-powder systems).
[0086] The protective element 417 can be conveniently made of a water-repellent material which is capable of drying rapidly, such as for example non-woven fabric or needled cloth.
[0087] As an alternative, it is possible to provide a fabric made of Kevlar or filtering fabric.
[0088] Conveniently, the edge 418 of the protective element 417 lies inside the edge 419 of the membrane 414 in order to allow to form a seal with the sole 416 .
[0089] As an alternative, the edge 419 of the membrane 414 can be folded around the edge 418 of the protective element 417 or said protective element could be thinned at its edge (if it has the same perimeter as the membrane 414 ) until it allows the sealing adhesive to penetrate between the membrane 414 and the sole 416 .
[0090] The protective element 417 protects the membrane 414 against external impacts or foreign objects which might penetrate through the holes provided in the sole 416 .
[0091] As an alternative, the protective element 417 can be arranged as in the second embodiment.
[0092] In a further alternative, the sole can be provided as in the third embodiment.
[0093] The shoe is manufactured by associating the membrane 414 and the protective element 417 with the assembly 410 , constituted by the upper 411 , the assembly insole 413 and a filler layer 413 a (mounted on the last), and subsequently joining the sole 416 .
[0094] As an alternative ( FIG. 8 ), the membrane 414 can be joined to the sole 416 first and then the composite element can be associated with the assembly 410 .
[0095] In practice it has been observed that the present invention has achieved its intended aim and objects.
[0096] A shoe with a waterproof and breathable sole has in fact been provided by using the “Strobel”, “ideal welt”, “pre-assembled” and other classic methods (modified appropriately) in a simpler manner than shoes known in the state of the art.
[0097] It should also be observed that the shoe according to the invention perfectly fulfills the need to have optimum exchange of heat and water vapor between the internal microclimate and the external one, while maintaining a complete impermeableness to water and moisture.
[0098] It is observed that all this has been achieved while maintaining a shoe structure which is highly flexible and adaptable to any type of styling and to any aesthetic and economical level required by the market.
[0099] It is also observed that the structure of the shoe according to the invention can be easily mass-produced, since the operations can be fully automated.
[0100] It is further observed that the structure of the shoe according to the invention allows a certain flexibility as regards the association of its components, thus leading to considerable production savings in relation to its flexibility and adaptability to the various manufacturing situations and conditions.
[0101] The present invention is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept; all the details may furthermore be replaced with other technically equivalent elements.
[0102] The material, as well as the dimensions, may be any according to requirements.
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A breathable shoe, including: an upper assembly ( 10;310;410 ) having a breathable upper ( 11;311;411 ); a membrane ( 14;314;414 ) made of a material which is waterproof and breathable, and a sole ( 16;116;216;316;416 ) made of perforated elastomer, which are all mutually attached such that the membrane is arranged between the upper assembly and the sole, and the sole is sealed perimetrically to the membrane, in a manner to prevent moisture to enter into the upper assembly from the sole through the membrane, and to permit moisture to leave the inside of the upper assembly through the membrane and through the sole. In one preferred embodiment, the membrane is first attached to the upper assembly so that the upper assembly is a unitary upper assembly including the membrane, and such unitary upper assembly is subsequently attached to the sole.
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FIELD OF THE INVENTION
The present invention relates generally to implements for use with tractors, skid steers and the like, and more specifically to a material-handling bucket for use as a loader on such vehicles.
BACKGROUND OF THE INVENTION
Material-handling buckets, or loaders, are common attachments for many types of equipment including tractors, skid steers, four wheelers and bulldozers. Loaders are most often attached to the front of such equipment with arms and hydraulic controls that allow the loader to be raised and lowered, and also rolled forward and backward. Although front-end loaders are designed for handling and transporting large amounts of bulk material, equipment operators typically use the loader for many other tasks.
For example, the front-end loader may be used to dig and excavate earth and soil. Operators may also use the loader to grade and level soil or other surface material after digging or excavating. The loader may also be used to break up earth and soil prior to excavating or leveling. Although front-end loaders are commonly used for these tasks, present loader designs are not optimal for scraping, grading and scarifying surface material.
When using the front-end loader on a tractor to dig or excavate soil, the front lip of the bucket is rotated downward and forced into the soil using the forward motion of the tractor. When the front lip of the bucket reaches the desired depth, the bucket is then rotated backwards so that the bottom of the bucket is level with the ground. Using the forward motion of the tractor, the soil can be dug and scooped into the bucket. However, when digging in this manner, the bucket blocks the operator's view of the digging area and makes it difficult for the operator to judge the optimal cutting depth.
When using the front-end loader to grade or level soil, the rear edge of the bottom surface of the bucket may be placed on the ground and the bucket dragged backward to pull earth and soil behind the bucket. This method, however, has disadvantages because the design of conventional buckets does not allow for much soil to accumulate behind the bucket when used in this manner. Also, the rear surface of conventional buckets is not specifically designed and reinforced to provide for scraping and grading in this manner.
The front edge of the bucket may also be used for scraping and grading. The front-end loader may be raised and the bucket rotated forward so that the bottom of the bucket is essentially vertical and the front edge of the bucket is in contact with the ground. The front edge of the bucket may then be dragged backward to pull earth and soil behind the bucket to grade the surface. This method also has disadvantages because tremendous torque is placed on the bucket when it is dragged backward in this position, creating undue wear and tear on the hydraulic cylinders that control the rotation of the bucket. The front edge of the bucket is also not specifically designed and reinforced to provide for scraping and grading in this manner.
Although a front-end loader may be used to break up discrete amounts of soil, conventional front-end loaders are not capable of scarifying large amounts of soil. To break up discrete amounts of soil, the bucket may be rotated forward so that the bottom of the bucket is essentially vertical. The bucket can then be lowered to drive the front edge bucket into the ground and break up the soil. This procedure can be repeated with the vehicle moved incrementally to create a series of cuts in the ground. This procedure, however, is time consuming, ineffective for scarifying a large area of ground and utilizes the hydraulics of the front-end loader rather than the forward or backward motion of the vehicle to break up the soil. Conventional front-end loaders have no means for scarifying soil while the vehicle is in motion or for scarifying the ground parallel to the direction of travel of the vehicle.
The need for versatile implements capable of transporting material and also grading/scraping/scarifying has been recognized in the prior art. U.S. Pat. No. 5,172,499 issued to Griffin discloses a modified box scraper that is also capable of collecting, transporting and dumping soil or other bulk material. This implement, however, does not have the versatility or functional utility of a conventional loader. Also, collected material must be manually dumped by activating a lever that releases the bottom wall of the collection box. Thus, although the disclosed implement is apparently effective for conventional scraping and grading, it does not provide the recognized benefits and utility of a conventional loader.
The need for scarifying teeth in combination with other functional features of an implement is also recognized in the prior art. Box graters/scrapers with scarifying teeth are common implements for tractors. These implements are typically attached to the rear three-point hitch on a tractor and pulled behind the tractor to break up, grate and level soil and other surface material. U.S. Pat. No. 5,515,625 issued to Keigley also discloses a rake implement for use with a skid steer that also includes removable scarifying teeth behind the rake. As noted by Keigley, the scarifying teeth “permit deep penetration and scarifying of the earth while still permitting the tines comprising the rake blade to level and work the soil.” However, although the benefit of combining scarifying teeth with other functional features of a tractor or skid steer implement has been recognized, scarifying teeth have not been effectively utilized in combination with a conventional loader.
Accordingly, an object of the present invention is to provide a loader that is capable of more effectively digging, grading and scarifying surface material.
A further object of the present invention is to provide a loader that is less subject to undue wear and tear when used for digging, grading and scarifying surface material.
Yet another object of the present invention is to provide a grader blade component for a conventional loader that does not interfere with the normal operation of the loader.
An additional object of the present invention is to provide scarifying teeth for a conventional loader that do not interfere with the normal operation of the loader.
A still further object of the present invention is to provide a combination grader blade with scarifying teeth for a conventional loader that does not interfere with the normal operation of the loader.
Still another object of the present invention is to provide a grader blade, scarifying teeth, or a combination grader blade with scarifying teeth that may be added to an existing loader or other conventional implement that does not interfere with the normal operation of the implement.
Yet another object of the present invention is to provide an improved method for digging, grading, scraping and/or scarifying earth with a conventional front-end loader.
Finally, an object of the present invention is to provide a combination loader/grader/scraper that is economical to manufacture, durable and refined in appearance.
SUMMARY OF THE INVENTION
The preferred embodiment of the present invention provides a blade with scarifying teeth on the rear surface of a conventional loader bucket. By rolling the bucket backward, the rear blade can be placed in contact with or inserted into the ground. In this position, the rear blade can also be dragged backward for scraping and grading. By rolling the bucket further backward, the scarifying teeth can be made to engage the ground with the blade in contact with the surface of the ground. Thus, when the rear blade is dragged backward in this position, the scarifying teeth break up the soil in advance of the blade. In some embodiments of the present invention, the bucket may be rolled still further backward so that the scarifying teeth engage the ground with the blade raised from the ground. When dragged backward or pushed forward in this position, the scarifying teeth may be used to break up the ground without simultaneously grading or collecting the scarified ground.
The rear scraping and scarifying blade does not interfere with normal operation of the loader. When material is scooped into the bucket with the bottom of the loader level to the ground or titled forward, the rear blade does not engage the ground. When the loader is lifted and tilted backward when transporting material, and when the loader is dumped, the rear blade remains out of the way at the rear of the bucket. Thus, the rear blade does not obstruct movement or rotation of the loader bucket, and also does not interfere with material being collected or dumped from the bucket.
The preferred embodiment of the present invention offers the advantage of improving the grading and earth leveling capabilities of a conventional loader without interfering with the normal operation of the loader. This and other advantages will become apparent as this specification is read in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the improved material-handling bucket with scraper blade and scarifying teeth of the present invention.
FIG. 2 is a side view of the improved material-handling bucket of the present invention with the bucket placed on the ground.
FIG. 3 is a side view of the improved material-handling bucket of the present invention with the bucket rolled back to engage the blade with the ground for grading and leveling.
FIG. 4 is a side view of the improved material-handling bucket of the present invention with the bucket rolled back still further so that the scarifying teeth engage the ground.
FIG. 5 is a side view of the improved material-handling bucket of the present invention connected to a vehicle.
DETAILED DESCRIPTION
The present invention may be used with any vehicle having the means to raise and lower, and also rotate forward and backward, a material-handling bucket. Although the preferred embodiment of the present invention is intended for use as a front-end loader such as those mounted on the front or forward end of a tractor or skid steer, those of skill in the art will recognize that the present invention is equally adaptable for use with other types of loaders. For example, the present invention may be used with a loader mounted on the rear of a tractor. The present invention may also be used with loaders mounted on other vehicles including four wheelers and bulldozers. However, for descriptive purposes, the present invention will be described in use on a front-end loader.
FIG. 1 shows a material-handling bucket 10 of the present invention. The bucket 10 includes mounts 12 for pivotally attaching the bucket to vertically movable arms (not shown) about a pivot point. The arms are in turn connected to a tractor, skid steer or other vehicle (not shown) about another pivot point. The bucket 10 may be raised and lowered in relation to the vehicle by the vertically movable arms. By further means well known in the art, the bucket 10 may also be rolled forward and backward. The bucket is typically raised and lowered, and also rolled forward and backward, with hydraulic cylinders (not shown), although other means are well known in the art. Finally, the bucket 10 may be moved horizontally by movement of the vehicle to which it is attached, but other means for horizontal movement of the bucket 10 are also contemplated and within the scope of the present invention.
The bucket 10 includes a first side panel 20 , a second side panel 22 , a bottom panel 24 , an upper rear panel 26 and a lower rear panel 28 . The front edge 30 of the bucket 10 is also identified in FIG. 1 .
The bucket 10 of the present invention also includes a blade 32 mounted on the rear panel 26 . The blade 32 is preferably welded to the lower rear panel 28 and supported by upper braces 34 and lower braces 36 (shown in FIG. 2 ) welded to the blade 30 and the lower rear panel 28 . The blade 30 also includes a plurality of scarifying teeth 38 welded to the blade 32 .
Other means for attaching the blade 32 and scarifying teeth 38 to the bucket 10 will be readily apparent to those of skill in the art. For example, the blade may be bolted to supports attached to the bucket 10 , allowing the blade to be easily replaced if it should become worn or broken during use. The scarifying teeth may also be bolted in place so that they can be easily replaced either individually or as a set. The blade and teeth may also be connected to the bucket 10 by means of pins or other connectors that allow them to be easily interchanged with blades and/or teeth of different sizes or grades, as is well known in the art of tractor and skid steer implements.
The blade 32 may also be constructed so that it is integral with the bucket 10 . For example, the upper rear panel 26 could be extended beyond the joint 40 shown in FIGS. 2-4 to create a rear blade portion that extends from the rear of the bucket 10 . Such an extension of upper rear panel 26 , or other extensions or modifications to the components of bucket 10 , would be within the scope of the present invention and readily apparent to those of skill in the art.
As shown in FIG. 2 , the blade 32 and scarifying teeth 38 do not engage the ground 42 when the bottom 24 of the bucket 10 is placed on the ground 42 . In this position, the bucket 10 may be moved forward to collect material in the bucket 10 . The bucket may then be lifted from the ground 42 for transport of the material, and the material dumped from the bucket 10 , all without interference or obstruction from the blade 32 and scarifying teeth 38 .
As shown in FIG. 3 , the bucket 10 may be rolled backward slightly so that the blade 32 contacts the ground 42 but the bottom panel 24 of the bucket 10 does not contact the ground 42 . Although the blade 32 is in contact with the ground 42 , the scarifying teeth 38 do not engage the ground 42 . In this position, the bucket 10 and blade 32 may be pulled backward by the vehicle to grade and level the ground 42 with the blade 32 . The blade 32 may also be lowered into the ground 42 in this position and pulled backward to dig into the ground 42 .
As shown in FIG. 4 , the bucket 10 may be rolled backward still further so that the blade 32 contacts the ground 42 and the scarifying teeth 38 engage the ground 42 . In this position, the bucket 10 and blade 32 may be pulled backward by the vehicle so that the scarifying teeth 38 break up the ground 42 in advance of the blade 32 .
Depending upon the means by which the bucket 10 is attached to a vehicle, the bucket 10 may be rolled backward even further when used with some vehicles so that the scarifying teeth 38 engage the ground 42 but the blade 32 is raised from the ground. In this position, the scarifying teeth 38 may be used to break up the ground without simultaneously grading or collecting the scarified ground. The vehicle may then easily collect the scarified ground in the bucket 10 on a return pass.
The inventors contemplate several modifications that may be made to the preferred embodiment of the present invention that fall within the scope of the invention. For example, the blade 32 may be implemented and used without scarifying teeth 38 . The scarifying teeth 38 may also be used according to the present invention without the blade 32 . It is contemplated that the scarifying teeth 38 may be connected directly to the bucket 10 by any number of means known to those of skill in the art. In this embodiment, the scarifying teeth 38 would remain effective for breaking up earth and soil with a loader or other implement.
FIG.5 . shows a material-handling bucket of the present invention. The bucket includes mounts for pivotally attaching the bucket to vertically movable arms 44 about a pivot point. The arms are in turn connected to a tractor, skid steer or other vehicle 46 about another pivot point. The bucket may be raised and lowered in relation to the vehicle by the vertically movable arms. By further means well known in the art, the bucket may also be rolled forward and backward. The bucket is typically raised and lowered, and also rolled forward and backward, with hydraulic cylinders 48 , although other means are well know in the art. Finally, the bucket may be moved horizontally by movement of the vehicle to which it is attached, but other means for horizontal movement of the bucket are also contemplated and within the scope of the present invention.
It is further contemplated that the rear blade of the present invention may be used in connection with other farm, construction and landscaping implements. For example, the rear blade of the present invention could be attached to the rear of a dozer blade so that, when the dozer blade is raised and rotated backward, the rear blade, with or without scarifying teeth, could be placed in contact with the ground. In this position, the rear blade could be dragged backwards to grade and level ground. The rear blade with scarifying teeth could be dragged backwards to break up and scarify the ground. Then, when the dozer blade is rotated forward and lowered, the scarified ground could be dozed. The rear blade of the present invention would thus be a useful addition to almost any implement that can be raised and lowered, and also rolled forward and backward.
Other alterations, variations, and combinations are possible that fall within the scope of the present invention. Although the preferred embodiment of the present invention has been described, those skilled in the art will recognize other modifications that may be made that would nonetheless fall within the scope of the present invention. Therefore, the present invention should not be limited to the apparatus and method described. Instead, the scope of the present invention should be consistent with the invention claimed below.
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A material-handling bucket which includes a blade with scarifying teeth on the rear of the bucket. By raising the bucket and rolling the bucket backward, the blade and teeth can be made to engage the ground to provide grading and scarifying capabilities for a conventional loader bucket. The blade and scarifying teeth, however, do not interfere with the normal loading operations of the bucket.
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This application claims the benefit of U.S. Provisional Application Serial No. 60/121,345, filed Feb. 24, 1999, entitled Method and Apparatus for Determining Potential Interfacial Severity for a Formation.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to computer implemented processes for improving drilling operations, and in particular to a system and method for facilitating the selection and use of drill bits by anticipating or predicting the potential occurrence of undesirable geographic conditions.
2. Description of the Prior Art
Interfacial severity is an undesirable geologic condition which impedes drilling operations. In general, drilling operations are performed in a manner which compensate for the occurrence of interfacial severity. One factor which can be controlled is the selection of particular drill bits from a group of available drill bits. Certain bits may operate better under high interfacial severity drilling conditions, while other bits are more prone to damage under high interfacial severity drilling conditions.
SUMMARY OF THE INVENTION
It is one objective of the present invention to provide a new system, method, and apparatus for providing an indicator of potential interfacial severity in a particular wellbore, which utilizes an inference engine computer program which consists of executable instructions, and which is adapted to utilize a plurality of wellbore parameters as inputs, and which produces an indicator of potential interfacial severity. It is another objective of the present invention to provide such an indicator which may be utilized in selecting particular drill bits for use in a particular wellbore.
These and other objectives are achieved as is now described. A method and apparatus are provided for generating an indicator of potential for abrupt changes in rock strength in a particular wellbore. Forensic wellbore data is obtained from at least one previously drilled wellbore which is determined to be comparable to the target wellbore. An interfacial severity computer program is provided. The program consists of executable program instructions. It is adapted to utilize a plurality of wellbore parameters, including at least one forensic wellbore data element. The interfacial severity computer program is loaded onto a data processing system. At least the forensic wellbore data, and possibly other wellbore parameter data elements, are supplied as an input to the interfacial severity computer program. The data processing system is utilized to execute program instructions of the interfacial severity computer program. This applies the inputs to the interfacial severity computer program which produces as an output an indicator of the potential for abrupt changes in rock strength in the particular target wellbore.
The above as well as additional objectives, features, and advantages will become apparent in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of the preferred embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a simplified pictorial representation of drilling operations which may be conducted in accordance with the present invention.
FIG. 2 is a block diagram representation of the general operations performed in the computer program in accordance with the preferred embodiment of the present invention.
FIG. 3 is a pictorial representation of a data processing system.
FIG. 4 is a flowchart representation of the data processing implemented steps of the preferred embodiment of the present invention.
FIG. 5 is a graphical representation of a beta test of the computer program of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
OVERVIEW OF DRILLING OPERATIONS:
FIG. 1 depicts one example of drilling operations conducted in accordance with the present invention with a downhole drill bit selected in accordance with the present invention based upon its suitability for the drilling conditions based at least in part upon its compatibility to a projected or anticipated potential interfacial severity as determined by an interfacial severity.
As is shown, a conventional rig 3 includes a derrick 5 , derrick floor 7 , draw works 9 , hook 11 , swivel 13 , kelly joint 15 , and rotary table 17 . A drillstring 19 which includes drill pipe section 21 and drill collar section 23 extends downward from rig 3 into wellbore 1 . Drill collar section 23 preferably includes a number of tubular drill collar members which connect together, including a measurement-while-drilling logging subassembly and cooperating mud pulse telemetry data transmission subassembly, which are collectively referred to hereinafter as “measurement and communication system 25 ”.
During drilling operations, drilling fluid is circulated from mud pit 27 through mud pump 29 , through a desurger 31 , and through mud supply line 33 into swivel 13 . The drilling mud flows through the kelly joint and an axial central bore in the drillstring. Eventually, it exits through jets which are located in downhole drill bit 26 which is connected to the lowermost portion of measurement and communication system 25 . The drilling mud flows back up through the annular space between the outer surface of the drillstring and the inner surface of wellbore 1 , to be circulated to the surface where it is returned to mud pit 27 through mud return line 35 . A shaker screen (which is not shown) separates formation cuttings from the drilling mud before it returns to mud pit 27 .
Preferably, measurement and communication system 25 utilizes a mud pulse telemetry technique to communicate data from a downhole location to the surface while drilling operations take place. To receive data at the surface, transducer 37 is provided in communication with mud supply line 33 . This transducer generates electrical signals in response to drilling mud pressure variations. These electrical signals are transmitted by a surface conductor 39 to a surface electronic processing system 41 , which is preferably a data processing system with a central processing unit for executing program instructions, and for responding to user commands entered through either a keyboard or a graphical pointing device.
The mud pulse telemetry system is provided for communicating data to the surface concerning numerous downhole conditions sensed by well logging transducers or measurement systems that are ordinarily located within measurement and communication system 25 . Mud pulses that define the data propagated to the surface are produced by equipment which is located within measurement and communication system 25 . Such equipment typically comprises a pressure pulse generator operating under control of electronics contained in an instrument housing to allow drilling mud to vent through an orifice extending through the drill collar wall. Each time the pressure pulse generator causes such venting, a negative pressure pulse is transmitted to be received by surface transducer 37 . An alternative conventional arrangement generates and transmits positive pressure pulses. As is conventional, the circulating mud provides a source of energy for a turbine-driven generator subassembly which is located within measurement and communication system 25 . The turbine-driven generator generates electrical power for the pressure pulse generator and for various circuits including those circuits which form the operational components of the measurement-while-drilling tools. As an alternative or supplemental source of electrical power, batteries may be provided, particularly as a back-up for the turbine-driven generator.
FIG. 2 is a block diagram pictorial representation of the broad concept of the present invention. As is shown, an inference engine 101 produces as an output 103 an 24 indicator of potential interfacial severity. Input 105 is provided to the inference engine 101 . In the preferred embodiment of the present invention, unconfined compressive strength forensic log data from offset wells is provided as one input. These wells are located proximate to the target well, and likely traverse geologic formations at particular depths. The target well is expected to traverse the same types of formations at generally the same types of depths. Therefore, the offset wells provide a good indication of the lithology that is going to be drilled in the target well. In the preferred embodiment of the present invention, this data is used in the planning stages of the target wellbore in order to select the types of bits which are more suitable for particular drilling conditions which have a greater suitability for anticipated interfacial severity conditions. In other words, the inference engine 101 is utilized in well planning operations in order to select particular bits which might perform better under projected conditions.
As is shown in the view of FIG. 2, the inference engine 101 includes a predetermined series of operations. In accordance with step 107 , the log data is prepared. This is done by generating values for particular depth increments (preferably one-half foot increments). In other words, the analog log data of unconfined compressive strength is digitized so that the log data is represented by a data array with each data element representing a value for a one-half foot (or other predetermined) section of depth. Next, in accordance with step 109 , the RMS value of unconfined compressive strength is calculated. Then, in accordance with step 111 , the average unconfined compressive strength is calculated. Then, in accordance with block 113 , the frequency of change is calculated. All of these calculations (for steps 109 , 111 , 113 ) are done for each ten foot window of log data. In other words, twenty data elements are utilized to generate a ten foot window of log data. This information is supplied to the algorithm, in accordance with block 115 , and the algorithm generates an interfacial severity index in accordance with step 117 . The interfacial severity 103 is supplied as an output from inference engine 101 .
The inference engine 101 of FIG. 2 is preferably constructed utilizing executable program instructions. Preferably, the program instructions are executed by a general purpose data processing system, such as that depicted in FIG. 3 .
With reference now to the figures and in particular with reference to FIG. 3, there is depicted a pictorial representation of data processing system 41 which may be programmed in accordance with the present invention. As may be seen, data processing system 41 includes processor 12 which preferably includes a graphics processor, memory device and central processor (not shown). Coupled to processor 12 is video display 14 which may be implemented utilizing either a color or monochromatic monitor, in a manner well known in the art. Also coupled to processor 12 is keyboard 16 . Keyboard 16 preferably comprises a standard computer keyboard which is coupled to the processor by means of cable 18 .
Also coupled to processor 12 is a graphical pointing device, such as mouse 20 . Mouse 20 is coupled to processor 12 , in a manner well known in the art, via cable 22 . As is shown, mouse 20 may include left button 24 , and right button 26 , each of which may be depressed, or “clicked”, to provide command and control signals to data processing system 41 . While the disclosed embodiment of the present invention utilizes a mouse, those skilled in the art will appreciate that any graphical pointing device such as a light pen or touch sensitive screen may be utilized to implement the method and apparatus of the present invention. Upon reference to the foregoing, those skilled in the art will appreciate that data processing system 41 may be implemented utilizing a so-called personal computer.
In accordance with the preferred embodiment of the present invention, the inference engine 101 (of FIG. 2) is constructed of executable instructions which are executed by a data processing system 41 . What follows is a discussion of interfacial severity, the interfacial severity index which is generated in accordance with the present invention, a discussion of application of the interfacial severity index to one test well, and a discussion of the contents of the computer implemented inference engine 101 of FIG. 2 .
INTERFACIAL SEVERITY
Rocks in the earth are generally oriented in layers. Damage may occur to a rock bit when it drills across an interface, from a rock layer of one strength into a rock layer of another strength. For example when a bit drills from a weak rock layer into a strong rock layer, there are instances in which the leading portion of the bit is drilling the strong layer while the trailing portion of the bit is still drilling the soft rock. In this instance, the majority of the bit weight (the force applied to the bit to cause it to drill) may be concentrated on the few cutters which are in the hard rock. Similar overloading of cutters may occur when drilling from a hard into a soft rock. Also, the rate of penetration (ROP) of bits is typically higher in soft rocks than in hard rocks. If a bit is drilling at a high ROP through soft rock encounters a hard interface, the cutters on the leading portions of the bit must also assume the job of decelerating the drill string. Finally, drilling from one layer into another can aggravate adverse bit dynamics and cause cutter damage. The severity of these changes in rock interface depends on the magnitude of the change from one interface to the next and the frequency with which new rock interfaces are encountered. The magnitude of the challenge that changes in rock interfaces pose to a bit is called “interfacial severity.” Colloquially, formations which have a high interfacial severity are said to be “atty.”
The goal of this work was to provide an index that ranges from “0” to “1” and that corresponds to the interfacial severity of a given formation. This index was to be derived from wire line data that is readily available.
An interfacial severity of “0” would correspond to no interfacial severity (a homogeneous rock) and “1” to a very severe interfacial severity. Values above 0.5 would be deemed to be problematic.
METHOD EMPLOYED IN DEVELOPING AN INTERFACIAL SEVERITY INDEX
The way that we have quantified interfacial severity, in this first embodiment, does not represent simply the magnitude of the change from one rock strata to the next. The interfacial severity index for a given depth is a measure of how much change there is in rock strength between the depth of interest and rocks nearby. That is, not defined at a point, but over an interval.
Conceptually there are at least three factors which must be considered when quantifying the interfacial severity index over an interval. An obvious factor is the relative magnitude of the change in rock strength from one stratum to the next. Large relative changes in strength are worse than small ones. A second factor is the magnitude of rock strength of the each of the rocks forming an interface. If the rock strength of both rocks is very low, then changes in rock strength are of little consequence, even though the percentage change across the interface might be high. It is only when the rock strength is high in at least one of the interfaces that interfacial severity becomes an issue. Finally, the frequency with which the changes occur over an interval is also a factor in determining the magnitude of the interfacial severity.
The algorithm of the preferred embodiment quantifies interfacial severity as follows. At every depth, a window of investigation ten feet in length is defined (five feet before the depth and five feet ahead of the depth). Each of the factors described above could be quantified in a multitude of ways. We have chosen to quantify them as follows. First, measure of the amount of change in rock strength is obtained by computing the RMS average (the “root mean square” value) of all the rock strengths in the window. Second, a measure of the magnitude of the rock strength in the window is determined by averaging all of the rock strengths in the window. Finally, measure of the frequency with which the rock strength changes is determined by summing the magnitude of all instances of change in rock strength, in which the change crosses a line defined by the average rock strength (number of times the strength signal curve goes from positive to negative or vise versa). This last term is referred to as “SSCD,” which stands for Sum of the Sign Change Deltas. All of these terms have units of rock strength (psi in this case).
These three terms are then combined simply by multiplying them together and dividing by a large constant. The constant is a scaling factor; its magnitude is chosen such that rocks which are known to be “ratty,” have an index of 0.5 or larger.
(Avg UCS)*(RMS Average of UCS)*(SSCD)/ 30 × 10 11
CREATION OF 10′ WINDOW WITH 0.5 FOOT INCREMENTS:
The subroutine needs data in 0.5 foot increments. Before it does anything, it calls a subroutine which extracts a 10′ window of data around the depth of interest and converts the data into 0.5 foot increments if necessary.
EXAMPLE WELL BAKER HUGHES EXPERIMENTAL TEST AREA (RETA), BEGGS OKLAHOMA:
The program of the present invention was run on BETA data as an example on logs taken from the BETA test site. The graph of FIG. 5 shows the resulting interfacial severity index for 2500 to 3050 feet depth. The lithology is shown in the top track. The bottom track shows the interfacial severity index. Note, for example, that in the Woodford Shale from 2580′ to 2650′, the interfacial severity is essentially zero. In this region the overall rock strength and the changes in rock strength is relatively low. However, between about 2650 and 2670 several short and hard stringers in the Misener Sandstone, Viola Limestone and Viola Dolomite leading into the Wilcox Sandstone. There are significant changes in unconfined compressive strength through this section which come in rapid succession. The interfacial severity index rises dramatically and reaches the maximum of 1. The interfacial severity through the Wilcox itself, from about 2670 to 2760 is generally moderate. The interfacial severity rises to high values again between about 3030 and 3050 feet in the Arbuckle Dolomite.
FIG. 4 is a flowchart representation of the computer executable instructions which compose the preferred embodiment of the present invention. Two inputs are provided to the computer program including inputs 201 , 203 . Input 201 is the target depth at which the index is desired. Input 203 is a list of the unconfined compressive strength in the depth range of interest. These inputs are provided to software block 205 , which extracts a window of unconfined compressive strength values from five feet shallower to five feet deeper than the target depth. After the ten foot window is constructed, control passes to block 207 , wherein the program calculates the average unconfined compressive strength for that interval, the root mean square average of the unconfined compressive strength for that interval, and the frequency of change (the SSCD) of the unconfined compressive strength. Next, control passes to block 209 , wherein the interfacial severity index is calculated as a function of the average, the root mean square average, and the frequency of change. In accordance with block 211 , the interfacial severity index is provided as an output at block 211 .
Although the invention has been described with reference to a particular embodiment, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended clams will cover any such modifications or embodiments that fall within the scope of the invention.
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A method and apparatus are provided for generating an indicator of potential for abrupt changes in rock strength in a particular wellbore. Forensic wellbore data is obtained from at least one previously drilled wellbore which is determined to be comparable to the target wellbore. An interfacial severity computer program is provided. The program consists of executable program instructions. It is adapted to utilize a plurality of wellbore parameters, including at least one forensic wellbore data element. The interfacial severity computer program is loaded onto a data processing system. At least the forensic wellbore data, and possibly other wellbore parameter data elements, are supplied as an input to the interfacial severity computer program. The data processing system is utilized to execute program instructions of the interfacial severity computer program. This applies the inputs to the interfacial severity computer program which produces an output and indicator of the potential for abrupt changes in rock strength in the particular target wellbore.
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BACKGROUND AND DISCUSSION OF THE INVENTION
The invention relates to an apparatus for disengaging a normally-engaged, spring-loaded clutch to assist a vehicle operator in actuating a lever, linkage or similar mechanism to disengage the clutch against the action of the spring.
Friction clutches are often used for engaging and disengaging a vehicle engine from its transmission, and such clutches are usually of the spring-loaded, normally-engaged type in which a compression spring biases a driven clutch member into engagement with the drive clutch member. These clutch members are capable of transmitting substantial torque loads particularly when used on heavy vehicles such as trucks or tractors. Since the torque on these vehicles is quite high, the springs employed for engaging the clutch must have a high compression strength to obtain sufficient pressure between the drive and the driven members to prevent slippage. It is desirable then that the compression springs be a substantially greater force than any opposing force or forces to create a more effective clutch engagement for transmitting the torque.
However, there are countervailing considerations in connection with the magnitude of the spring force employed for biasing the clutch members together. To disengage a spring-loaded clutch the biasing action of the engaging springs must be overcome, and thus the magnitude of any spring force employed for this purpose should be limited to near the force it takes to disengage the clutch mechanism. For a disengaging operation the operator usually moves a foot pedal or hand lever connected through a linkage to the clutch members to overcome the action of the spring. Upon release of this lever the clutch reverts to its normal engaged position under the action of the springs. When an operator moves the clutch-operating lever to disengage the clutch by overcoming the force of the engaging springs he must hold the clutch lever in this disengaged position during the change in gear shift ratio and until the clutch is to be reengaged. This operation can be performed a multitude of times particularly in driving in city traffic or other similar traffic where many stops and starts are required. As a result an operator expends a considerable time and effort in physically overcoming the high compression of the clutch springs.
To relieve the operator of this burden many devices have been employed to allow the use of engaging springs of greater force and still permit the operator to easily and conveniently overcome the biasing action of such springs. These devices have been called assisting or boosting devices and are characterized by, for example, an over-center spring mechanism which is a tension spring having one end pivotally attached to a pivotally-mounted, actuating lever and having its other end pivotally attached to a fixed support. A specific example of an over-center spring mechanism is shown in U.S. Pat. No. 1,927,643. In this patent the spring is adapted to operate over the center line which lies through the rotational axis of the lever and the pivotal attachment of the springs to the support where the spring urges the lever to rotate in a direction to disengage the clutch when it is on one side of the center line and in opposition to the rotational urging force on the lever caused by the clutch engaging springs. The force produced in this manner on the lever is the product of tension force developed by the spring multiplied by its effective moment arm which is the length of the line perpendicular to the rotational axis of the lever and perpendicular to the direction of the tension force. Thus, the spring becomes increasingly more effective as the lever is moved further and further towards its clutch disengaged position since the effective moment arm becomes greater.
A problem with these devices is that a substantial lever movement is required before the spring reaches the position where it is effective in substantially assisting the operator in releasing the clutch. Another problem with these types of springs lies in controlling the amount of biasing caused by the increased moment during actuation of the lever. It is undesirable that the force rotating the lever should ever reach a value greater than the biasing action of the clutch engaging springs since the clutch will not return to its original position when the lever is deactivated. As a result, care must be taken in effecting the relationship between the spring and the position of the lever to assure that the biasing force never reaches a value greater than that of the clutch engaging springs.
On approach in solving this problem has been a spring and piston assisting device as shown in the U.S. Pat. No. 3,187,867 to Sink which relates to an assist device used to rotate a clutch actuating lever to disengage a normally-engaged, spring-loaded clutch. The assist device includes a cylindrical casing with an actuating rod for reciprocal movement within the casing. An exposed portion of the rod extending from one end of the casing is engaged with a linkage for actuating the clutch, and the cylinder casing is rotatably attached at another end to a stationary support. A spring located at one end of the cylinder within the casing engages a bushing which in turn is pressed against a flange of the casing. The other end of the spring engages a bushing which in the normal position engages balls resting in peripherally-spaced grooves formed in the casing. The rod also includes complementary grooves about its outer surface which in a normal position are laterally displaced from the grooves in the cylinder. However, upon actuation of the clutch mechanism the rod or shaft will be pressed inwardly relative to the cylinder such that the grooves in the rod will eventually register with the grooves in the cylinder casing. At this registered position the spring acting on the bushing transmits force through the balls and shaft thereby imparting an assist force to the operator actuating the system.
This system also suffers from deficiencies in that the balls and grooves for transmitting the force require close tolerances to insure that the spring force is properly transmitted to the shaft for providing the assistance needed to actuate the clutch.
The assist mechanism of the present invention overcomes many of the problems of complexity, expense and unreliability which have characterized assist mechanisms of the past. In one embodiment of the invention the mechanism includes a housing which is fixed relative to a rotatable clutch release shaft which is in turn keyed to a yoke for driving a clutch member away from an engaged position. Within the housing there is a sector splined to the clutch release shaft to produce rotation of the shaft and ultimately rotation of the yoke. Engaged with this sector is a rack which provides input for operator pedal effort and is spring-loaded to produce the assist force to the input. A portion of the rack extends beyond the housing for engagement with the linkage to a pedal within the cab or other actuating mechanism to move the clutch assist mechanism. A "free-travel" mechanism within the housing provides for a degree of unassisted relative movement by the rack with respect to the housing when the rack is actuated through the clutch-actuating linkage. Upon traversing the "free-travel" extent of rack movement, the rack will overcome the "free-travel" mechanism and permit the spring within the housing to assist in driving the rack relative to the housing toward a clutch-disengaged position. This rack movement is transmitted into rotational movement through the sector to complete the disengagement of the clutch.
In one embodiment of the invention the "free-travel" is achieved through a piston-cylinder arrangement where the assist spring is engaged with the piston for providing the assisting force during movement toward a clutch disengaged position. The piston, however, is constrained from movement by interaction of balls with grooves in the cylinder walls until the piston is released by action of a rack after "free-travel" movement is completed. During the "free-travel" portion of the rack traverse, the rack movement is relative to the stationary piston. During movement toward the clutch disengaged position after an initial "free" travel, grooves in the rack register with the balls. In this position the balls engage rack recesses to provide a means for permitting the assist spring to operate on the rack.
In another embodiment of the invention the "free-travel" is achieved through a piston-cylinder arrangement integrated with a detent mechanism to provide for a "free-travel" movement before the assist spring is actuated. The piston is constrained from movement by the interaction of a spring-loaded poppet ball until release by action of the rack after "free-travel" portion of rack movement has been traversed. On a portion of the rack entending through the piston, blocking members are spaced apart on either side of the piston a distance equivalent to the length of "free-travel". During movement toward a clutch disengaged position one of the blocking members can engage the piston after an initial "free-travel" and release the detent mechanism for permitting the assist spring to operate on the rack in a manner similar to that of the first embodiment discussed above.
The provision of unassisted initial or "free-travel", allows the operator to "feel" the necessary "free-travel" between the clutch release yoke and the release bearing. This is required to determine if the clutch needs adjusting, since as the driven members wear, the release bearing moves toward the fly wheel. Thus, loss of free travel is indicative of clutch wear and serves to readily determine means for assuring that clutch is properly adjusted. In cases of clutches with internal self-adjusting mechanisms, maintenance of free travel assures that the self-adjustor is working properly.
The invention provides the ability to tailor the device, maximize control and avoid unreasonably high pedal efforts or excessive, larger pedal travel which produces operator fatigue and discomfort. The timing of the application and the amount of the bias is a function of, among other factors, the positioning of the rack "free-travel" mechanism and housing stop mechanisms, the size of the rack and sector, and the amount of force and rate of the assist spring. Another advantage which results from the invention is the diminishing of the assist force of the spring during rack movement as disengagement is continued. Some popular types of heavy duty, pull-type clutches exhibit release bearing load curves which rise to a maximum value during initial release, and thereafter diminish until full release is achieved. In the present invention as the assist spring extends with rack translation, the amount of assist force diminshes which may produce a nearly constant, comfortable pedal effort from engaged to release or disengaged positions. On clutches having increasing bearing loads with increasing release travel, increasing pedal efforts could be reduced. Staging of stiff springs would also be possible to overcome the increased pedal effort required.
In the case of full power hydraulic and pneumatic arrangements such "feel" as discussed above in connection with the invention is difficult to obtain and often requires the addition of detenting devices within the control valving system. However, this is to be distinguished from a full hydraulic arrangement where the operator's input energy to the pedal creates the energy to displace the fluid and release the clutch as opposed to an engine driven pump. In the former system there is little loss of "feel". Rather, the amount of input effort is proportional to the amount of resistance at the output.
Other advantages are afforded by the self containment of the mechanism of the present invention. Not only is clutch disengagement facilitated by eliminating the need for substantial anchorage and securing means associated with the over-the-center-spring designs, but the unit of the present invention also safely contains the spring mechanism to avoid injury. The unit is sealed and lubricated, protecting the more critical components against a rather harsh track and road environment. In the event the assist spring should fail the mechanism would fail safe since the clutch could still be released, although with substantially more effort, and secondary damage would be minimal. The use of a rack and sector to gain additional mechanical advantage and the use of a coiled spring configuration compacts the design of the invention, and allows the use of a high reliability spring with excellent fatigue strength. The combination of external pressure and high stress has often been a problem with leaf spring-assist mechanisms.
Other advantages of the invention will become more apparent from a discussion of the preferred embodiments which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a clutch release mechanism of the invention.
FIG. 2 is a cross-sectional view of the release mechanism shown in FIG. 1 taken along line 2--2.
FIG. 2A is a clutch activated by the release mechanism of FIG. 2.
FIG. 3 is a cross-sectional view of the release mechanism shown in FIG. 2 taken along line 3--3.
FIG. 4 is a cross-sectional view of another embodiment of the invention.
FIG. 5 is a cross-sectional view of the embodiment of FIG. 4 taken along line 5--5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be seen in FIG. 2A, a clutch mechanism 10 is spring-loaded to maintain engagement between clutch plates 12 to transfer torque between the engine and the shaft 16 of the drive train not shown in this figure. The clutch serves to engage and disengage drive member 14 which is connected to the engine and a driven member or shaft 16 which is connected to the drive train for transferring the torque from the engine ultimately to the wheels. For actuating the clutch plates from an engaged to a disengaged position a linkage connects a pedal within the vehicle cab (not shown) to pressure plate 20 of driven member 16. A clutch fork 22 is engaged with a thrust bearing 21 for moving pressure plate 20 to the desired disengaged position, and is mounted for angular movement with clutch release shaft 24 which forms part of the clutch assist assembly 26 shown generally in FIG. 1.
The assist assembly 26 is integrated with the lever 18 to aid the operator in disengaging the pressure plate 20 from the drive member 14 typically to change gear ratios in the transmission. More specifically, the clutch-assist assembly includes a housing 28 in which are found several elements to assist the operator in disengaging the clutch. The housing 28 is journalled onto clutch release shaft 24 by a journal 30 which circumscribes the shaft 24 and allows the shaft to move rotationally independently of the housing. The clutch release shaft 24 has a spine portion 33 about which journal 30 is rotatably fixed. A sector 32 which is a plate member having a circular cutout portion 34 with splines 36 is fixedly secured with splines 33 of shaft 24 for rotation with shaft 24. A portion 38 of sector 32, remote from the circular cutout portion 34, includes an arcuate portion 40 with teeth 43 for engaging rack 42 which moves along a linear path in the lower part of housing 28. The series of spline gear teeth 43 are equally spaced on arcuate portion 40 for engaging complementary gear teeth 44 upstanding in the rack 42. In this way the linear motion of rack 42 is transferred to rotational motion of the clutch release shaft 24 through the sector 32. The arcuate portion 40 of sector 32 in conjunction with the movement of rack 42 is sufficient to provide for rotational movement through at least a 16° arc. This movement of sector 32 is completely within the housing and is sufficient to disengage the clutch.
It is by the movement of rack 42 that the assist mechanism eventually provides additional bias to enable the operator to disengage clutch plates 12 more readily. For this purpose, rack 42 has an exposed portion 46 at one end, and another end 48 of the rack is engaged by the force of a spring within housing 28. A "free-travel" mechanism 100 is integrated with the end 48 of the rack to provide for rack movement over a portion of the path without the assist force of the spring being imparted to the rack. Upon subsequent movement, however, the "free-travel" mechanism is actuated thereby permitting the force of the spring to be imparted to the rack and to assist movement of the rack toward a position of clutch disengagement.
"Free-travel" mechanism 100 includes a piston 102 arranged within cylinder 104 for relative movement therein along a generally linear path corresponding to the path of rack movement. Spherical bearings or balls 106 and 106' are carried within ball cylinders 107 and 107' of piston 102 and can be moved in the annular space between the rack 42 and cylinder 104 under certain conditions. These bearings cooperate with other elements of the mechanism to provide the "free-travel" described above and transmit assist-spring force to the rack after the "free-travel" path has been traversed. For this dual function there is provided a cylinder groove 108 which completely circumscribes the internal surface of cylinder 104 and extends radially, transversely to the path of movement of rack 42. The groove 108 is sufficiently deep that it can accommodate the bearings 106 and 106' in the opposed relationship as shown in FIG. 2 such that the force imparted upon the piston 102 by the spring 114 will be directed, through the bearings when in groove 108, to the cylinder wall. Rack 42 defines opposed recesses 110 and 110' for receiving bearings 106 and 106' when the recesses are registered with groove 108. As with the groove 108, recesses 110 and 110' are configured to accommodate the bearings such that the force imparted upon piston 102 by spring 114 will be directed, through the bearings when located in the recesses, to the rack and at least in part in the direction of clutch disengagement. The bearing movement with the piston is a function at least in part of the bearing size, annular space dimension around rack 42 inside of cylinder 104, and the groove and recess configuration. Each bearing has a diameter greater than the radial dimension of the annular space between the rack and the inner wall of the cylinder such that in normal circumstances the bearings simply cannot fit in the annular space. The recesses and groove however are configured to receive a sufficient portion of each bearing such that the remaining portion of a bearing is less than the radial dimension of the annular space to permit rack movement within cylinder 104 when bearings 106 and 106' are in recesses 110 and 110' or groove 108. With this configuration the piston is controlled by the location of the bearings with respect to the groove and recess.
When the bearings are located in groove 108 initial travel of the rack relative to the bearings 106 and 106' is permitted. However, when the rack recesses register with these bearings in groove 108 the bearings will move into recesses 110 and 110' by riding out of groove 108 due to the action of the piston, and thereby allow the force imparted to the bearings by spring 114 to be transferred to the rack 42 rather than the cylinder walls. During further movement in this condition the bearings will move with the rack 42 toward the clutch disengaged position, along with the piston 102.
The assist spring 114 under the normal condition prior to actuation by the operator is maintained in a compressed disposition between cap 116 at an end of cylinder 104 remote from the housing 28. A portion of the piston 102 is configured to maintain the spring in a proper seated disposition against a face of the piston to insure that the force of the assist spring 114 is not otherwise impaired by improper arrangement of the spring. Piston 102 includes a protruding center portion 118 which is circumscribed by spring 114 and an annular flange portion extending radially toward the cylinder wall to define a spring seat 120 against which the assist spring 114 seats or presses. The end of rack 42 includes an extended rod portion 122 of a diameter smaller than the remainder of the rack for extension through a hole 123 in the center of the piston and toward end cap 116 as can be seen in FIG. 2. The innermost portion 115 of piston 102 engages shoulder 117 formed by rack portion 122 being of smaller diameter.
A helical secondary spring 124 circumscribes the extended rod portion 122 and is maintained in a compressed state between the face of the protruding center portion 118, piston 102 and a spring retainer 128 on the end of the rack. With secondary spring 124 in the compressed disposition the rack is biased toward a clutch engaged position, i.e., toward the right when the mechanism is viewed as it is shown in FIG. 2. The secondary spring 124 provides a lesser force than primary assist spring 114 when under compression, and is readily overcome by operator pedal effort which moves rack 42 out of housing with lever 18 when the latter is moved to the left by the operator for clutch disengagement. Because of the action of secondary spring 124, rack 42 will revert to its starting position adjacent piston 102 upon clutch pedal release and clutch engagement.
To insure the proper positioning of the recess 110 relative to the ball bearings 106 and 106' it is desirable to maintain the rack in a fixed orientation relative to the longitudinal axis of the piston and cylinder. This is accomplished through a mechanism for allowing the longitudinal movement of the rack relative to the cylinder while preventing relative rotational movement. For this purpose the rack is provided with the longitudinal slot 134 into which extends a fixed rack pin 130 mounted on the wall of housing 28. The effective diameter of pin 130 is slightly smaller than the width of the slot, and the pin is displaced from the bottom of the slot such that there can be relative longitudinal movement between the rack and cylinder while relative rotational movement is prevented. Similarly, to maintain proper piston orientation, the piston 102 also carries a piston pin 132 which extends into slot 134. As a result of this configuration ball bearings 106 and 106' as carried by the piston will always be in the correct orientation relative to the recesses on the shaft.
In operation, when it is desired to change gear ratios, the clutch pedal or other similar linkage mechanisms will be depressed or otherwise operated by the operator in the cab. (The pedal and its associated mechanism is not shown in the drawings.) This depression through the linkage mechanism connected to the exposed portion 46 of rack 42 will effect rack movement to the left as shown in FIG. 2 to initiate movement of the clutch mechanism. In this initial movement ball bearings 106 and 106' are in engagement with cylinder 104, and consequently the force imposed by the spring 114 on piston 102 is transferred through the ball bearings to the cylinder wall. Even though force is imposed on the rack by operator actuation the piston will not be moved, but rather the rack will be moved relative to balls 106 and 106' when sufficient force is applied to overcome the action of secondary spring 124. This "free-travel", i.e., unassisted rack movement, occurs until the recesses 110 and 110' register with the ball bearings 106, 106' in groove 108. Once this position is reached the ball bearings 106 and 106' will move radially inwardly out of groove 108 and into the recesses 110 and 110'. As a result of this radial movement by the ball bearings the force transmitted by assist spring 114 will then be directed to the rack rather than the wall of the stationary cylinder. Consequently, further depression of the clutch pedal by the operator will be assisted by the action of assist spring 114 on the rack. More specifically the assist spring by acting on the piston 102 presses against the bearings in recesses 110 and 110' which transfers the force of the spring to the rack and provide an assist force to the operator in moving the clutch to a disengaged position.
Upon return to the normal position when the clutch is engaged, the entire rack and piston assembly will move as a unit toward the right as shown in FIG. 2 under the action of clutch springs. Once ball bearings 106 and 106' register with cylinder groove 108 the bearings will move radially outwardly into groove 108 upon continued movement of rack 42 to the right of rack as shown in FIG. 2. The ball bearings cannot continue movement to the right with the rack since they move into groove 108 of cylinder 104 due to the force of rack movement. However, there will be a slight continual movement of the rack toward the right, due at least in part to the action of secondary spring 124; but this will be relative to piston 102 since the piston will be fixed by the positioning of the ball bearings within the groove 108. Movement of the rack will continue until its shoulder 117 abuts the internal surfaces of protrusion 115 of piston 102 which prevents further movement. In this position the mechanism 100 is ready for the next disengagement of the clutch mechanism.
The housing 28 includes a cover plate 86 which is releasably secured to the front portion of housing 28 at threaded bores 85. This allows ready access to those portions of the mechanism which may require lubrication, repair or replacement while protecting these portions of the assist mechanism from debris and other damage during their normal operation. For holding the mechanism in place, particularly those elements which are fixed to the shaft, in place there is provided a clamp assembly 88. This assembly is a U-shaped, internally splined clamp 87 to engage splines of release shaft 24 and includes two legs 89 for receiving clamp bolt 90. When the elements, the sector, rack, housing and shaft, are in the proper disposition, clamp assembly 88 is then placed on the shaft last as can be seen in FIG. 2 with the bolt 90 threaded down to secure clamp 87 in place and hold both housing 28 and the sector 32 in the proper disposition. Housing 28 is secured in place by projection 91 and arm 93.
Another embodiment of the clutch release mechanism of the invention is shown in FIGS. 4 and 5 where like reference numerals are used in referring to parts similar to those in the embodiment of FIGS. 2 and 3. The major distinction between the embodiments relates to the movement of the assist mechanism prior to actuation of the assist spring 114.
The assist spring mechanism 100 includes a poppet assembly 54 similar to the assembly described in conjunction with the embodiment of FIG. 2 except for the configuration and location of the groove for receiving the poppet ball. A piston 56 is provided adjacent the end of rack 42 for movement within the cylinder portion 55 in cooperation with other elements of the clutch release assist mechanism. The piston has an outer surface in which the groove 57 is carved for receiving spring-loaded, poppet ball 53 of poppet assembly 54. The rack 42 has a smaller distal end shaft 60 which extends through a hole in the center of the piston to provide for relative movement between the piston and the rack. At the end of shaft 60 there is a spring retainer 64 for holding secondary spring 62 between the retainer 64 and an internal surface of the piston 56. The secondary spring 62 maintains a bias on rack 42 in a direction away from clutch disengagement and in this case toward the right end of the housing as shown in FIG. 4. At the end of the cylinder 55 there is an end cap 66 for engaging and retaining primary assist spring 68 which is the major force providing the assist of the clutch release mechanism as does the spring 114 in connection with the embodiment of FIG. 2.
In operation, the clutch pedal or linkage as discussed above is activated to depress poppet roll 53 into its housing and initiate the spring assist mechanism. However, the initial movement will be a translation of the rack 42 leftward as shown in FIG. 4 toward a position of clutch disengagement and through a path of "free-travel". The "free-travel" is defined by the distance between the end of spring retainer 64 and the opposed internal surface of the piston 56. This "free-travel" overcomes the bias of the secondary spring 62. Once the "free-travel" has been traversed, upon continued depression of the clutch pedal or other actuating mechanism the force will be sufficient to force poppet ball 53 upwardly into its housing thereby releasing the force of the assist spring against the end of the rack and moving the entire piston assembly to the left or toward clutch disengagement. Thus once the poppet assembly has been disengaged in this manner the assist spring then will apply assist force in the same direction for clutch disengagement. Upon release of the clutch pedal the rack and cylinder will be moved to the right as shown in FIG. 4 due to the force of the clutch springs and secondary spring will serve to insure that the rack is returned sufficiently to seat the poppet ball 53 in groove 57 for the next actuation of the clutch.
It can be seen from the above description that the clutch assist mechanisms of the invention overcomes many problems which have characterized by the prior art. It should be understood, however, that the above is merely a discussion of the preferred embodiments of the invention.
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A clutch release assist mechanism for avoiding excessive clutch pedal efforts. The assist mechanism includes a spring-loaded apparatus to bias the clutch toward a release disposition, but the assist function is not activated until after initial movement of the release mechanism has been effected by the operator through pedal displacement. The amount of spring bias to assist the mechanism is less than that of the clutch to permit the clutch to revert to a closed or engaged position once the release mechanism has been deactivated. This mechanism includes a rack operated in conjunction with a piston and cylinder arrangement to provide for "free travel" before activation of an assist spring. The rack in turn operates through a sector or pinion to rotate a clutch release shaft between a clutch disengaged and engaged positions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application No. 60/589,304, filed Jul. 20, 2004, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
While cleansing compositions comprising various surfactants and structuring agents, such as, for example, acrylate copolymers, have been described (e.g., U.S. Pat. No. 6,635,702 B1, U.S. Pat. No. 6,642,198), it has been found that the use of anionic and amphoteric surfactants in combination with acrylate copolymers do not always provide desired characteristics, such as sufficient foam. Acrylate copolymer in cleansing systems can inhibit foaming with use of typical surfactants, such as sodium laureth sulfate and cocamidopropyl betaine.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed, in part, to novel cleansing compositions and methods for making same. Specifically, in certain embodiments, there are provided compositions comprising an acrylate copolymer, an alkoxylated methyl glucoside polyol, and a surfactant. Another embodiment of the invention relates to methods for making cleansing compositions.
DETAILED DESCRIPTION OF THE INVENTION
In certain embodiments, the invention is directed to cleansing compositions that are structured liquids that provide improved foaming, excellent skin feel, and/or good viscosity/rheological profiles for dispensing and the ability to suspend other additives. In certain embodiments, the compositions of the invention are non-emulsion liquid cleansing compositions.
In certain embodiments, the present invention is directed to cleansing compositions comprising at least one alkoxylated methyl glucoside polyol and at least one acrylate copolymer. Preferably, the methyl glucoside is alkoxylated with ethylene or propylene oxide.
According to one embodiment of the present invention, a composition is provided comprising an alkoxylated methyl glucoside polyol, an acrylate copolymer and at least one surfactant. In certain embodiments of the invention, the surfactant comprises an anionic surfactant. In certain embodiments of the invention, the surfactant comprises an amphoteric surfactant. In certain embodiments of the invention, the composition comprises both an anionic surfactant and an amphoteric surfactant.
In certain embodiments of the invention, the anionic surfactant is preferably present in an amount of about 3% to about 25% by weight of the total composition, about 5% to about 18%, or about 7% to about 12% (all by weight of the total composition).
In certain embodiments of the invention, the amphoteric surfactant is preferably present in an amount of about 0.05% to about 15% by weight of the total composition, about 0.5% to about 10%, or about 1% to about 8% (all by weight of the total composition).
In certain embodiments of the invention, the acrylate copolymer is preferably present in an amount of about 0.1% to about 12% by weight of the total composition, about 0.5% to about 8%, or about 1% to about 5% (all by weight of the total composition).
In certain embodiments of the invention, the alkoxylated methyl glucoside polyol is preferably present in an amount of about 0.05% to about 6% by weight of the total composition, about 0.1% to about 4%, or about 0.2 to about 2% (all by weight of the total composition).
In certain embodiments, the alkoxylated methyl glucoside polyol is a methyl glucoside alkoxylated with ethylene or propylene oxide. In certain embodiments, mixtures of ethoxylated glucoside polyols and propoxylated glucoside polyols may be used. Preferably, the ethoxylated and/or propoxylated methyl glucoside is present in an amount of about 0.05% to about 6% by weight of the total composition, about 0.1% to about 4%, or about 0.2% to about 2% (all by weight of the total composition).
In certain embodiments, a basic neutralizing agent is preferably present in an amount of about 0.01% to about 5% by weight of the total composition, about 0.05% to about 4%, or about 0.1% to about 3% (all by weight of the total composition).
In certain embodiments, the composition of the invention additionally comprises water. The amount of water may vary, but may be up to about 99% by weight of the total composition, for example, about 35% to about 97%, or about 50% to about 90% (all by weight of the total composition).
In certain embodiments, the composition may further comprise effective amounts of optional ingredients including, but not limited to: colorants, fragrances, antibacterial, preservatives, antioxidants, beads, mica, glitter, opacifying agents, and pearlizing agents. In certain embodiments, the beads may comprise fragrance, exfoliating ingredients and/or moisturizing ingredients.
According to one preferred embodiment of the invention, the composition comprises beads containing shea butter. Preferably, the beads have a diameter in the range of about 100 to about 1200 microns.
In certain embodiments, the preferred pH of the composition is at least about 5.5, for example, about 6.0 to about 7.5, or about 6.4 to about 7.2.
Alkoxylated methyl glucoside polyols suitable for use in this invention include, without limitation, those having an average degree of alkoxylation of about 8 to about 22. Suitable alkoxylated methyl glucoside polyols include, but are not limited to, ethoxylated and propoxylated methyl glucosides. Examples include, but are not limited to, methyl gluceth-10, methyl gluceth-20, PPG-10 methyl glucose ether, and PPG-20 methyl glucose ether.
Examples of suitable anionic surfactants include, but are not limited to, alkyl sulfates, ethoxylated alkyl sulfates, alkyl sulfonates, alkyl olefin sulfonates, alkyl succinates, alkyl sulfosuccinates, alkyl ethoxy sulfosuccinates, acyl and alkyl glutamates, alkyl phosphates, alkyl ether carboxylates, alkyl isethionates, and acyl amides.
Suitable amphoteric surfactants may include, but are not limited to, betaine surfactants. Examples of suitable amphoteric surfactants include, but are not limited to, alkyl betaines, alkylamido betaines, alkyl sulfobetaines, alkyl sultaines and alkylamido sultaines. Preferably, the alkyl and acyl groups generally contain from about 8 to about 18 carbons.
Suitable acrylate copolymers include, without limitation, those described in U.S. Pat. No. 6,635,702 B1 (hereby incorporated by reference herein) and those selected from the group consisting of:
monomers or copolymers of one or more of methacrylic acid, acrylic acid, itaconic acid, esters of any of the foregoing and mixtures of any of the foregoing; a member of group (a) copolymerized with one or more members selected from the group consisting of Steareth-20, Steareth-50, Ceteth-20.
Examples of suitable acrylate copolymers include, without limitation, those sold under the trademarks CARBOPOL® AQUA SF-1 from Noveon (Cleveland, Ohio), SYNTHALEN® W2000 from 3V (Wehawkin, N.J.), ACULYN® 22, and ACULYN® 33 available from International Specialty Products Corporation (Wayne, N.J.).
Suitable alkaline neutralizing agents include, without limitation, inorganic and organic neutralizers selected from the group consisting of alkali hydroxides (such as ammonium, sodium, and potassium) and alkanolamines (such as triethanolamine, isopropanolamines), preferably, sodium hydroxide or triethanolamine.
In certain embodiments, compositions of the invention may optionally comprise opacifying and/or suspending agents including, but not limited to: glycol stearates and glycol distearates, including, without limitation, ethylene glycol distearate, ethylene glycol monostearate and polyethylene glycol distearate; coated micas, glitter and mixtures thereof.
Compositions according to the invention may be made using conventional mixing techniques known to those skilled in the art for mixing ingredients.
EXAMPLES
The invention is further demonstrated in the following examples. The examples are for purposes of illustration and are not intended to limit the scope of the present invention. In the Examples, as elsewhere in this application, values for n, m, etc. in formulas, molecular weights and degree of ethoxylation or propoxylation are averages. Temperatures are in degrees C. unless otherwise indicated. The amounts of the components may be in weight percents based on the standard described; if no other standard is described then the total weight of the composition is to be inferred (active basis). Various names of chemical components include those listed in the CTFA International Cosmetic Ingredient Dictionary (Cosmetics, Toiletry and Fragrance Association, Inc., 7 th ed. 1997).
General Method of Making Compositions
Using the types and amounts of ingredients listed in the examples, the products are prepared at ambient temperature (approximately 20-25 degrees C) by adding the DMDM Hydantoin to the water in a vessel equipped with center turbine agitation. The acrylate copolymer is then added to the water phase and mixed. The sodium laureth sulfate is added to the mixture and then neutralized with sodium hydroxide to a pH range of 6.5-7.5 at 25° C. Cocamidopropyl betaine is then added and mixed. The other ingredients are added in order and mixed until uniform. The citric acid is added to adjust the pH to approximately 6.4-7.2. The sodium chloride is added to adjust the viscosity to approximately 4300 centipoise (cps), wherein the formulation viscosity is in the range of 2500-5500 cps as measured by a Brookfield DV II+ Viscometer using Spindle # 5 at 20 RPM at 25° C.
Example 1
Pearlized Liquid Hand Soap with Glucams
TABLE 1
% (weight/
%
weight on
(weight/
an active
INCI Name
Tradename
weight)
basis)
Water
Water
44.10
83.12
DMDM Hydantoin
GLYDANT
0.40
0.24
PLUS ®
Acrylate Copolymer (30%)
CARBOPOL ®
8.50
2.55
AQUA SF-1
Sodium Laureth Sulfate
STANDAPOL ®
35.22
8.98
(25.5%)
ES-2
Sodium Hydroxide (50%)
Sodium Hydroxide
0.70
0.35
Cocamidopropyl Betaine
EMPIGEN ®
5.35
1.61
(30%)
BS/CQ
Tetrasodium EDTA (39%)
DISSOLVINE ®
0.08
0.03
E-39
Methyl Gluceth-10
GLUCAM ™ E-10
0.50
0.50
PPG-10 Methyl Glucose
GLUCAM ™ P-10
0.30
0.30
Ether
Glycol Distearate
EUPERLAN ® PK
2.00
1.04
3000 AM
Butyrospermum Parkii
HC-1741 Beads
0.50
0.50
(Shea Butter), Gelatin,
Acacia Senegal Gum,
Iron Oxide
Fragrance
Skin Balm
0.35
0.35
Citric Acid (50% solution)
Citric Acid
0.10
0.05
Sodium Chloride (25%
Sodium Chloride
1.50
0.38
solution)
Total weight
100.00
100.00
Example 2
Pearlized Liquid Hand Soap without Glucams
TABLE 2
% (Weight/
%
weight on
(Weight/
an active
INCI Name
Tradename
weight)
basis)
Water
Water
44.90
83.92
DMDM Hydantoin
GLYDANT
0.40
0.24
PLUS ®
Acrylate Copolymer (30%)
CARBOPOL ®
8.50
2.55
AQUA SF-1
Sodium Laureth Sulfate
STANDAPOL ®
35.22
8.98
(25.5%)
ES-2
Sodium Hydroxide (50%)
Sodium
0.70
0.35
Hydroxide
Cocamidopropyl Betaine
EMPIGEN ®
5.35
1.61
(30%)
BS/CQ
Tetrasodium EDTA (39%)
DISSOLVINE ®
0.08
0.03
E-39
Methyl Gluceth-10
GLUCAM ™
0.00
0.00
E-10
PPG-10 Methyl Glucose
GLUCAM ™
0.00
0.00
Ether
P-10
Glycol Distearate
EUPERLAN ®
2.00
1.04
PK 3000 AM
Butyrospermum Parkii
HC-1741 Beads
0.50
0.50
(Shea Butter), Gelatin,
Acacia Senegal Gum,
Iron Oxide
Fragrance
Skin Balm
0.35
0.35
Citric Acid (50% solution)
Citric Acid
0.10
0.05
Sodium Chloride (25%
Sodium Chloride
1.50
0.38
solution)
Total weight
100.00
100.00
Example 3
Clear Antibacterial Liquid Hand Soap
TABLE 3
%
(Weight/
%
weight on
(Weight/
an active
INCI Name
Tradename
weight)
basis)
Water
Water
44.18
83.00
DMDM Hydantoin
GLYDANT
0.42
0.25
PLUS ®
Acrylate Copolymer (30%)
CARBOPOL ®
8.74
2.62
AQUA SF-1
Sodium Laureth Sulfate
STANDAPOL ®
36.25
9.24
(25.5%)
ES-2
Sodium Hydroxide (50%)
Sodium Hydroxide
0.72
0.36
Cocamidopropyl Betaine
EMPIGEN ®
5.51
1.65
(30%)
BS/CQ
Tetrasodium EDTA (39%)
DISSOLVINE ® E-
0.21
0.08
39
Methyl Gluceth-10
GLUCAM ™ E-10
0.50
0.50
PPG-10 Methyl Glucose
GLUCAM ™ P-10
0.50
0.50
Ether
Butyrospermum Parkii
HC-2329 Beads
0.50
0.50
(Shea Butter), Gelatin,
Acacia Senegal Gum, Iron
Oxide
Triclosan
IRGASAN ®
0.12
0.12
DP300
Fragrance
Cosmolem
0.35
0.35
FD&C Colors
Color
0.40
0.40
Citric Acid (50% solution)
Citric Acid
0.10
0.05
Sodium Chloride (25%
Sodium Chloride
1.50
0.38
solution)
Total weight
100.00
100.00
Example 4
Rheology Testing
Rheology of cleansing liquids is key to a consumer's perception of consistency and dispensing. Consumers perform flow experiments when they use the product. How a product flows in a bottle and is dispensed, how the product is pumped and dispensed and how the product is spread out in use to generate lather are all examples of a shear force being applied.
A series of rheological measurements including strain sweep and creep tests were conducted. All rheological measurements were conducted using a Paar Physical MCR300 Rheometer equipped with a TEK 150 P-CF peltier plate, a 50 mm parallel plate (PP50) and a 1 millimeter gap at 23° C.
Strain sweeps are used to define the linear viscoelastic (LVE) region and determine the magnitude of G′ (elastic modulus) and G″ (viscous modulus) of an intact substance and is expressed as tan (delta) which equals G″ over G′. If tan (delta) is greater than 1.0, the substance is viscous dominant and if tan (delta) is smaller than 1.0, the substance is elastic dominant. Creep tests determine the relative contribution of the elastic and viscous elements.
Table 4: Key Rheological Parameter Results
TABLE 4
Pearlized
Pearlized
Liquid Hand
Liquid Hand
Soap with
Soap without
Rheology
Glucams
Glucams
Parameter
Example 1
Example 2
Elastic Portion, %
45.3
23.3
G′ within LVE
77.0
83.1
G″ within LVE
29.6
38.0
Tan (delta), G″/G′
0.38
0.46
Yield Value (Pa)
3.6
4.2
The rheological measurements indicate that the Liquid Hand Soap with the Glucams has a higher elastic portion, a lower tan (delta) and a lower G″. The greater the value of G″ or tan (delta) the stringier the product, which is consistent with sensory evaluations and not as desirable.
Example 5
Sensory Panel—Hand Wash Dispensing Study
For evaluating aesthetic properties, a composition of Example 1 was compared on the basis of aesthetics for foaming and dispensing from a liquid hand soap container to the composition of Example 2.
Methodology:
Products:
Pearlized Liquid Hand Soap with Glucams (control) Example 1
Pearlized Liquid Hand Soap without Glucams Example 2
Procedure:
Two products were tested in two phases: a sequential monadic hand wash phase and a side-by-side dispensing phase.
Part 1—Hand Wash Evaluation: Each panelist washed with each product over 2 test sessions. Panelists dispensed the product using their normal habits, then washed their hands with the product (in water temperature about 37° C.+/−1° C.) and evaluated the product. Each panelist evaluated all products in a balanced/randomized order of presentation. Panelists answered a series of questions related to the dispensing and hand washing-properties of the product.
Part 2—Dispensing Evaluation: Upon completing the hand wash portion of the study, panelists evaluated the dispensing properties of the 2 products (randomized presentation). Panelists pumped each product twice into a dish to evaluate the dispensing properties. Panelists were instructed to pump as they would normally pump, wait for the pump to recover (count to 10) and then pump the product again. This procedure was repeated with each product. Panelists answered a series of questions related to the dispensing properties in between each product.
Subjects:
79 liquid hand soap users participated in the study.
Results of Comparison of Pearlized Liquid Hand Soap with Glucams Versus Without Glucams
Part I: Hand Wash and Dispensing (see Table 6)
Pearlized Liquid Hand Soap without Glucams was rated as having less lather compared to the Pearlized Liquid Hand Soap with Glucams.
Part II: Dispensing Only (see Table 5)
The Pearlized Liquid Hand Soap without Glucams was rated as being more stringy as it was dispensed compared to the Pearlized Liquid Hand Soap with Glucams.
TABLE 5
Rate how stringy the product was as you dispensed it
Pearlized Liquid
Pearlized Liquid
Hand Soap without
Hand Soap with
Rating
Glucams N = 78
Glucams N = 79
Very Stringy
%
%
7
1.3
1.3
6
12.8
5.1
5
16.7
9.0
4
16.7
20.5
3
20.5
19.2
2
23.1
33.3
1
9.0
11.5
Not at all
Mean
3.5
3.0
Stringy
TABLE 6
Rate the Amount of Lather generated while washing
Pearlized Liquid
Pearlized Liquid
Hand Soap without
Hand Soap with
Rating
Glucams N = 78
Glucams N = 79
A Lot of Lather
%
%
7
1.3
1.3
6
6.4
15.2
5
15.4
26.6
4
24.4
25.3
3
28.2
17.7
2
12.8
8.9
1
11.5
5.1
Very Little Lather
Mean
3.5
4.1
Example 6
Foam Evaluation Testing—Cylinder Shake Test
The foam characteristics of liquid hand soap products were evaluated using a mechanical cylinder shake method. The procedure uses hard water, synthetic sebum and a Gaum Foam Machine available from Gaum, Inc., Robbinsville, N.J.
Hard Water Preparation: In a 2000 milliliter volumetric flask combine 40 grams of magnesium chloride ( ) and 45 grams of calcium chloride and fill volumetric to line with deionized water. This will produce 25,000 ppm water hardness. To prepare 250 ppm hard water, put 20 milliliters of 25,000 ppm hard water solution into a 2000 milliliter volumetric flask and fill to the line with deionized water.
Synthetic Sebum Preparation:
The Synthetic Sebum was prepared by melting together the following ingredients at about 71° C. while stirring with a spatula.
% weight/weight
Palmitic Acid
10.0
Stearic Acid
5.0
Coconut Oil
15.0
Paraffin
10.0
Spermaceti
15.0
Olive Oil
20.0
Squalene
5.00
Cholesterol
5.00
Oleic Acid
10.0
Linoleic Acid
5.0
100.0
Foam height testing was performed on the compositions in Examples 1 and 2 above. 15 grams of liquid hand soap were added to 84 grams of 250 ppm hard water and 1 gram of Synthetic Sebum. The hard water was prepared by mixing together 40 grams of MgCl 2 .6H 2 O with 45 grams of CaCl 2 .2H 2 O and diluting to 250 ppm. The test mixture was then heated with moderate agitation and slow heating to 40.5° C. This dispersion was then carefully poured into a 600 ml. graduated cylinder containing a plastic water-filled tube. The cylinder was then mounted onto the center of a Vertical Rotator Assembly and rotated at a constant speed of 30 rpm. The action of the circular mixing of the cylinder and the free falling action of the water-filled tube in the cylinder generated foam which could be measured as foam height using the gradations on the side of the cylinder. After 8 complete revolutions, the Flash Foam Height was measured and after an additional 12 complete revolutions (a total of 20 revolutions) the Maximum Foam Height was measured. At this time the Drainage Time was also measured. Drainage Time is defined as the time measured from the completion of the 20 revolutions to the time at which 100 mls. of apparent liquid has drained. Drainage Time is a measure of the wetness and stability of the foam.
TABLE 7
Foam Evaluation Testing
1 gram Sebum
15 grams Liquid Soap
84 grams 250 PPM Water
At 40.5° C.
Flash
Maximum
Drainage Time
Product Code
Foam (ml)
Foam (ml)
(Min.Sec.)
Pearlized Liquid
325
400
5.77
Hand Soap
without Glucams
Pearlized Liquid
375
495
4.65
Hand Soap
with Glucams
The results of foam evaluation testing indicate that the Pearlized liquid hand soap with Glucams had more flash foam and maximum foam height. The drainage time took less time and represents a more stable foam.
All numerical ranges described herein include all combinations and subcombinations of ranges and specific integers encompassed therein.
Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.
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Novel cleansing compositions and methods for making same are described. Preferred embodiments provide compositions comprising an acrylate copolymer, an alkoxylated methyl glucoside polyol, and a surfactant. Preferred alkoxylated methyl glucoside polyols among those useful herein may include ethoxylated and/or propoxylated methyl glucoside polyols.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part utility application of the nonprovisional utility patent application Ser. No. 13/354,828, filed on Jan. 20, 2012, in the United States Patent Office, claiming priority to the provisional patent application, Ser. No. 61/438,165 filed in the United States Patent Office on Jan. 31, 2011 and is expressly incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a helmet. More particularly, the present disclosure relates to a safety light helmet worn when riding a motorcycle and similar vehicles.
BACKGROUND
[0003] Safety is among one of the greatest concerns to people who participate in motorcycling, bicycling, skateboarding, dirt biking, and any other sports, which may require protective gear to be worn by riders. This is especially true given the proximity of riders on or around busy roads and highways. The wearing of a safety helmet while participating in these activities is an important safety measure taken by riders to reduce the risk of injury in the event of an accident.
[0004] Motorcycle and bicycle helmets are well-known means of protection worn by riders to protect head during collisions. Helmets have been improved to conform better to the rider's head and provide a greater degree of protection.
[0005] However, there exists a need for additional measures to be taken to prevent accidents from occurring in the first place. It is also important that any preventative measure not take away the effectiveness and functionality of the protective mechanism.
[0006] For example, U.S. Pat. No. 5,327,587 to Marni Hurwitz entitled “Illuminated Safety Helmet” discloses a battery-powered electroluminescent strip adhered to the top exterior surface of the helmet.
[0007] U.S. Pat. No. 4,186,429 to Walter Johnson entitled “Flashing Light Safety Device for Cyclists Helmets” discloses a flashing light mounted atop a cyclists' helmet to provide 360 degrees of visibility.
[0008] U.S. Pat. No. 5,327,588 to Louis Garneau entitled “Safety Helmet for Cyclists” discloses a streamlined, aerodynamically contoured safety helmet with light device anchored into an external shell cavity located in the lower end portion of the helmet.
[0009] U.S. Pat. No. 6,464,369 to Mario Vega entitled “Helmet with Safety Light” discloses a helmet with a safety light disposed within a cavity on the back exterior portion of the helmet's shell.
[0010] However when a light is affixed to a safety helmet, problems often encountered include a compromise of the existing aerodynamics, aesthetics, or safety functionality of the helmet. An external light may add bulkiness, which may compromise aerodynamic efficiency, rider comfort and overall aesthetics. More notably, the addition of a light may reduce the effectiveness of the helmet in preventing head injury. For example, U.S. Pat. No. 4,186,429 features a light affixed to the top of the helmet with an elevated position giving the rider visibility in all directions. However, there is the possibility that in the event of a collision wherein the top of the helmet is the first point to contact the pavement, another vehicle, or some other fixed object, the light fixture will be forced upon impact through the top portion of the helmet shell thereby harming the rider. Additionally, the elevated position of the light on top of the helmet could affect secondary considerations such as aerodynamic qualities and aesthetic appearance of the helmet.
[0011] While these units may be suitable for the particular purpose employed, or for general use, they would not be as suitable for the purposes of the present disclosure as disclosed hereafter.
[0012] In the present disclosure, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which the present disclosure is concerned.
[0013] While certain aspects of conventional technologies have been discussed to facilitate the present disclosure, no technical aspects are disclaimed and it is contemplated that the claims may encompass one or more of the conventional technical aspects discussed herein.
BRIEF SUMMARY
[0014] An aspect of an example embodiment in the present disclosure is to provide a safer helmet for riding a motorcycle or similar vehicles. Accordingly, an aspect of an example embodiment in the present disclosure provides safety light helmet having a light on the helmet that provides 360-degree visibility.
[0015] Another aspect of an example embodiment in the present disclosure is to provide a light that does not compromise aerodynamics and safety. Accordingly, the present disclosure provides a safety light that is a tapered oval positioned on the top center crown of a helmet, the light breaking away upon impact so that the safety of the rider is not compromised by the light penetrating the helmet.
[0016] The present disclosure describes a safety light helmet that enhances the visibility of a rider to surrounding vehicle riders and pedestrians. Whether an example embodiment contains a flashing, constant, or intermittent lighting pattern, use of the device will reduce accidents by putting others on notice of the exact location of the rider. The light also serves as a back-up safety mechanism if a headlight or taillight were to fail while the rider is on the road. The safety light helmet is a helmet with a light affixed to the top center of the helmet providing 360-degree visibility. The safety light detaches immediately during a collision without causing injury to the rider. The safety light helmet has a plurality of light bulbs operative for displaying a plurality of light patterns. The light is rechargeable.
[0017] The present disclosure addresses at least one of the disadvantages of the prior art. However, it is contemplated that the present disclosure may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claims should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed hereinabove. To the accomplishment of the above, this disclosure may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact, however, that the drawings are illustrative only. Variations are contemplated as being part of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the drawings, like elements are depicted by like reference numerals. The drawings are briefly described as follows.
[0019] FIG. 1 is a perspective view of an example embodiment of a safety light helmet.
[0020] FIG. 2 is an exploded view of an example embodiment of a safety light.
[0021] FIG. 3 a is a side elevational exploded view of an example embodiment of safety light attaching to a helmet, the helmet shown in cross-section.
[0022] FIG. 3 b is a top plan view of an example embodiment of the safety light.
[0023] FIG. 4 is an exploded view of example embodiment of the safety light attaching to the helmet.
[0024] FIG. 5 is a side elevational view of a rider wearing the safety light helmet.
[0025] FIG. 6 is a perspective view of a further example embodiment of a safety light from the side.
[0026] FIG. 7 is a perspective view of a further example embodiment of a safety light from the rear.
[0027] FIG. 8 is a perspective view of a further example embodiment of a safety light from the bottom.
[0028] FIG. 9 is a side elevational view of the further example embodiment of the safety light helmet.
[0029] FIG. 10 is a perspective view of the further example embodiment of the safety light helmet.
[0030] FIG. 11 is a perspective view of a further example embodiment of the safety light attaching to the helmet.
[0031] FIG. 12 is a perspective view of another example embodiment of a safety light attaching to the helmet.
[0032] The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, which show various example embodiments. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that the present disclosure is thorough, complete and fully conveys the scope of the present disclosure to those skilled in the art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] FIG. 1 shows an outside view of a safety light helmet 10 with a safety light 22 , a light switch 24 , and a rubber seal 23 installed. From this view, one is able to gain a greater appreciation for the special orientation of the safety light 22 on top of the helmet 10 . Geometrically, the safety light 22 blends into the exterior surface of the helmet 10 . The positioning of the safety light 22 is such that the helmet does not lose any of its aerodynamic or aesthetic qualities while still providing 360 degrees of visibility to surrounding vehicles and pedestrians. A light switch 24 is disposed on the side of the safety light 22 above the light base. The light switch 24 may be horizontally disposed in the center of light when viewing the light from its right side. A rubber seals 23 lines the exterior of the safety light 23 to prevent moisture from getting inside the fixture.
[0034] The configuration of the light 22 , rubber seal 23 , metal washer 18 , cap 16 , and cylinder 12 is better understood with reference to FIG. 2 . Reference number 12 shows the cylinder within which the light unit is positioned. The cylinder 12 is made of hard plastic and designed so that it breaks upon impact in the event of a collision. Thread grooves line the outer circumference of the cylinder 12 in order to provide means through which the cylinder 12 may be attached to the cap 16 on the inside of the helmet 10 . An underlying thin metal plate or washer 18 is located at the bottom of the cap 16 to prevent the cylinder 12 from protruding beyond the cap upon impact.
[0035] FIG. 3 shows a side view of an example of the safety light of the present disclosure prior to installation into a helmet as well as an example of a top view of a safety light of the present disclosure. From this view, one is able to gain a greater appreciation of the configuration of the lighting unit with respect to the helmet shell. As illustrated by FIG. 3 , panel a) the cylinder 12 is positioned through the bored hole 14 in the helmet shell to engage the cap 16 disposed inside the helmet 10 . The length of the cylinder 12 and depth of the bored hole 14 will vary with respect to the thickness of the helmet shell. Threaded grooves on the exterior of the cylinder 12 and the interior of the cap 16 allow for the cylinder 12 to engage the cap 16 by way of screwing the two parts together. The method of screwing the two parts together would require one to position the cylinder 12 through the bored hole 14 and match the cylinder 12 with the cap 16 . The bored hole 14 may also have a metal ring fitted around its circumference. The metal ring has an inner diameter, comparable to the outer diameter of the cylinder 12 , within which the cylinder 12 will be positioned. FIG. 3 a also exemplified the ease of detachability of the safety light 22 from the helmet 10 . By merely unscrewing the cylinder 12 from the cap 16 the user is able to detach the light from the helmet 10 .
[0036] FIG. 3 , panel b) shows a top plan view of the safety light 22 . The means for lighting may consist of, but is not limited to: light-emitting diodes (“LEDs”), 12-volt powered bulbs, or some other power source located on the user or on the user's mode of transport if applicable. Furthermore, the lighting pattern may include flashing, constant, or intermittent lighting schemes.
[0037] The lighting pattern is configurable for emergency personnel to duplicate the pattern used to indicate that an emergency vehicle is operating in emergency mode. The lighting pattern is configurable for non-emergency riders to distinguish the rider from a motorcycle vehicle operating in emergency mode.
[0038] In one example embodiment, the switch 24 is activated and the light bulbs inside the light 22 are turned on. The switch 24 is toggled again and the lights flash. In a further example embodiment, the lights flash in an oscillating pattern. The switch 24 is toggled again and at least one light bulb lights up in the front of the light to provide a reading light.
[0039] FIG. 4 shows a detailed structure of an example of a safety light helmet of the present disclosure.
[0040] FIG. 5 illustrates a rider 100 wearing the safety light helmet 10 . The helmet 10 has an outer shell 20 having a curved crown. The light 22 is on the top center 20 T of the crown. The light 22 is midway between the sides 10 S of the helmet 10 . The light 22 thus situated is visible in all directions, that is, 360 degrees. Other riders, drivers and pedestrians can see the light 22 on the rider as the rider comes towards them, passes by them and continues away from them.
[0041] The light 22 is selectively attachable to the helmet 10 , allowing the light 22 to be attached during dusk to dawn riding and allowing the light 22 to recharge during daylight. The rider 100 can reattach the light 22 during the day and as needed, as for example, during foggy or rainy conditions.
[0042] FIG. 6 shows an example embodiment of the light 22 in detail. The light 22 has a top dome 28 that is an aerodynamically tapered oval. Inside the dome 28 is a plurality of light bulbs 26 in an array shown by broken lines. The dome 28 is constructed from material such as breakaway plastic that easily breaks away and shatters into small pieces. The light bulbs 26 are disclosed hereinabove and can display a plurality of lighting patterns.
[0043] The light 22 has a switch 24 that has a plurality of positions operative for controlling the lighting patterns. The lighting patterns include flashing, constant and intermittent patterns as described hereinabove. In one example embodiment, the light bulbs 26 are LEDs capable of displaying lights of different colors.
[0044] FIG. 7 shows the rear of the light 22 . In addition to the switch 24 , the light 22 has a port 30 for recharging. In one example embodiment, the port 30 is a USB port 30 for recharging using a USB (Universal Serial Bus) connector, however, other connectors for recharging are envisioned within the inventive concept.
[0045] FIG. 8 shows the bottom 22 B of the light 22 . As indicated by the lines of curvature, the bottom 22 B is contoured conforming to the curve of the helmet outer shell 20 .
[0046] As shown in FIGS. 6-8 , the dome 28 has a lip 32 surrounding the contoured bottom 22 B of the light 22 . In one example embodiment, the lip 32 is configured for coupling to the top center crown of the helmet as explained hereinbelow.
[0047] FIG. 9 shows in greater detail the placement of the light 22 on the helmet 10 . The light 22 is on the top center crown 20 T of the helmet shell 20 . The bottom 22 B conforms to the curve of the shell 20 . Noteworthy, is the position of the light 22 , which is optimal for 360-degree visibility, but also is placed such that a helmet visor 34 can be fully opened without interference of the light 22 . The lip 32 has a front 32 F and a rear 32 R and the rear 32 R of the lip that is taller than the front 32 F, so that bottom 22 T of the light 22 maintains conformance to the shell 20 , but also maintains the light 22 to be parallel to the ground. The light 22 in this position parallel to the ground maintains the 360-degree visibility.
[0048] FIG. 11 illustration one example embodiment of the safety light helmet 10 . The helmet 10 also has an inner shell 20 N. In this example embodiment, the top center crown 20 T of the outer shell has at least one cavity 38 that extends into but not beyond the inner shell 20 N. The light 22 has at least one cylinder 40 attached to the contoured bottom 22 B of the light 22 , the at least one cylinder 40 inserting into the at least one cavity 38 at the top center crown 20 T of the shell, the at least one cylinder 40 selectively coupling the light 22 to the outer shell 20 of the helmet 10 , the at least one cylinder 40 magnetically coupling to the at least one cavity 38 . In this illustration, a magnet 36 is placed on the cylinder 40 , but the magnets can be placed in the cavity, can be in a pair, one in the cavity and one on the cylinder and other variations familiar to those of ordinary skill in the art. The contoured bottom 22 B of the light 22 constrains the light from rotating out of position on the top center crown 20 T of the helmet 10 .
[0049] The light 22 is a breakaway light, the magnet 36 in the at least one cavity 38 releasing upon an impact, allowing the light 22 to decouple from the helmet 10 so that the integrity of the shell 20 is maintained preventing the light 22 from damaging the shell 20 or injuring the rider.
[0050] FIG. 12 illustrates a further example embodiment of the safety light helmet 10 . A bracket 42 is coupled to the outer shell 20 at the top center crown 20 T. The bracket 42 has a groove 44 configured for coupling to the light 22 . The light 22 slides into the bracket 42 and the groove 44 engages the lip 32 , selectively mounting the light 22 onto the outer shell 20 of the helmet 10 .
[0051] The lip 32 of the light 22 has a front 32 F, a rear 32 R and a pair of sides 32 S and the groove 44 of the bracket 42 extends along the sides 32 S and the rear 32 R of the light 22 . The bracket 42 has a front lock 46 operative to engage the front 32 F of the lip.
[0052] The contoured bottom 22 B of the light 22 and the bracket 42 constrain the light 22 from rotating out of position on the top center crown 20 T of the helmet 10 .
[0053] The light 22 in the bracket 42 is a breakaway light 22 , the front lock 46 unlocking upon an impact, allowing the light 22 to decouple from the helmet 10 so that the integrity of the shell 20 is maintained preventing the light 22 from damaging the shell 20 and injuring the rider.
[0054] FIG. 10 shows an example embodiment of the safety light helmet 10 with the light 22 coupled to the outer shell 20 according to the methods described hereinabove.
[0055] It is understood that when an element is referred hereinabove as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.
[0056] Moreover, any components or materials can be formed from a same, structurally continuous piece or separately fabricated and connected.
[0057] It is further understood that, although ordinal terms, such as, “first,” “second,” “third,” are used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer” or “section” discussed below could be termed a second element, component, region, layer or section without departing from the teachings herein.
[0058] Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, are used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It is understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0059] Example embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein, but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.
[0060] In conclusion, herein is presented a safety light helmet. The disclosure is illustrated by example in the drawing figures, and throughout the written description. It should be understood that numerous variations are possible, while adhering to the inventive concept. Such variations are contemplated as being a part of the present disclosure.
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A safety light helmet is a helmet with a light affixed to the top center of the helmet for 360-degree visibility by other riders and vehicles when passing a rider wearing the helmet. The safety light detaches immediately during a collision without causing injury to the rider. The safety light helmet has a plurality of light bulbs operative for displaying a plurality of light patterns. The light is rechargeable.
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[0001] This application is a divisional application of U.S. application Ser. No. 10/537,241, filed Nov. 22, 2006 which was the National Stage application of No. PCT/US03/038695, filed on Dec. 5, 2003 which in turn was a continuation-in-part of U.S. Provisional Patent Application Ser. No. 60/431,270, filed Dec. 6, 2002, of the same title and by the same inventor on which a claim of priority and benefit of filing date is made. This invention relates to a type of doctor for a coating apparatus for coating a traveling web material, such as paper, or for coating the surface of a roll and then transferring said coating to a traveling web in a pressure nip form by another roll, blade or other pressure applying device.
BACKGROUND OF THE INVENTION
[0002] It is known to use a doctor roll in a coater such as a short dwell time applicator (“SDTA”) or a film coater as shown in U.S. Pat. Nos. 4,250,211 and 5,749,972, these patents being incorporated herein by reference, in conjunction with a backing roll to meter coating applied to a moving paper web or first to a roll surface and then onto a moving web of paper. These doctor rolls are difficult to locate or hold in a coater as space is restricted. Heretofore, when the doctor roll was loaded into the web or roll surface being coated, the doctor roll was moved toward or away from the web or roll surface to increase or decrease the loading, respectively. Generally, the doctor roll also tended to move downstream in the direction of the web or roll surface travel. This latter movement was somewhat inconsistent, and consequently variation and/or inconsistency in the coating lay and metering by the doctor roll could occur.
SUMMARY OF THE INVENTION
[0003] The disadvantages of the prior art are overcome by the apparatus of the present invention which provides a method and means for supporting the doctor roll to minimize any movement or travel of the doctor roll in a direction of that of the moving surface of the web or roll and minimizes the inconsistency of coating applied to the surface of the web or roll. To accomplish this, the roll is supported in a roll carrier or support which is permitted to move or generally pivot on a support rod, generally being used as the motion may be somewhat greater than a true pivot connection. The support rod itself may form and close off part of the coater application chamber. To support the doctor roll, a rear or downstream (relative to the direction of web or roll surface movement or travel) support for the doctor roll is provided. To accommodate movement of the roll due to loading by a conventional means (such as a load tube), relative contact surfaces between the roll carrier and roll rear support may be curved or radiused to permit the roll carrier or support and roll therein to move, slide or pivot more freely. Preferably, the rear roll support can be in the form of a releasable element or blade, while the curved or radiused surface may be formed on the rear of the roll carrier or support. Thus, the pivoting of the roll support and moving along the radius provides a more consistent environment for the doctor roll, and therefore lay of coating and/or doctoring of coating on the moving web or roll surface, and consequently more consistently coated paper web.
DESCRIPTION OF THE DRAWING
[0004] FIG. 1 is a schematic, full scale as filed, cross sectional elevational view of a doctor assembly of the present invention.
[0005] FIG. 2 is a full scale as filed, view similar to FIG. 1 but of a second embodiment.
[0006] FIG. 3 is a partial view similar to FIGS. 1 and 2 , but showing a roll carrier or support for a solid doctor roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] Referring to FIG. 1 , the coater device is given reference numeral 1 . Also part of the coater is body 2 which forms part of the coating chamber 3 and also forms one wall of the coating inlet 3 A. The movable wall of the coating chamber as well as the outer wall of the coating chamber is formed by members 4 and 5 . Member 5 can be designed to include a clamp tube (not shown but similar to 14 described below) to secure the orifice plate member 6 .
[0008] An internal coating inlet seal 7 seals the ends of the coating inlet outside of the web run and under the edge dams 8 and 9 . There is a metal support for the felt edge dam 9 . This assembly seals the ends of the applicator between the orifice plate 7 , roll 10 and doctor assembly 11 . The edge dam assembly can be adjusted laterally on the dovetail or groove 7 A on seal 7 .
[0009] The doctor assembly 11 A comprises the carrier, bed or support 11 for the doctor roll or bar 12 . The bed or carrier 11 is made of UHMW polyethylene or similar material.
[0010] The doctor roll or device 12 can be a solid bar ( FIG. 3 ) or a hollow tube ( FIG. 1 or 2 ), with or without grooves on its outer surface. If solid, the doctor device is consequently generally of a smaller diameter than a hollow rod type doctor roll. Either type of doctor roll may be driven to rotate in a direction, usually, opposite the direction of the moving surface travel, be it a web or roll surface. The doctor's diameter can range from ⅜″ to 1½″. If a hollow tube is used for the doctor device 12 , it can be of sweated construction with cold water flowing through its center. A curved bar 13 supports the front of the support 11 . The curved bar 13 is clamped to the main coater by an air pressurized clamp tube 14 . The upper surface of the curved bar 13 , as shown in FIG. 1 , forms a side of the application zone and seals against the edge dam assembly. Reliefs or cutouts 15 are provided in the support 11 for the doctor bar 12 . These reliefs allow the bar 12 to rotate more easily. Lateral grooves 16 with the pipe taps or other type connections are provided in either end of the support bed 11 . Water is provided to these connections and circulated through these grooves or channels 16 to clean and lubricate the doctor bar or roll 12 . A convex radius 17 is provided on the support or bed 11 swung from a pivot point (pivot axis) 17 A on its wall. A support plate 18 supports the rear of the support bed 11 of the doctor assembly so that it is contained and not allowed to be moved by the friction against the travel of the web or surface being doctored. Alternatively, the support plate could be provided with a concave contact surface of the support.
[0011] When the doctor roll is driven (as indicated by the small arrow 18 A) in a direction opposite backing roll rotation (as indicated by the large arrow 18 B), it has a tendency to lift the roll up at the rear when not in contact with the backing roll. In order to counteract this tendency, associated means both on the doctor roll support 11 and the rear support plate 18 can be provided. For example, the rear support plate or retainer 18 may have an upper hooked end 118 which engages in a retaining groove 118 B in the doctor support 11 (see FIGS. 2 and 3 ). This arrangement acts as a baffle to prevent coating from egressing towards the loading tube 119 . A doctor load tube 19 (somewhat similar to tube 14 in construction) is provided. It is pressurized with air or other fluid to increase the force of the doctor device against the traveling surface or web being doctored. A flexible profile bar 20 supports the load tube 19 . This bar can be profiled (adjusted in its cross machine direction) to give the desired doctor force by adjusting the differential screws thread profile screws 21 . There is a plurality of the screws 21 spaced 3 to 4 inches apart laterally across the coater assembly. The doctor support 11 , on the enlarged shaped 13 A end of the curved bar 13 , allows the doctor assembly to pivot on the extended tip of the curved bar 13 when the loading by the load tube 19 is changed. The pivot point 17 A shown at dovetail groove 23 retains the support 11 to the complementary shaped end or tip 13 A of the curved bar 13 . This connection allows movement and also seals the pivot. It should be understood there are other generally pivot type connection options, such as a rod and socket assembly, or other means that could be used.
[0012] FIG. 2 is similar to FIG. 1 , except it shows the hooked plate or retainer 118 which can engage with the groove 118 B on the support 11 to limit lift of the doctor. As the coaters shown in FIGS. 1 and 2 are generally similar except for this difference, similar reference numerals are used in FIG. 2 , except the number is 100 higher. For example, 4 of FIG. 1 is shown as 104 in FIG. 2 .
[0013] FIG. 3 is similar to FIGS. 1 and 2 , but only shows the solid doctor rod 212 and its support 211 . Note that the doctor rod 212 and its complementary groove receiving the rod are smaller in diameter than for a hollow doctor roll. Again, except for these differences, the rod and support of FIG. 3 is similar to those of FIGS. 1 and 2 , and reference numerals are also similar, except given numbers 200 higher, that is, 23 in FIG. 1 or 123 in FIG. 2 , becomes 223 in FIG. 3 .
[0014] It should be understood that the doctor support of the present invention that can be used with any doctor be it generally integral in a coater, such as a short dwell time applicator type, or in a stand alone doctor roll, such as in a dip roll, separate doctor. It should also be understood that the doctor roll could have a plain smooth surface roll or a grooved roll. It should be further understood that the invention could be used when coating a paper or board web either directly or indirectly via a transfer roll. While specific elements and steps have been described, it should be understood that equivalent elements and steps will fall within the scope of the following claims.
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A doctor apparatus is disclosed and includes a doctor roll ( 12 ) supported in a coater ( 1 ) suitable for applying coating to a paper web surface or a roll surface ( 4 ) for subsequent transfer to the paper web. The doctor includes a doctor roll ( 12 ), a support ( 11 ) for the doctor roll ( 12 ), a front support ( 3 ) for holding the roll support ( 11 ) and a rear support or retainer ( 18 ) cooperates with and helps stabilize the support ( 11 ) and doctor roll ( 12 ). The present invention minimizes the variation moving of the doctor roll ( 12 ) has on the coating on the moving surface ( 4 ), be it web or roll, and thus can improve coating quality.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending application Ser. No. 11/796,060 filed Apr. 26, 2007 entitled “Horse Mounting Aid Assembly”, now U.S. Pat. No. 7,575,849, and Ser. No. 12/378,125 filed Feb. 11, 2009 entitled “A Stirrup Assembly” which is a continuation-in-part of said application Ser. No. 11/796,060. Full disclosures of said applications are incorporated herein by reference, the priority of which is hereby claimed.
BACKGROUND
The subject of this application relates to the field of equestrian equipment, and more particularly to a stirrup arrangement which permits the horseman to more safely and easily mount, ride and dismount a horse, or other rideable animal.
Traditionally, stirrups form parts of conventional horse mounting equipment and may be positioned on one or both sides of the saddle. Stirrups are designed not only to assist the rider in mounting, but also in maintaining balance during riding, and when dismounting.
For safety while riding, the bottom, foot resting, portion of the stirrup is generally located at a level where the rider's feet are comfortably engaged when the rider is in the saddle. Depending upon the height of the horse and the leg length of the rider, this may result in the stirrup being too high for the rider to easily engage for mounting the horse. Riders often attempt to overcome this difficulty by searching for something to stand on, or having another person physically assist them. Appropriate items, or persons, are often not available.
Another possibility is adjusting the stirrup to a lower than functional level for mounting, however, this presents the additional problem of readjusting the stirrup when the rider is sitting in the saddle. Even a highly experienced rider is dangerously exposed to an accident while trying to perform this maneuver. When the rider, in the saddle, attempts to reach down for drawing up the stirrup, the required leaning to one side can lead to a fall. Using traditional stirrups, the only safe way to adjust the height is to have another person, one who is dismounted, adjust them for the rider.
In the alternative, a rider may attempt to climb upon an object such as a bucket or ladder to reach the stirrup, but this also can lead to injury caused by the instability of the object or the animal moving at a critical time.
OBJECTS OF THE IMPROVEMENT
One object of the improved stirrup is to greatly increase the safety and convenience of mounting a horse or other rideable animal. Another object is the elimination of mounting drawbacks associated with traditional stirrups and substituting safe, reliable alternatives, without giving rise to excessive costs.
It is yet another object to define herein a fully integrated stirrup assembly which assists a person in mounting a horse from the ground, helps to keep the person safe during such mounting, and provides a simple, reliable transformation of the mounting procedure, and subsequent ride, into a more enjoyable activity.
SUMMARY OF THE IMPROVEMENT
The present improvement in stirrups creates a fully integrated arrangement which is safer, easier to use and more reliable for mounting and riding, as well as being suitable for either English or western type saddles. The improved stirrup allows the rider's foot to be safely positioned in the device during mounting and riding while prohibiting the rider's foot from becoming dangerously stuck or trapped therein.
These advantages are achieved through the provision of a mounting aid assembly which comprises, in one form, a pivotally mounted bottom portion, or step, to which a hollow, open ended, receiver or volume is attached. The receiver, in this example, comprises a cage formed from spaced-apart thin bars or wires, but may be constructed from a variety of other materials. The step presents a generally vertical, out-of-the-way, mounting support surface when pivoted to latched, riding position. However, in response to a small angular rotation in the opposite direction, for example, about a quarter circle, it engages a positioning stop fixed to the stirrup iron. Here the mounting support surface presents a generally horizontal, foot supporting attitude at a location substantially lower than the stirrup support surface used for riding. In this location the mounting support surface serves as a more convenient and safe target for the rider's foot insertion and subsequent swinging upwardly into the saddle. Once in the saddle, this example only needs a simple forward kick to pivot the step into the prior upper, latched position, where the foot is safely and comfortably received for riding without exposure to trapping in case of a fall. It further provides a simple, convenient and effective way to stow the mounting step when not needed.
In another form, the improved stirrup arrangement comprises a mounting step rigidly connected to, and supported by, a laterally offset brace which, in turn, is pivotally connected to a lower, laterally offset, area of the stirrup. The step and its support brace together form an “L” shape whereby, upon pivoting the brace, the mounting step is stowed, generally vertically and in greater part, above the level of the riding footrest, where it becomes a side wall of the stirrup foot entry. A resilient spring arrangement, associated with the pivotal connection, allows the sidewall step to rotate, and thereby move outwardly and downwardly under pressure. This movement creates a lateral opening, permitting a foot, otherwise trapped in the stirrup, to be released.
For mounting, the step and brace are rotated against the spring arrangement by hand to a position where the step latches into a horizontal, foot receiving attitude, well below the stirrup footrest. After mounting, foot pressure on the footrest releases the latch and the step rotates under spring pressure to its side wall, that is, riding position.
In both forms, appropriate stops are provided to limit rotation of the step between a functional, mounting aid position and a safe, foot withdrawal position. When the mounting aid device is pivoted from its normally stowed, upper, position downwardly, in both forms the step descends a sufficient distance below the stirrup support surface to substantially assist the rider in the mounting procedure. Once the rider is mounted, in one form of the improved stirrup, a quick forward jerk of the rider's foot will provide the impetus for the mounting portion to pivot up, roughly through about a quarter circle, and latch in foot protecting position. In the other form the mounting step device is hand cocked to its lower step position, where it locks for aiding the mounting procedure. After mounting the rider's foot on the footrest triggers a return of the mounting of the sidewall position where excess side pressure by the rider's foot causes pivotal wall movement sufficient to release an otherwise trapped foot.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the drawings, wherein like parts are designated by like numerals.
FIG. 1 is a perspective view of a first embodiment of the improved stirrup arrangement, showing the mounting step in stowed position and, by broken lines, also in functional position.
FIG. 2 is a perspective view of the stirrup arrangement of FIG. 1 showing, by broken lines, a rider's foot in riding position.
FIG. 3 is a front elevational view of the stirrup arrangement of FIG. 1 showing the mounting step in functional position and, by broken lines, in stowed position.
FIG. 4 is a front elevational view of the stirrup arrangement of FIG. 1 showing, by broken lines, an intermediate position of the mounting step pivoting toward the stowed position.
FIG. 5 is a partial, perspective view of the stirrup arrangement of FIG. 1 showing the mounting step in functional position and engaged with a mounting foot outlined by broken lines.
FIG. 6 is a partial perspective view of the stirrup arrangement of FIG. 1 showing the triggering of the mounting step release, resulting in the mounting step resting in the closed, sidewall stowed, position.
FIG. 7 is a partial elevational view of the stirrup of FIG. 1 with a portion broken away to show details of the mounting step latch release.
FIG. 8 is a perspective view of a second embodiment of the improved stirrup arrangement, showing the mounting step in latched, stowed position and, by broken lines, a rider's foot safely received in riding position.
FIG. 9 is a side elevational view of the embodiment of FIG. 8 showing the mounting step unlatched into functional mounting position and receiving a foot, illustrated in broken lines.
DETAILED DESCRIPTION
As required, detailed embodiments of the improvement are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the arrangement in virtually any appropriately detailed structure.
Referring to the drawings in more detail, in the embodiment of FIGS. 1-7 , the numeral 10 designates one type of stirrup assembly, or arrangement, in accordance with the present improvement. The assembly 10 comprises a modified English-style stirrup, or sometimes called stirrup iron, although it should be understood that the claimed features are appropriate also with modified western-style stirrups shown in FIGS. 8 and 9 .
The stirrup assembly 10 includes the basic functional parts to be considered a stirrup iron, such as a frame member 11 and footrest 12 but, in addition, has an auxiliary portion comprising a stirrup aid member, or mounting step device 14 , comprised, in this example, of a laterally offset brace 16 supporting a mounting step 18 . The upper end 20 of the mounting step device 14 is pivotally connected to the underside 22 of the bottom part, or footrest 12 , of the stirrup iron. The footrest 12 has sufficient lateral extension for receiving a rider's foot 25 thereon, FIG. 2 .
The pivotal connection between the mounting step device 14 and the footrest 12 , in this example, is provided by depending, spaced apart bearing mounts 26 , FIGS. 5 and 6 , receiving a transverse shaft 28 fixed to the device upper end 20 and surrounded by a helical spring 30 . The mounting step device upper end 20 is shaped to provide a surface 21 , FIG. 6 , which contacts the underside 22 of the footrest 12 when the mounting step device 14 is rotated to the mounting position shown in FIG. 5 . The surface 21 thereby provides a stop, rigidly preventing the mounting step from rotating beyond the position shown in FIG. 3 for mounting function. Contact between the brace 16 and the underside 22 of the footrest 12 produces a stop which prevents rotation in the opposite direction, past that shown in FIG. 2 .
An offset, axially projecting pin 32 , FIG. 5 , is shown mounted in the shaft 28 resting in contact against one end 34 of a trigger lever 36 . This contact prevents the transverse shaft 28 from rotating under pressure from helical spring 30 , thus maintaining the mounting step device in depending, functional position.
The trigger lever 36 is mounted for rocking on a transverse pin 38 and, at its other end 40 , terminates in a generally vertically projecting post 42 extending through and above an opening 44 in the footrest 12 . An appropriate spring 46 , best seen in FIG. 7 , applies resilient pressure against the end 34 of the trigger lever 36 , whereby the post 42 is urged upwardly through the opening 44 when such movement is not resisted by frictional contact with the pin 32 under the torsional pressure from the helical spring 30 . However, when a foot is placed on the footrest 12 the post 42 is urged, by the under surface of the foot, downwardly, releasing the pin 32 and thereby permitting the helical spring 30 to rotate the mounting step 18 into its sidewall, stowed position, FIG. 2 . The pin 32 then rests beneath the lever trigger end 34 , preventing the post 42 from rising until the mounting step is again needed, FIG. 6 .
The stirrup iron, in this example, has a fixed sidewall 48 which locates on the horse side of the stirrup assembly during normal use. The sidewall 48 is fixed to one end 50 of the footrest 12 and curves at its upper portion 52 to produce a shape similar to the inverted letter “J.” The upper portion 52 of the sidewall 48 includes a bridge 54 through which an adjustable leather support strap (not shown) may be engaged in a conventional manner.
In the example shown in FIGS. 1-7 the footrest 12 is supported only by the connection 56 between the sidewall 48 and the footrest 12 , however, the sidewall and connection can be modified in size and strength as needed for performance. The desired closure, or surrounding of the foot resting on the footrest, in this example, is provided by the mounting step 18 when in stowed position, as best illustrated in FIG. 2 . It is to be understood that additional braces or sidewall members (not shown) could be used in conjunction with the stowed mounting step 18 to provide additional resistance against foot release under special circumstances, such as unusually hard riding. However, this would tend to defeat the safety feature offered by the improved arrangement by increasing the danger of foot locking in the stirrup in case of a fall.
One functional operation series for the example shown in FIGS. 1-7 is as follows: FIG. 1 illustrates, in broken lines, a finger contacting the mounting step 18 , shown in a stowed position from prior use of the stirrup iron. By being pulled downwardly, the mounting step 18 rotates about the shaft 28 , winding the helical spring 30 . This movement also rotates the pin 32 counterclockwise about the axis of the shaft 28 , toward the position 33 , as shown in broken lines, FIG. 7 . This allows the spring 46 to raise the post 42 to the point where the trigger lever 36 urges the post 42 through the footrest 12 to a position terminating above the footrest surface, as shown in FIG. 3 . This also allows the pin 32 to engage the end 34 of the lever 36 , locking the mounting step 18 in a position substantially below the footrest 24 and at a level more conveniently reached by the person mounting the horse to more easily swing up and over the horse and into the saddle (not shown). The foot is then removed from the mounting step 18 and placed on the footrest, virtually automatically depressing the post 42 down to approximately the same level as the footrest surface. This causes trigger lever end 34 to move off of the pin 32 whereupon the helical spring 30 rotates the brace 16 , and its attached mounting step 18 clockwise as shown in FIG. 4 and the arrow 19 of FIG. 7 . The rotation stops when the mounting step reaches the stowed position shown in FIG. 2 for riding. The above results are obtained while the rotating mounting step moves only through about a quarter circle instead of the apparent need for a half circle or greater rotation.
Further, if the rider should fall, due to rough riding or other reason, the stowed mounting step 18 will rotate outwardly and downwardly, under the pressure of a foot, which may otherwise be trapped. This will produce a release, virtually eliminating the danger of a foot lock, and being dragged head down. In the event a rider prefers a greater resistance to rotation than supplied, this can often be adequately addressed through selecting a helical spring of greater resistance.
Turning now to the second embodiment, illustrated in FIGS. 8 and 9 , which is adapted for use with a western-style stirrup iron 58 having spaced apart side walls 59 . A bottom portion or mounting step 60 is rotatably connected by side mounted pivots 62 for pivotal motion from a forwardly projecting position, shown in FIG. 8 , to a generally vertical position shown in FIG. 9 . The rotation from the horizontal to the vertical position is restricted, in this example, by a projecting stop 64 which is positioned to contact a mating projection 65 on mounting step sidewalls 66 and 68 . The center area 70 of the bottom portion or mounting step 60 has an extension 72 providing additional support for contact between the foot, shown in broken lines, and the mounting step, FIG. 9 .
Spaced-apart thin bars or wires 74 extend from the sidewalls and center of the mounting step 60 to an anchor rod 76 , also connected to the bottom portion or mounting step 60 , together forming a hollow, open ended cage for receiving the foot therein. Although thin bars or wires are shown in the present example, the hollow open ended foot receiver may be constructed of a variety of other materials, such as leather, screen or suitable plastic.
The mounting step 60 is normally maintained in position forwardly and frontally of the stirrup iron 58 by means of one or more appropriate latches 78 which, in this example, engage the anchor rod 76 . In this position a receiving volume is created whereby a foot may enter the open end and ride comfortably without danger of the foot extending through the stirrup iron and being dangerously trapped in case of a fall.
When, however, it is desired to utilize the device as a mounting step, it is a simple matter to release the latch 78 whereupon the bottom portion or mounting step 60 moves through a surprisingly small approximate quarter circle, whereupon the projection 64 of the sidewall 66 contacts the stop 62 and the mounting step 60 is presented for use at a significantly lower level than the riding surface or footrest 80 . In this location the mounting step 60 , and its extension 72 , are presented generally horizontally and substantially lower than the functional stirrup surface, thereby serving as a more convenient and safe target for the rider to utilize by foot insertion and swinging upwardly into the saddle.
Once in the saddle a simple forward kick against the mounting step by the foot will easily pivot the step into the prior upper latched position where the foot confining configuration is in effect for safe riding. In addition, the arrangement described provides a convenient and effective ability to stow the mounting step.
Many other changes and modifications can be made in the design of the present arrangement without departing from the spirit thereof. Therefore it is requested that the rights to the improvement be limited only by the scope of the appended claims.
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A horse stirrup which also functions as a mounting aid by providing, in the same assembly, a foot supporting platform for riding, as well as a convenient, lower level platform for mounting. The mounting platform, and related structure, also function, in cooperation with the riding platform, to reduce the exposure of the rider to stirrup foot lock in case of a fall.
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TECHNICAL FIELD
[0001] The invention relates to an aerodynamic side mirror assembly and a method of manufacturing the same.
BACKGROUND OF THE INVENTION
[0002] Motor vehicles are generally equipped with side mirror assemblies that extend outboard of vehicle body structure in order to allow a driver to view images of objects outside of the vehicle and rearward of the side mirror assembly. Although side mirror assemblies are generally streamlined to the extent possible, because they increase the lateral profile of the vehicle, they nevertheless increase the drag on the motor vehicle, with a corresponding reduction in fuel economy.
SUMMARY OF THE INVENTION
[0003] A side mirror assembly is provided with a plurality of mirror members arranged in a longitudinal array to decrease the lateral profile of the side mirror assembly, and thereby potentially increase fuel economy, without sacrificing field of view for the driver. The mirror members are arranged with reflective surfaces, at least some of which are angled with respect to a longitudinal axis running through the array, with the angles generally decreasing in a forward direction along the array. An image of an object outside of the vehicle reflected by the mirror members is not reversed (i.e., the image is not a “mirror image” in which right and left sides are switched or flipped), thus increasing the ability of the driver to mentally process the image and respond in an appropriate manner.
[0004] In one embodiment, the mirror members may be selectively moved from the configuration described above, to a configuration in which the mirror members are arranged to form the equivalent of a continuous, planar mirror member. The change in configuration may be in response to a change in vehicle speeds, with the longitudinal array being used for high vehicle speeds and the substantially contiguous, planar arrangement being used for lower vehicle speeds in which aerodynamic drag is less affected by the side mirror assembly. A drive assembly may be used to automatically change the configuration of the mirror members in response to a repositioning of a housing for the side mirror assembly with respect to the vehicle.
[0005] At least some embodiments of the side mirror assemblies described herein may be manufactured by a method that includes injection molding a substantially transparent base that has surfaces spaced apart from one another in a longitudinally-oriented array. At least some of the surfaces are not parallel with one another and are positioned at obtuse angles with respect to longitudinal axis running through the surfaces. The surfaces are aluminized to form reflective mirror members on the surfaces. A clear protective coating may be placed on the aluminized surfaces. The aluminized surfaces are then overmolded with additional transparent material, as was used for the base, to encase the reflective mirror members within this material.
[0006] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic illustration in plan view of a partially formed side mirror assembly having a transparent base member with stepped base surfaces;
[0008] FIG. 2 is a schematic illustration in plan view of the transparent base member of FIG. 1 , with the stepped base surfaces having aluminized mirror members thereon and with a protective coating over the mirror members;
[0009] FIG. 3 is a schematic illustration in plan view of the side mirror assembly of FIGS. 1 and 2 with the transparent base member overmolded to encase the stepped base surfaces and mirror members;
[0010] FIG. 4 is an alternative embodiment of a side mirror assembly formed according to the method illustrated in FIGS. 1-3 , but having aluminized mirror members with a convex shape;
[0011] FIG. 5 is a schematic illustration in fragmentary, partial cross-sectional plan view of the side mirror assembly of FIGS. 1-3 mounted to a vehicle, and illustrating reflection of an image by the mirror members without reversing the image;
[0012] FIG. 6 is a schematic illustration in fragmentary, partial cross-sectional plan view of a third embodiment of a side mirror assembly, illustrating the side mirror assembly in two positions with respect to a vehicle body, with the mirror members moving from a first configuration (shown in phantom) to a second configuration via a drive assembly when the position of the side mirror assembly is changed; and
[0013] FIG. 7 is a partial front view of the side mirror assembly of FIG. 6 , showing the mirror members in the second configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to the drawings, wherein like reference numbers refer to like components, FIGS. 1-3 illustrate a method of manufacturing a first embodiment of a side mirror assembly 10 , shown in FIG. 3 . In FIG. 1 , a base member 12 is formed by blow-molding. The base member 12 is a transparent plastic material having stepped surfaces 14 , 16 , 18 , 20 , 22 , and 24 . As illustrated in FIG. 2 , the stepped surfaces 14 , 16 , 18 , 20 , 22 , and 24 are aluminized to form mirror members 26 , 28 , 30 , 32 , 34 and 36 on the respective stepped surfaces. A clear protective coating 40 is coated over each of the mirror members 26 , 28 , 30 , 32 , 34 and 36 . As illustrated in FIG. 3 , the base member 12 with stepped surfaces 14 , 16 , 18 , 20 , 22 , and 24 and mirror members 26 , 28 , 30 , 32 , 34 and 36 is then overmolded, i.e., additional transparent material as was used to form base member 12 is molded over base member 12 to form a final molded shape in which the mirror members 26 , 28 , 30 , 32 , 34 and 36 are encased in the transparent plastic material. The stepped surfaces 14 , 16 , 18 , 20 , 22 , and 24 and the protective coating 40 shown in FIGS. 1 and 2 are not apparent after the over-molding to the final shape of FIG. 3 . Blow-molding to the final shape of the side mirror assembly 10 adds a rounded forward surface 42 which is forward facing when the side mirror assembly 10 is mounted to a vehicle body, as shown in FIG. 5 , to add to the aerodynamic nature of the elongated side mirror assembly 10 .
[0015] Referring to FIG. 3 , the mirror members 26 , 28 , 30 , 32 , 34 , and 36 are spaced apart from one to another in a longitudinally-oriented array 44 oriented with a longitudinal axis 46 extending through the mirror members 26 , 28 , 30 , 32 , 34 , and 36 . Referring again to FIG. 2 , in this embodiment, each of the mirror members 26 , 28 , 30 , 32 , 34 , and 36 has a respective substantially planar reflective surface 50 , 52 , 54 , 56 , 58 , and 60 . As is clear in FIG. 3 , the reflective surfaces 50 , 52 , 54 , 56 , 58 , and 60 , are positioned at various angles with respect to the longitudinal axis 46 . The reflective surface 50 is at an angle Θ 1 of approximately 90 degrees with respect to the longitudinal axis 46 . The reflective surfaces 52 , 54 , 56 , 58 , and 60 are at various angles Θ 2 , Θ 3 , Θ 4 , Θ 5 , and Θ 6 with respect to the longitudinal axis 46 . Each of the angles Θ 2 , Θ 3 , Θ 4 , Θ 5 , and Θ 6 is obtuse (i.e., greater than 90 degrees). At least some of the various angles Θ 1 , Θ 2 , Θ 3 , Θ 4 , Θ 5 , and Θ 6 are different from one another. Generally, the angles increase from Θ 2 to Θ 6 .
[0016] Additionally, each of the mirror members, 26 , 28 , 30 , 32 , 34 , and 36 is characterized by a respective width W 1 , W 2 , W 3 , W 4 , W 5 , and W 6 . The widths generally increase from W 6 to W 1 , i.e. the widest mirror member 26 is oriented at the end of the mirror assembly 10 intended to be toward the front of the vehicle, while the narrowest mirror member 36 with a width W 6 is rearward. Preferably, the widths of the mirror members increase in order as follows: W 6 , W 5 , W 4 , W 3 , W 2 , and W 1 . The different widths of the mirrors account for the variation in distance that light must go through in traveling from the object 74 of FIG. 5 to the eye 70 . The widths may also be designed to account for different reflective indices of the media (i.e., air, base member 12 , then air) that the light travels through. The preferred size of the angles Θ 1 , Θ 2 , Θ 3 , Θ 4 , Θ 5 , and Θ 6 and widths W 1 , W 2 , W 3 , W 4 , W 5 , and W 6 along the longitudinal array 44 allows the side mirror assembly 10 to reflect an image of an object outside of a vehicle without reversing the image. This is indicated in FIG. 5 , which shows a fragmented portion of the side mirror assembly 10 mounted to a vehicle 62 . Specifically, the side mirror assembly 10 is mounted via a mounting member 64 to a vehicle door 66 in a longitudinal position substantially aligned with the position of an A-pillar member 68 . The mounting member 64 may be of a plastic, metal, or other sufficiently rigid and strong material to retain the side mirror assembly 10 to the door 66 . With the side mirror assembly 10 operatively connected to the vehicle 62 in this manner, a driver positioned in a driver's seat, indicated by a schematic representation of an eye 70 can utilize the side mirror assembly 10 by looking through the window 72 to view an object 74 located outside of the vehicle 62 without reversing an image of the object 74 . The mounting member 64 may be pivotable to allow adjustment of the mirror members 26 , 28 , 30 , 32 and 34 with respect to the position of the eye, especially for different eye positions of different drivers.
[0017] As illustrated in FIG. 5 , the object 74 is divided into zones Z 1 and Z 2 . The closest zone Z 1 , i.e., the zone most inboard and therefore closest to the viewer, has an image reflected by the mirror member 26 to the eye 70 in a viewing zone Z 1 A. As used herein, “inboard” refers to a direction laterally inward toward a longitudinal centerline of a vehicle. “Outboard” refers to a direction laterally outward from a longitudinal centerline of the vehicle. The zone Z 2 of the object 74 has an image reflected by the mirror member 28 , which is closer to the eye 70 and at a greater angle Θ 2 to the longitudinal axis 46 , as shown in FIG. 3 , and therefore able to reflect the further outboard zone Z 2 A in a viewing zone Z 1 A. The boundaries of light reflected from the object 74 off of the respective reflective surfaces 50 , 52 to the eye 70 is marked by phantom lines coincident with the opposing ends of the respective reflective surfaces 50 , 52 ; such boundaries establish the zones Z 1 , Z 2 and the viewing zones Z 1 A, Z 2 A. It is assumed to any refraction of light entering and exiting the base material 12 prior to reflection off of the mirror members 26 , 28 is negligible. However, the angles of the mirror members 26 , 28 , 30 , 32 , 34 , and 36 with respect to the longitudinal axis 46 as well as the widths W 1 , W 2 , W 3 , W 4 , W 5 and W 6 may be adjusted to take such refraction into account so that the object 74 is reflected by the mirror members 26 , 28 , 30 , 32 , 34 and 36 without reversal of the image as described above.
[0018] The mirror member 28 reflects zone Z 2 in place of a mirror portion 76 of mirror member 26 that would have been needed to extend outboard from mirror member 26 in order to reflect an image of the same zone Z 2 . The additional mirror members 30 , 32 , 34 and 36 , having reflective surfaces 54 , 56 , 58 and 60 being at respectively increasing angles with respect to the longitudinal axis 46 of FIG. 3 , reflect zones respectively in order outboard from zone Z 2 , creating additional viewing zones respectively in order moving counterclockwise from viewing zone Z 2 A, extending the field of vision outboard of object 74 . Respectively larger mirror portions of a mirror would need to extend outboard of mirror portion 76 to cover the same field of vision. Thus, by stacking the mirror members 26 , 28 , 30 , 32 , 34 and 36 in a longitudinal array 44 , the same field of vision is viewable as with a much wider single plane mirror, and this achieved without reversing the image. The side mirror assembly 10 extends much less outboard of the vehicle door 66 than would a single mirror offering the same field of vision, thus minimizing the drag affect of the side mirror assembly 10 on the vehicle 62 . By increasing by hundreds or even thousands the number of mirror members of side mirror assembly 10 , while decreasing the width of the mirror members, the side mirror assembly 10 may offer a relatively wide field of vision with an almost paper thin overall width.
[0019] FIG. 4 shows an alternative embodiment of a side mirror assembly 100 manufactured according to the same method described with respect to FIGS. 1-3 . The stepped surfaces (no longer visible in the FIG. 4 ) of the base member used in forming the side mirror assembly 100 are slightly convex, so that the aluminized mirror members 126 , 128 , 130 , 132 , 134 and 136 aluminized on the stepped surfaces have a convex shape, allowing each to have a wider view, as is understood by those skilled in the art.
[0020] The side mirror assemblies 10 and 100 may thus be manufactured according to a method, described with respect to side mirror assembly 10 , that requires injection molding a substantially transparent base 12 so that the base 12 has stepped surfaces 14 , 16 , 18 , 20 , 22 and 24 spaced apart from one another in a longitudinally-oriented array 44 in which at least some of the stepped surfaces 14 , 16 , 18 , 20 , 22 and 24 are not parallel with one another and are positioned at obtuse angles Θ 2 , Θ 3 , Θ 4 , Θ 5 , and Θ 6 with respect to the longitudinal axis 46 . The stepped surfaces 14 , 16 , 18 , 20 , 22 and 24 are then aluminized to create respective reflective surfaces 50 , 52 , 54 , 56 58 and 60 thereon. After that, a clear protective coating 40 may be coated over each of the reflective surfaces 50 , 52 , 54 , 56 , 58 and 60 prior to over-molding the aluminized surfaces to encase the mirror members 26 , 28 , 30 , 32 , 34 and 36 within transparent plastic.
[0021] Referring to FIGS. 6 and 7 , another embodiment of a side mirror assembly 210 is shown that is selectively movable between a low speed position best suited for relatively low vehicle speeds, where aerodynamic drag is less significant, and a high speed position 210 A, shown in phantom, that extends much less outboard of a vehicle 262 than when in the low speed position. The side mirror assembly 210 is mounted to a vehicle door 266 via a mounting member 264 at a longitudinal position on the vehicle 262 roughly equivalent with an A-pillar member 268 to which the door 266 is hinged. The side mirror assembly 210 includes a housing 280 pivotably attached to the mounting member 264 , and movable either manually or via a motor acting on a pivot member 282 between the low speed and high speed positions. The housing 280 is shown fragmented in order to view a plurality of mirror members 226 , 228 , 230 , 232 , and 234 arranged with respective reflective surfaces 252 , 254 , 256 , 258 and 260 in a planar configuration, referred to herein as a second configuration. In the planar configuration, the reflective surfaces 252 , 254 , 256 , 258 , and 260 lie in a single plane, and function the same as a single mirror pane of equivalent size.
[0022] When the housing 280 moves to the high speed position 210 A, the mirror members 226 , 228 , 230 , 232 and 234 are controlled to move to a first configuration in which the mirror members 226 , 228 , 230 , 232 and 234 are positioned in a longitudinal array 244 with a longitudinal axis 246 running therethrough. The mirror members 226 , 228 , 230 , 232 and 234 are of increasing widths from mirror member 234 to mirror member 226 , rearward to frontward with respect to the vehicle 262 . Additionally, the mirror members 226 , 228 , 230 , 232 , and 234 have respective reflective surfaces disposed at decreasing angles with respect to the longitudinal axis 246 rearward to frontward, as described with respect to corresponding mirror members 26 , 28 , 30 , 32 and 34 in the embodiment of FIG. 3 . Thus, the mirror members 226 , 228 , 230 , 232 and 234 reflect an image of an object outside of the vehicle 262 without reversing the image to an occupant (not shown) seated inside of the vehicle 262 (i.e., on the opposite side of window 272 from the side mirror assembly 210 . As the side mirror assembly 210 is moved between the low speed and high speed positions, a drive assembly 288 causes the mirror members 226 , 228 , 230 , 232 and 234 to move between the planar configuration and the longitudinal array configuration. The drive assembly 288 includes a motor 290 that drives a worm gear 292 in the direction of the arrow shown to move from the planar configuration to the configuration of the longitudinal array 244 as the housing 280 is moved. The worm gear 292 intermeshes with gears 293 , 294 , 295 , 296 and 298 to turn the gears 293 , 294 , 295 , 296 and 298 a respective amount relative to the worm gear 292 that depends on the tooth ratio of the respective gears 293 , 294 , 295 , 296 and 298 to the worm gear. Each respective gear 293 , 294 , 295 , 296 and 298 is mounted via a respective shaft 300 , 302 , 304 , 306 and 308 for common rotation with a respective one of the mirror members, as best shown in FIG. 7 . Thus, by choosing appropriate gear counts for the gears 293 , 294 , 295 , 296 and 298 relative to the worm gear 292 , the angle of the reflective surfaces of the mirror members 226 , 228 , 230 , 232 and 234 to the longitudinal axis 246 is controlled and the correct configuration of mirror members is assured. FIG. 7 shows the mirror members 226 , 228 , 230 , 232 and 234 in the planar configuration with the mirror surfaces effectively forming a single continuous mirror pane.
[0023] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A side mirror assembly is provided with a plurality of mirror members arranged in a longitudinal array to decrease the lateral profile of the side mirror assembly, and thereby potentially increase fuel economy, without sacrificing field of view for the driver. The mirror members are arranged with reflective surfaces angled with respect to a longitudinal axis running through the array, with the angles generally decreasing in a forward direction. An image of an object outside of the vehicle reflected by the mirror members is not reversed (i.e., the image is not a “mirror image” in which right and left sides are switched or flipped), thus increasing the ability of the driver to mentally process the image and respond in an appropriate manner. A method of manufacturing a side mirror assembly is also provided.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a washing machine, more particularly, to a washing machine having a floatage clutch that performs the intermittence of power in cleansing and dehydrating operations by using the floatage thereof.
[0003] 2. Description of the Related Art
[0004] Generally speaking, a washing machine is used to clean, rinse and dehydrate clothes and the like by using a mechanical operation via an electric driving motor. The washing machine includes a cleansing part for performing a cleansing work, and a driving part for driving the cleansing part. The washing machines can be classified into agitator type washing machines, drum type washing machines, and pulsator type washing machines according to a cleansing manner of the cleansing part.
[0005] The cleansing part of the pulsator type washing machine as described above, as shown in FIG. 1, includes a water tub 12 installed in a case 10 , a cleansing basket 14 rotatably contained in the water tub 12 , a pulsator 16 disposed at the bottom of the cleansing basket for forming a water stream, a water tab 17 , and a drain valve 18 . The cleansing basket 14 is punched with numerous dehydration holes 14 a in a sidewall thereof.
[0006] In addition, the driving part includes a driving motor 20 , a transmission 30 and a clutch mechanism 40 for driving the pulsator 16 and the cleansing basket 14 by receiving a driving force of the driving motor 20 , a belt connection means for transferring the driving force of the driving motor 20 to the clutch mechanism 40 , and a brake means for maintaining the stable fixed state of the transmission 30 .
[0007] As shown in FIG. 2, the transmission 30 includes a gear box 32 , an upper and lower pulsator shafts 33 and 34 connected each other via a gear means disposed within the gear box 32 , and a spin shaft 35 fixed to the gear box 32 (See FIG. 4). The upper pulsator shaft 33 is designed to be rotatably fitted in the spin shaft 35 and connected to the pulsator 16 . The spin shaft 35 is connected to the cleansing basket 14 and fixed to the gear box 32 . The lower pulsator shaft 34 is formed with a serration part 341 on the lower end thereof and constructed to be protruded exceeding the gear box 32 downwardly (See FIG. 3.).
[0008] As shown in FIG. 3, the clutch mechanism 40 includes a spin shaft block 42 fixed to the lower end of the gear box 32 , a spring block 46 disposed on the one side of the spin shaft block 42 , which is engaged with the serration part 341 of the lower pulsator shaft 34 and fixed to a pulley 44 of the belt connection means, and an one-way spring 48 disposed to be surrounded the spin shaft block 42 and the spring block 46 (See FIG. 1). Here, a tight fastening state and a releasing state of the one-way spring 48 is controlled according to the rotating direction thereof.
[0009] In addition, as shown in FIG. 4, the gear means constructed in the gear box 32 of the transmission 30 includes a pinion gear 50 attached to the lower end of the upper pulsator shaft 33 , an eccentric crank 52 formed with a rack gear portion 521 to be engaged with the pinion gear 50 , a first gear 54 disposed on the same rotating axial line to be engaged with the eccentric crank 52 , and a second gear 56 attached to the upper end of the lower pulsator shaft 34 to be engaged with the first gear 54 .
[0010] The brake means includes a brake disk 60 disposed under the gear box 32 , a brake frictional portion 62 formed on the top surface of a frame 19 of suspension means, which has a corresponding shape to the brake disk 60 , and position adjustment means (not shown) for controlling the separation and contact states between the brake disk 60 and the brake frictional portion 62 by vertically adjusting the position of the gear box 32 according to the operating direction of the driving motor 20 (See FIG. 1).
[0011] A washing process of the pulsator type washing machine constructed as described above includes the following steps in order: 1) a water supply step for supplying water into the cleansing basket 14 through the water tab 17 ; 2) a cleansing step for circulating the water and laundry during a desired time via the rotating operation of the pulsator 16 ; 3) a rinsing step for rinsing the laundry as much as certain times by supplying clear rinsing water not containing any detergents after draining the water through the drain valve 18 ; and 4) a dehydrating step for driving the cleansing basket 14 at a high speed to dehydrate the laundry.
[0012] In the water supply step of the washing process, the water just entered through the water tab 17 is changed into a cleansing water containing a detergent with by passing in a detergent container. Also, in the cleansing step, a removal work of contaminants clinging to the laundry is performed under a chemical operation of detergent contained in the cleansing water as well as a physical operation of the pulsator 16 . The pulsator 16 is repeatedly rotated, that is intermittently reversed, in forward and backward by the transmission 30 , so that a both directional water stream composed of a left-and-right water stream and an up-and-down water stream can be formed to effectively perform the cleansing work of the laundry.
[0013] Then, in a state that the clear rinsing water not containing the detergent is supplied during the rinsing step, the detergent clinging to the laundry is also effectively removed by using the both directional water streams formed by the rotation of the pulsator 16 in the same manner with the cleansing step. Finally, in the dehydrating step, the cleansing basket 14 is rotated in one direction at a high speed after the rinsing water is completely drained, then the water contained in the laundry can be discharged via the dehydration holes 14 a due to centrifugal force. In this case, the laundry is tightly contacting with the inner wall of the cleansing basket 14 .
[0014] In the dehydrating step, since the cleansing basket 14 and the pulsator 16 are simultaneously rotated in the same direction, it is possible to prevent the damage of the laundry from being caught to the pulsator 16 . Also, the water discharged through the dehydration holes 14 a of the cleansing basket 14 is drained out of the washing machine as soon as the drain valve 18 is opened.
[0015] Meanwhile, the rotating operation of the cleansing basket 14 and the pulsator 16 in all steps are performed by the driving part as described above. The operation of the driving part will be explained in detail as follows.
[0016] First of all, in the cleansing step, the pulley 44 is rotated in clockwise direction by the driving force of the driving motor 20 , and then the spring block 46 connected with the pulley 44 and the lower pulsator shaft 34 coupled with the serration portion of the spring block 46 are rotated. At this time, the one-way spring 48 loosened, and since the brake disk 60 and the brake frictional portion 62 are in tightly contact with each other, so the gear box 32 is in a fixed state. In addition, as the lower pulsator shaft 34 is rotated, the first gear 54 engaged with the second gear 56 and the second gear 56 within the gear box 32 are rotated, and at the same time, the eccentric crank 52 disposed on the same rotating axial line of the first gear 54 is actuated.
[0017] In this case, the eccentric crank 52 is linearly reciprocated about the rotating axial line due to the structural feature thereof, then the upper pulsator shaft 33 can be reciprocated by the pinion gear 50 engaged with the rack gear portion 521 of the eccentric crank 52 , and consequently the pulsator 16 can be achieved in the forward and backward rotation.
[0018] Additionally, in the dehydrating step, the driving motor 20 is rotated in counterclockwise direction in opposite to the cleansing step, and the spring block 46 connected with the pulley 44 and the lower pulsator shaft 34 coupled with the spring block 46 are rotated in counterclockwise direction. In this case, the one-way spring 48 is fastened so that the spring block 46 and the spin shaft block 42 can be coupled, and the brake disk 60 and the brake frictional part 62 are separated by the operation of the position adjustment mechanism. Therefore, the gear box 32 and the spin shaft 35 are rotated with the spin shaft block 42 . Since, the upper pulsator shaft 33 is rotated in the same direction, then the cleansing basket 14 and the pulsator 16 are rotated at the same time to perform a dehydrating work.
[0019] According to the related pulsator type washing machine, because the pulsator 16 is rotated in forward and backward to generate the complex water stream, the effect of cleansing is relatively high. And, the conversion from the cleansing step to the dehydrating step is automatically performed due to the conversion of operating direction of the driving motor 20 and the linking structure of the transmission 30 and the clutch mechanism 40 .
[0020] However, substantial problems exist in this related construction. First of all, the structures of the transmission 30 and the clutch mechanism 40 for transferring the driving force of the driving motor 20 to the pulsator 16 and the cleansing basket 14 have complex structures, which deteriorates the productivity of the washing machine. Also, since the cleansing work is performed only by the simple forward and backward rotation of the pulsator 16 , it is impossible to achieve various cleansing operations suitable for the feature of the laundry, thereby deteriorating a merchant ability of the washing machine.
SUMMARY OF THE INVENTION
[0021] The present invention has been made to overcome the above-described problems. Accordingly, it is an object of the present invention to provide a washing machine having a floatage clutch, which can smoothly switch a power transmission state in the conversion between the cleansing step and the dehydrating step by using the floatage thereof, and which can secure the stability of the switching process.
[0022] To achieve the above objects, there is provided a washing machine comprises a water tub; a cleansing basket rotatably contained within the water tub; a pulsator rotatably mounted on the bottom surface of the cleansing basket, having a wing part for forming a water stream, a hub part disposed in the center of the wing part, and a hollow shaft part protruded from the bottom of the hub part exceeding the cleansing basket downwardly; a driving motor for generating a driving force required to rotate the cleansing basket and the pulsator; a transmission for transmitting the driving force of the driving motor to the cleansing basket and the pulsator, having a hollow dryer shaft integrated to the cleansing basket; and a washing shaft penetrating the hollow dryer shaft, of which the upper end passes the hollow shaft part of the pulsator and then is fixed to the hub part, and of which the lower end is connected with the driving motor; and a floatage clutch for allowing the cleansing basket to selectively cooperate with the pulsator by being intermittently actuated depending on the existence and nonexistence of water, having a float engaged with the washing shaft to be capable of moving up and down and linked with the hollow shaft part of the pulsator to be capable of moving up and down due to floatage, and a fixed member fixed to the upper end of the hollow dryer shaft to be separated from and coupled with the float at the lower side thereof.
[0023] The float of the floatage clutch includes a hub portion inserted into the hollow shaft part of the pulsator, and a tube portion, disposed around the hub portion, for allowing the water to be flown into a space defined between the hub portion and the tube portion, wherein the fixed member is constructed as a shaft of which the lower end is connected with the cleansing basket and of which the upper end is inserted into the hub portion of the float.
[0024] The water absorption holes are formed on the top surface of the pulsator, and a centrifugal wing portion is provided on the bottom surface of the pulsator, wherein the water absorbed via the water absorption holes pass a filtering net through a fluid channel between the water tub and the cleansing basket by shaping the tube portion of the float as a conical form to facilitate the smooth movement of the water via the water absorption holes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a cross sectional view illustrating the construction of a related washing machine.
[0026] [0026]FIG. 2 is a perspective view illustrating the construction of a transmission of the related washing machine.
[0027] [0027]FIG. 3 is an exploded perspective view illustrating the construction of a clutch mechanism of the related washing machine.
[0028] [0028]FIG. 4 is a perspective view illustrating the construction of gear means applied in the transmission of the related washing machine.
[0029] [0029]FIG. 5 is a perspective view illustrating the construction of essential parts of a washing machine in accordance with an embodiment of the present invention,
[0030] [0030]FIG. 6 is an exploded perspective view illustrating the construction of a floatage clutch applied in the washing machine in accordance with the embodiment of the present invention.
[0031] [0031]FIG. 7 is a cross sectional view taken on the line VII-VII in FIG. 6 illustrating the construction of a float of the floatage clutch applied in the embodiment of the present invention.
[0032] [0032]FIG. 8 is a state view illustrating the operation of the floatage clutch applied in the embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] An embodiment of the present invention will now be described in more detail with reference to FIG. 5 to FIG. 8. In the following description, same drawing reference numerals are endowed in the same parts with the related construction.
[0034] First, FIG. 5 shows a washing machine in accordance with the embodiment of the present invention. The washing machine includes a water tub 12 , a cleansing basket 14 contained within the water tub 12 , a pulsator 16 rotatably mounted in the cleansing basket 14 , a transmission 70 for controlling the rotating direction of the pulsator 16 and the cleansing basket 14 , a floatage clutch 80 for allowing the cleansing basket 14 to selectively cooperate with the pulsator 16 by being intermittently actuated depending on the existence and nonexistence of water, and a driving motor 22 for generating the driving force required to rotate the cleansing basket 14 and the pulsator 16 .
[0035] Here, the pulsator 16 includes a wing part 161 , a hub part 162 disposed in the center of the wing part 161 , and a hollow shaft part 163 formed in the bottom plane of the hub part 162 . The hollow shaft part 163 is constructed to be protruded exceeding the cleansing basket 14 downwardly.
[0036] The transmission 70 includes a hollow dryer shaft 72 integrated to the bottom plane of the cleansing basket 14 , several bearings 76 supporting the hollow dryer shaft 72 , and a washing shaft 74 mounted by penetrating the hollow dryer shaft 72 , is fixed to the hub part 162 by passing the hollow shaft part 163 of the pulsator 16 , and is connected with the driving motor 22 .
[0037] In addition, the floatage clutch 80 includes a float 82 coupled with the washing shaft 74 to be capable of moving up and down, and a fixed member 83 fixed to the upper end of the hollow dryer shaft 72 . The fixed member is able to be separated from and coupled with the float at the lower side of the float. The float 82 has a hub portion 821 to be inserted into the hollow shaft part 163 of the pulsator 16 , and a tube portion 822 constructed around the hub portion 821 . The fixed member 83 is constructed as a shaft of which the lower end is connected with the cleansing basket 14 and the upper end is inserted into the hub portion 821 of the float 82 (See FIG. 6).
[0038] Here, the hub portion 821 of the float 82 is formed with an inner top surface of convex-concave shape teethed structure. The tube portion 822 has an opened bottom plane as well as is divided into several sections to form several clearances 82 a as shown in FIG. 7, then the water is capable of flowing around the hub portion 821 .
[0039] The washing machine constructed as described above will be operated as follow.
[0040] First, if a given quantity of water is supplied into the cleansing basket 14 in the water supply step, the float 82 is floated up and separated from the fixed member 83 due to the floatage thereof, as shown in FIG. 8 a . The the floatage clutch 80 is reached to a power cutoff state, so the driving force of the driving motor 22 is transferred only to the washing shaft 74 .
[0041] At this moment, the water entered the pulsator 16 upwardly is flown around the hub portion 821 via the several clearances 82 a defined between the separated tube portions 822 of the float 82 . Accordingly, the lower region of a space between the hollow shaft part 163 and the hub portion 821 of the float 82 is closed with the water.
[0042] Therefore, the water can't invade to the interior space of the hollow shaft part 163 by virtue of the air pressure within the hollow shaft part 163 .
[0043] In this power cutoff state of the floatage clutch 80 , when the driving motor 22 is driven, only the pulsator 16 connected with the washing shaft 74 is rotated in the initial of the cleansing step. After that, the driving motor 22 is repeatedly driven in forward and backward, then the pulsator 16 also is rotated in forward and backward direction in the same manner with the driving motor. The driving motor and the pulsator is intermittently onversed in the forward and backward rotation.
[0044] Due to the forward and backward rotation of the pulsator 16 , a rotating water stream can be formed. If the pulsator 16 is continuously rotated in one direction more than a certain time, the cleansing basket 14 is also rotated in the same direction with the pulsator by the water stream. Then, the water can be discharged via dehydration holes 14 a out of the cleansing basket 14 due to the centrifugal force. Furthermore, the discharged water can be again flown into the cleansing basket 14 through the fluid channel between the cleansing basket 14 and the water tub 12 . This washing manner is designated as a centrifugal washing manner (so-called waterfall current washing manner).
[0045] The washing process is performed the cleansing step, a rinsing step, and a dehydrating step in order. Just before the dehydrating step, as the water used for rinsing laundry is drained, the floatage is gradually eliminated. Thus, as shown in FIG. 8 b , the float 82 begins to drop by the weight thereof, and the hub portion 821 of the float 82 and the fixed member 83 are engaged with each other, so the floatage clutch 80 is switched into the power transmission state.
[0046] In this power transmission state of the floatage clutch 80 , when the washing shaft 74 is driven by the driving motor 22 , the float 82 engaged with the washing shaft 74 is rotated. Also, the fixed member 83 engaged with the hub portion 821 of the float 82 and the cleansing basket 14 coupled with the fixed member 83 are rotated in the same direction with the washing shaft 74 .
[0047] Therefore, the cleansing basket 14 is rapidly rotated in one direction and then the laundry is tightly contacted with the inner wall of the cleansing basket 14 , then the water contained in the laundry cab be discharged via the dehydration holes 14 a due to the centrifugal force. The cleansing basket 14 and the pulsator 16 are simultaneously rotated in the same direction as described above, so it is possible to prevent the laundry from being caught to the pulsator, and consequently to prevent the damage of the laundry.
[0048] Meantime, since the water does not invade the interior of the hollow shaft part 163 of the pulsator 16 as described above, the washing shaft 74 disposed within the hollow shaft part 163 does not contact with the water. Accordingly, the operating stability of the floatage clutch 80 can be improved.
[0049] Since, various foreign impurities fell down from the laundry may be mixed in the water during the cleansing step, the various foreign impurities mixed in the water is interposed between the float 82 and the washing shaft 74 , if the water is invaded the washing shaft 74 . Consequently, it is possible to prevent the smooth conversion of the floatage clutch 80 by blocking the motion of the float 82 .
[0050] Further, in accordance with the present embodiment, several water absorption holes 16 a extended to the fluid channel between the cleansing basket 14 and the water tub 12 are punched on the top surface of the pulsator 16 . A centrifugal wing portion 164 is provided along the bottom of the wing part 161 . The tube portion 822 of the float 82 is constructed as a conical shape so as to facilitate the smooth movement of the water flowing under the pulsator 16 downwardly via the several water absorption holes 16 a.
[0051] Here, the water entered the interior space of the pulsator 16 via the water absorption holes 16 a in the cleansing step, and a centrifugal force is generated by the centrifugal wing portion 164 rotating with the pulsator 16 to be applied to the entered water. Thus, the entered water allows to pass a filtering net 90 disposed in the upper part of the cleansing basket 14 via the fluid channel between the cleansing basket 14 and the water tub 12 due to the centrifugal force. In this way, it is possible to effectively filter the impurities mixed in the water.
[0052] As described above, the washing machine according to the present invention can provide the following advantages. The power transmission switching in the case of the conversion from the cleansing step to the dehydrating step can be easily performed due to the floatage clutch of simple structure. Also, since the operation stability of the flotage clutch is improved due to the structural feature of the float, the merchant ability and the productivity thereof can be increased.
[0053] While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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The present invention relates a washing machine having a floatage clutch for performing the conversion of a cleansing step and a dehydrating step. This floatage clutch can be actuated only by using floatage and gravity to be generated during the feeding/draining of water without a separate driving part. Accordingly, the construction of clutch part can be simplified, and consequently the cost of manufacturing of the washing machine can be reduced.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to methods of superficially applying low-viscosity liquids onto given components. In particular, the invention relates to a method of coating on a low-viscosity, in-solution oil repellent obtained by dissolving a fluorine-based oil repellent resin in a highly volatile organic solvent.
2. Description of the Related Art
Forming coatings of oil-repellent resins, which primarily are fluoroplastic resins, on designated portions of mechanical devices to impart water-repellency or oil-repellency to those areas is conventional. Forming such coatings without restrictions has, however, proven difficult, in that various contrivances to do so have been brought about to date.
For example, methods of brush application, of spraying on with a sprayer, of dipping in a solution and subsequently drawing out and drying, of spin-coating, of transfer-printing, and of dripping a solution onto designated regions with a brush or like instrument are known. Furthermore, direct formation of an oil-repellent film onto the target surface by means of vacuum deposition or plasma polymerization has also been proposed.
Vacuum and other vapor-deposition techniques, however, necessitate large-scale equipment. Dip-coating and spin-coating are prohibitive of application to designated areas. With brush application, because the tip of the brush deforms, applying a material onto designated areas proves challenging. A particular problem with brush application is that the oil repellent solidifies due to evaporation of the solvent and clings to the brush in the vicinity of the tip, whereby the flexibility of the brush is compromised and at the same time clumps of the solidified oil repellent end up adhering to the target object, such that the applicability of this technique to precision components is especially problematic.
Japanese Unexamined Pat. App. Pub. No. 2004-289957 to Misu et al. discloses an ingenious method in which, using a pair of nozzles whose tips are closely adjacent, an in-solution oil repellent is on the one hand supplied from one of the nozzles while being aspirated through the other, whereby the oil repellent is applied locally with the nozzles being kept out of contact with the target object.
BRIEF SUMMARY OF THE INVENTION
A method of applying an in-solution oil repellent according to the present invention includes contacting onto a surface of a target object an applicator tip having rigidity such that it basically does not deform from the level of pressing required for applying the solution, and, via a contacting piece in the applicator tip, coating-on the in-solution oil repellent. A capillary gap through which the in-solution oil repellent is supplied opens near the contact surface where the contacting piece contacts the target object.
According to this method, the oil repellent is supplied from near the contact surface, and therefore the adverse effect of solidification of the oil repellent due to evaporation of the solvent is relatively small. Moreover, since the contacting piece has rigidity, microparticles of the oil repellent, which form due to solidification, pulverize by being pressed by the contacting piece and dissolve again in the in-solution oil repellent that is supplied subsequently. Therefore, the microparticles do not produce dust or contaminate the surrounding area. Moreover, since the contacting piece has rigidity, the size of the contact area does not vary throughout the application operation, so that the in-solution oil repellent can be applied at a constant width.
The applicator tip may be one that deforms when pressed against the repellent-coating target object. As long as the pressing force is constant, however, the amount of deformation will necessarily be constant. Likewise, if the force is removed, the tip will necessarily return to its original form quickly.
An application method in which the solution is applied, and after the solvent evaporates and the oil repellent loses flowability, the solution is applied once again to the same location also produces beneficial results. In some cases, broken bits of oil repellent solidified near the tip end of the contacting piece do not disappear sufficiently by a single application. Even in such cases, uniformity of the coating film can be enhanced by applying the solution a plurality of times.
In the double application, at least the starting point of the oil repellent application needs to be coated two times. The oil repellent solidified at the tip end of the contacting piece is very likely to remain at the repellent-application starting point, but by applying the oil repellent two times to at least that portion, it is possible to improve the portion in which the problem is most likely to occur.
Since the viscosity of the in-solution oil repellent is often very low, the amount of outflow may be too large unless the size of the capillary gap or the like is selected appropriately. Even when the size of the capillary gap cannot be selected freely, a large amount of outflow of the in-solution oil repellent due to hydraulic pressure is prevented by keeping the opening of the capillary gap and the liquid surface of the in-solution oil repellent substantially at the same level.
As another method of adjusting the amount of outflow of the in-solution oil repellent, a porous material or the like for restricting the flow of fluid may be disposed in the interior of a reservoir for the in-solution oil repellent, or in a flowpath for supplying the in-solution oil repellent to the capillary gap. This may be disposed at a portion that is immersed in the in-solution oil repellent, or may be attached near the opening of the reservoir that is not immersed in the in-solution oil repellent. The flow resistance of the in-solution oil repellent or the flow rate of the air coming from outside into the reservoir drops, allowing the outflow rate of oil repellent from the opening of the capillary gap to lower. When this method is used, it is possible to employ a configuration in which hydraulic pressure is applied intentionally.
The applicator tip may be configured so that the circumference of the contacting piece is covered by a sheath. Covering with the sheath prevents the in-solution oil repellent from evaporating. In addition, by imparting rigidity or resilience to the sheath, it becomes possible to select a material with smaller rigidity or resilience for the contacting piece.
A rolling object may be employed as the contacting piece. The contacting piece is rotated relative to the object to which the in-solution oil repellent is applied, so that the in-solution oil repellent can be applied while the contacting piece is being rolled. The application may be made even with materials that are not suitable for application by sliding the contact surface.
As a configuration of the applicator tip, a solid member may be used as the contacting piece and a capillary gap may be secured between the contacting piece and a sheath. Conversely, a material having micro-gaps in the interior thereof may be selected as the contacting piece, and the micro-gaps may be used as the flowpath of the in-solution oil repellent. Moreover, a porous material may be used as the contacting piece. The applicator tip may have an elongated shape. This facilitates the operation of coating repellent onto very narrow areas. Application to narrow areas between component parts is also facilitated.
The use of an urging mechanism for pressing the applicator tip against the object to which the oil repellent is applied is efficacious. A high-quality coating film is obtained with a simple mechanism.
From the following detailed description in conjunction with the accompanying drawings, the foregoing and other objects, features, aspects and advantages of the present invention will become readily apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 illustrates an example of an applicator for applying an in-solution oil repellent;
FIG. 2 is an enlarged view of the applicator;
FIG. 3 is another example of the applicator for applying an in-solution oil repellent;
FIG. 4 illustrates an example of an applicator tip;
FIG. 5 illustrates another example of the applicator tip;
FIG. 6 illustrates still another example of the applicator tip; and
FIG. 7 illustrates an in-solution oil repellent reservoir.
DETAILED DESCRIPTION OF THE INVENTION
Spindle motors that are built into such devices as hard disk drives in many cases have a shaft on the surface of which an oil-repellent film composed of fluoropolymer is formed to prevent the lubricant from leaking. In the in-solution oil repellent applied to the shaft surface the concentration of the fluoropolymer is typically 1% and the solvent used is highly volatile. The application method according to the invention was carried out to apply this kind of solution using application apparatus as described in the following.
First Embodiment
FIG. 1 illustrates the overall configuration of an applicator 2 for applying the in-solution oil repellent on a circumferential surface of the shaft. FIG. 2 illustrates a portion of the applicator near applicator tips for applying the in-solution oil-repellent, viewed in a shaft-axis direction.
A work holder 7 serves to hold the shaft in a position where the oil-repellent is applied to the shaft. In this example, the shaft has a diameter of 2.5 mm. The work holder 7 has an inwardly curved surface at its center, and the inner side of the curved portion is provided with two applicator tips spaced apart along the shaft axis. A shaft 1 , which is an object to which the oil-repellent is to be applied, is connected to a rotating mechanism 22 via a chuck 21 so that it can be rotated when applying the oil-repellent. The shaft 1 , the chuck 21 , and the rotating mechanism 22 are supported by a hinge joint 24 so that the front end side of the shaft can be lifted, as illustrated by dotted line in the figure. With the configuration illustrated in FIG. 1 , because the left hand side of the hinge joint 24 in the figure is heavier, the shaft 1 is automatically pressed against the work holder 7 due to the effect of gravity. If the pressing force is so large that the tip ends of the applicator tips 3 deform, a spring 23 may be provided to tug backwards on the rotating mechanism 22 to reduce the urging force to an appropriate level.
Even if the shaft 1 is attached to the rotating mechanism 22 slightly tilted, the tilt may be compensated since the shaft's front end can be lifted easily; therefore, the oil-repellent is applied stably. The same applies even if the shaft surface has slight surface unevenness.
Referring to FIG. 2 , two applicator tips 3 for applying the in-solution oil repellent to the shaft surface are provided along the shaft circumference. Providing two applicator tips 3 , 3 enables them to support the shaft 1 stably when applying the solution. The two applicator tips 3 , 3 may supply in-solution oil repellents with varying concentrations. The applicator tips 3 , 3 are supplied with the in-solution oil repellent via flowpaths 9 , 9 from reservoirs 5 , 5 . Varying the concentration of the in-solution oil repellent in the reservoirs enables application of solutions with varying concentrations.
Because the solvent of the in-solution oil repellent vaporizes very quickly, under conditions in which the shaft is rotated about two times a second, the in-solution oil repellent loses flowability and solidifies before the shaft undergoes one rotation. The in-solution oil repellent applied by the applicator tip that is on the right in FIG. 2 solidifies before it reaches the applicator tip that is on the left.
It is also acceptable that the applicator tip 3 be in a single location. Since the application is carried out while the shaft 1 is being rotated, only one applicator is sufficient to apply the in-solution oil repellent onto the whole circumference, and to apply two coats easily. While in this embodiment application was conducted at a rate of rotation of 100 rpm, the rate of rotation may be faster; but application becomes problematic at a rate higher than 300 rpm.
Second Embodiment
FIG. 3 is a schematic view illustrating an applicator 12 according to another embodiment. In the applicator 12 an applicator tip 3 is supported by a sliding mechanism 25 that can move along a radial direction of the shaft 1 . The applicator tip 3 and a reservoir 5 are pressed against the shaft surface by a spring 23 , so that the in-solution oil repellent is applied while the shaft 1 is being rotated. The spring and the sliding mechanism serves to compensate the tilt and surface unevenness of the shaft 1 to enable stable application of the solution. It should be noted that a chassis or the like for mounting the applicator 12 is not depicted in FIGS. 1 through 3 for simplicity.
Third Embodiment
FIGS. 4A and 4B are enlarged views illustrating examples of the applicator tip 3 , which show cross-sectional views on the left and front views on the right.
Referring to FIG. 4A , the applicator tip 3 has a contacting piece 4 that is rectangularly prismatic in form, and a sheath 6 for accommodating the contractor 4 therein. Capillary gaps 11 extending along the axis form at four circumferentially separate locations between the contractor 4 and the sheath 6 . The interior of the capillary gaps 11 are filled with the in-solution oil repellent to openings 46 near the tip end of the applicator tip 3 .
A contact surface 45 forms adjacent to the openings 46 of the capillary gaps, on which the in-solution oil repellent spreads along the surface of the contacting piece 4 , and the in-solution oil repellent is applied onto the surface of the object to which the in-solution oil repellent is to be applied in the application work.
Referring to FIG. 4B , a contacting piece 41 has a capillary gap 11 extending along the axis and having an opening in the center of a contact surface 45 . Outside the region depicted in the drawing, the capillary gap 11 is connected to a reservoir from which the in-solution oil repellent is supplied. Unlike the method illustrated in FIG. 4A , solidified oil repellent rarely forms at the opening of the capillary gap during the application work because the opening is at the center of the contacting piece.
Since the sheath 6 has a sufficient rigidity in both the applicator tips shown in FIGS. 4A and 4B , the applicator tips 3 as a whole have great rigidity so that precise application work can be carried out stably.
Fourth Embodiment
FIGS. 5A and 5B are enlarged views illustrating other examples of the applicator tips 3 , which show cross-sectional views on the left and front views on the right.
Referring to FIG. 5A , a contacting piece 42 is made of a bundle of fine fibrous material having micro-gaps through which a liquid can flow along the axis direction. The contacting piece 42 is accommodated in the interior of a sheath 6 , which ensures rigidity. The rear end of the contacting piece 42 is connected to a flowpath, which is not illustrated in the figure, through which the in-solution oil repellent is supplied. The micro-gaps themselves form the termini of the flowpath. The in-solution oil repellent 10 in this case oozes out on the tip end of the contacting piece 42 to cover the tip end.
FIG. 5B illustrates an example of a simpler configuration of the applicator tip. Referring to FIG. 5B , a contacting piece 42 is likewise formed by a bundle of fine fibrous material having micro-gaps through which a liquid can flow along the axis direction. Unlike the applicator tip shown in FIG. 5A , that shown in FIG. 5B does not have a sheath 6 . The rigidity of the applicator tip is ensured by the contacting piece 42 alone. For this reason, the degree of deformation of the applicator tip by depressing is greater than the configuration shown in FIG. 5A . Nevertheless, selecting the material appropriately allows the contacting piece to have a sufficient resilience. Therefore, the configuration shown in FIG. 5B is also capable of smooth application work.
Moreover, since the configuration shown in FIG. 5B does not have a sheath 6 , a large amount of solvent evaporates from the side face of the
Fifth Embodiment
FIG. 6 illustrates an example in which a contacting piece 43 has a spherical shape. The spherical contacting piece 43 is held freely rotatively in a recess 47 formed at one end of a sheath 6 so that a capillary gap is provided between the inner circumferential surface of the end portion and the surface of the contacting piece 43 . The in-solution oil repellent is supplied to the capillary gap through a flowpath 9 and is delivered by the rolling motion of the contacting piece 43 to a contact surface 45 that faces an object to which the in-solution oil repellent is to be applied. The capillary gap itself forms the terminus of the flowpath 9 . In this configuration, the contacting piece 43 rotates at all times during the application, so the contact surface 45 shifts to adjacent locations on the sphere one after another.
The applicator tip 3 shown in FIG. 6 applies the in-solution oil repellent by means of rolling motion, not sliding motion, of the contact surface and is therefore suitable for such applications that the application accompanying sliding is inappropriate.
Sixth Embodiment
FIG. 7 shows an embodiment in which adsorbent fibers 50 are filled in the interior of the reservoir 5 so that the in-solution oil repellent can be held in the reservoir more stably. The adsorbent fibers may pack the entire interior of the reservoir, or may be fitted only near an air vent 51 to restrict airflow into the reservoir. Either way makes it possible to reduce the flow rate of the in-solution oil repellent, which has a very low viscosity and flows out very easily, from one end of the applicator tip, so that the outflow of an excessive amount of in-solution oil repellent can be prevented. It should be noted that instead of the adsorbent fibers 50 , the reservoir may be filled to a given extent with a particulate substance.
Other Embodiments
Although the first to six embodiments above illustrate a cylinder-shaped shaft as the object to which the in-solution oil repellent is applied, applications of the application method of the invention is not limited to cylindrical components. The application method according to the invention may even be applied to an inner circumferential surface of cylindrical bearing sleeve as long as the tip(s) of the applicator can be brought in contact therewith. The application method according to the invention may of course be applied easily to non-curved surface portions of machine components, such as flat surfaces.
Only selected embodiments have been chosen to illustrate the present invention. To those skilled in the art, however, it will be apparent from the foregoing disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing description of the embodiments according to the present invention is provided for illustration only, and not for limiting the invention as defined by the appended claims and their equivalents.
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Enables the uniform, accurate application, onto microscale areas, of an in-solution oil repellent of low viscousness and in which the solvent is of extremely high volatility. A contacting piece that comes into contact with a target for application of the repellent is encased inside a sheath structure that, including the contacting piece, is lent rigidity. Therein, while the in-solution oil repellent is fed along the inside of the sheath structure, along the contacting piece itself, and onto the repellent-application target, it is coated on by the contacting piece tracing the surface of the application target. Giving at least the application start-point two coats, or a number of applications greater than that, yields a coating film of still higher uniformity.
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FIELD OF THE INVENTION
[0001] This invention relates generally to secure dropboxes, and more particularly to a mailbox that is highly resistant to vandalism and robbery.
BACKGROUND OF THE INVENTION
[0002] Valuable goods and documents are often left unattended in mailboxes, especially in rural or suburban areas where mail is not deposited directly into a home door slot. A vandal may damage many mailboxes in a single night, causing the contents to be scattered and damaged. Thieves open and remove the contents of mailboxes to obtain checks, personal information, prescription drugs, and other valuables.
[0003] Some vandalism is prevented simply by constructing mailboxes of stronger or more resilient materials. To protect the contents, some mailboxes have a lock, to which both the owner and the postman have keys. These locks are typically simple “cabinet” locks with a finger that rotates 90° between locked and unlocked positions. Such locks are a deterrent to casual snoops, but are easily forced open by thieves. Also, the keys are simple and can be easily duplicated and the mailbox owner does not have exclusive possession of the key.
[0004] Reinforced mailboxes are available that have a convenient unlocked entrance for use by the postman and a locking access door, with some type of baffle between. The locking door may have a hasp for a padlock or a built-in “cylinder” lock. With such a dual-access mailbox, the owner of the mailbox has the only keys and the postman is not inconvenienced by having to unlock and lock the mailbox when delivering mail. The baffle prevents thieves from retrieving items out of the mailbox by inserting an arm or tool through the unlocked entrance.
[0005] Such a mailbox deters thieves greatly, but is still vulnerable. Most padlocks can be cut, given a strong enough tool, and cylinder locks can generally be opened by a very strong blow to the front of the cylinder. Tools are available that allow thieves to punch out a cylinder lock from a reinforced mailbox and remove the contents in only a couple of minutes. Therefore, there is a need for a reinforced mailbox that requires sufficient time, skill, and tools to open it that experienced thieves pass it by in favor of one easier to open.
[0006] Also, padlocks are somewhat inconvenient to use. In the case of a keyed padlock, the keyway is at the bottom and the body of the padlock must move approximately an inch vertically relative to the hasp and be rotated in order to open. Unlocking or locking such a padlock requires the use of two hands, one for the key and the other to manipulate the padlock. If one is holding items, such as the retrieved mail, the items must be put down to leave both hands free to operate the padlock. Thus, there is a need for a reinforced mailbox that is convenient to unlock and lock, even while holding an item.
[0007] There is further a need for secure enclosures for uses other than receiving mail. For example, law enforcement personnel often confiscate or otherwise receive items in evidence that must be maintained securely. They may have to interrupt their duties and travel a long distance to take a gull, a packet of cash, illegal drugs, or other items to a central location for deposit into evidence storage. There is a need for a secure dropbox for uses such as law enforcement evidence deposit. Such a dropbox must be convenient for the depositor to use, yet very secure to maintain a proper chain of custody.
SUMMARY OF THE INVENTION
[0008] This invention is a secure enclosure that is adapted for use as a mailbox for home or business, evidence dropbox for law enforcement agencies, or key dropbox for an auto repair shop or rental agency.
[0009] Items such as mail or keys are deposited conveniently through an unlocked portal.
[0010] The secure enclosure includes a secure compartment that is accessible through a locking door. A baffle between the unlocked portal and the secure compartment makes it impossible to remove items from the secure compartment by inserting an arm or elongate tool through the unlocked portal.
[0011] On the door is mounted a lock lock housing of stainless steel. A rotary shackle padlock is held snugly by the bottom and wrap-around sides of the lock housing Such that the rotary shackle can engage a hasp to lock the door, yet the rotary shackle padlock cannot be twisted, pried, or jerked so as to break the rotary shackle or the hasp. When locked to the hasp, the rotary shackle padlock cannot be removed from the housing.
[0012] The lock lock housing and door of the enclosure reinforce the body of rotary shackle padlock such that the mechanism of rotary shackle padlock cannot be punched out using an impact tool. The rotary shackle padlock and lock housing combine to create a visual deterrent to robbery by being obviously difficult and time-consuming to open by force.
[0013] The secure enclosure is convenient for both persons with access to the secure compartment and other persons who deposit items into the unlocked portal. Persons depositing items, such as mail carriers, do not need a key or combination to drop items into the portal.
[0014] Unlocking the door to the secure compartment can be done with only one hand because the rotary shackle padlock does not need to be moved to unlock it. The rotary shackle padlock remains in the lock housing and the key remains in the keyway when the door is open, so the open lock does not have to be held while retrieving mail. The key can only be removed from the keyway when the rotary shackle padlock is locked, making it less likely that the door could be left unlocked accidentally.
[0015] The secure enclosure is constructed of strong materials such as hardened steel, such that it cannot be opened readily by a smashing with a baseball bat or sledge, or by cutting with a saw.
[0016] The secure enclosure is a convenient and secure dropbox that many persons can deposit items into without having a key or knowing a combination. The known, quick methods that thieves use against locked mailboxes and similar enclosures will not open the secure enclosure.
[0017] The invention will now be described in more particular detail with respect to the accompanying drawings in which like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a rear left perspective view of a preferred embodiment of the secure enclosure of the present invention.
[0019] FIG. 2 is an enlarged perspective view, partly cut away, of the door of the secure enclosure of FIG. 1 , with door partially open.
[0020] FIG. 3 is an enlarged perspective view, partly exploded and partly cut away, of the lock, housing, and door of the enclosure of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 is a rear left perspective view of secure enclosure 10 of the present invention. FIG. 2 is an enlarged perspective view, partly cut away, of the rear wall 22 and door 46 of secure enclosure 10 with door 46 partially open.
[0022] Secure enclosure 10 generally includes front wall 21 (shown in phantom), back wall 22 , two side walls 23 , and top 24 , which are connected so as to enclose receiving compartment 30 and secured compartment 40 . Receiving compartment 30 includes unsecured portal means 32 , such as hatch 33 , for conveniently inserting items to be stored into secure enclosure 10 . Hatch 33 can be opened and used by anyone, without a key. Secured compartment 40 includes securable access means 45 , such as door 46 , and requires a key to open.
[0023] Door 46 is illustrated in FIG. 1 and is herein described as being located on back wall 22 , although door 46 may alternatively be located on front wall 21 or either of side walls 23 . Door 46 is preferably attached to back wall 22 by hinge 47 and opens downwardly. The weight of rotary shackle padlock 70 holds door 46 fully downward, allowing the use of both hands to get mail out of secure compartment 40 . Door 46 may alternatively open upwardly, but in that case, door 46 must be supported in the open position, such as with a hand. Door 46 may alternatively open to one side, but a strong wind may tend to blow door 46 shut, also required door 46 to be held open.
[0024] Hasp 51 cooperates with rotary shackle padlock 70 and lock housing 60 to securely lock door 46 in a closed position.
[0025] FIG. 3 is an enlarged perspective view, partly exploded and partly cut away, of lock 70 , lock housing 60 , and door 46 of enclosure 10 of FIG. 1 .
lock housing 60 both protects rotary shackle padlock 70 from tampering and attaches rotary shackle padlock 70 to back wall 22 lock housing 60 is preferably fabricated from a strong, tough material such as stainless steel lock housing 60 includes a back 61 , a first side 63 , second side 64 , and bottom 65 . Back 61 has a first screw hole 62 and a second screw hole 69 bored through it. First side 63 and second side 64 are spaced apart so as to accept rotary shackle padlock 70 with a tight friction fit. Bottom 65 supports rotary shackle padlock 70 and shields padlock 70 from being pried or twisted from below. lock housing 60 is mounted onto door 46 by inserting first screw 67 through first screw hole 62 . First screw 67 is countersunk and is flush with back 61 of lock housing 60 when installed, allowing rotary shackle padlock 70 to be pushed into lock housing 60 . First side 63 and second side 64 fit snugly against the sides of rotary shackle padlock and curve over the front of rotary shackle padlock 70 . First side 63 and second side 64 thus help shield body 71 of rotary shackle padlock 70 against cutting or drilling and prevent rotary shackle padlock 70 from moving laterally or outwardly with respect to door 46 .
[0028] Second screw 68 is then inserted into second screw hole 69 and screwed down. Second screw 68 is not countersunk, and so protrudes from back 61 to function as a retainer for rotary padlock 70 by interfering against the apex of notch 72 . Second screw 68 is tightened by passing a screwdriver through notch 72 to second screw 68 . Thus, lock housing 60 holds rotary shackle padlock 70 tightly against movement to either side or downward. Second screw 62 prevents upward movement relative to lock housing 60 . “Upward” as used in this specification and in the claims means in a direction away from bottom 65 of lock housing 60 .
[0029] Rotary shackle padlock 70 , a commercially available product, includes body 71 ; rotary shackle 73 , which includes engaging end 74 ; engaging aperture 76 ; and rotary shackle drive means, such as keyway 75 . Keyway 75 admits a key (not shown) that rotates the interior gears (not shown), which move rotary shackle 73 . Rotary shackle 73 includes an engaging end 74 that moves across notch 72 in an arcuate manner when driven by the interior gears and engages into engaging aperture 76 to lock padlock 70 .
[0030] An alternative rotary shackle drive means is the front dial (not shown) of a combination rotary shackle padlock (not shown). Other rotary shackle drive means will be obvious to those skilled in the art but are not described herein.
[0031] Rotary padlock 70 thus may be locked and unlocked without body 71 moving relative to hasp 51 . This feature allows rotary padlock 70 to be tightly held within lock housing 60 , unlike sliding shackle padlocks. Sliding shackle padlocks require movement of the body of the lock relative to the hasp in order to lock or unlock it and are, therefore, unsuitable for use as a part of secure enclosure 10 .
[0032] Additional features of rotary padlock 60 are that keyway 75 is located on the front of rotary padlock 70 and that the key cannot be removed from keyway 75 when rotary padlock 70 is unlocked. Thus, rotary padlock 70 can be easily unlocked and locked by a person using only one hand, even when rotary padlock 70 is attached within lock housing 60 . One-hand operation is especially convenient when locking secure enclosure 10 after retrieving items, such as mail. The mail may be held securely in one hand while locking secure enclosure 10 with the other hand.
[0033] A sliding shackle padlock typically requires a user to grasp the padlock with one hand and tilt it upward to make the keyway visible. A user inserts a key (or operates a combination dial) with the other hand, turns the key, and moves the body of the padlock vertically downward relative to the hasp means to disengage the shackle. Next, the body of the padlock is rotated and the shackle is removed from the hasp means. When a sliding shackle padlock is used to lock a mailbox, a user typically holds the padlock while retrieving mail from the mailbox. The key may be left in the keyway, but is subject to falling out. Because of the substantial movement and manipulation involved in unlocking and locking a sliding shackle padlock, such a lock cannot be rigidly attached to an enclosure Such as a mailbox and is inconvenient in use. Items held in the hand, Such as retrieved mail, are typically set on the ground or gripped in the teeth while operating the padlock.
[0034] Rotary shackle padlock 70 and hasp 51 cooperate to lock door 46 . Hasp 51 includes tongue 52 , a rod of strong material such as hardened steel, attached to back wall 22 and projecting outwardly. Free end 53 of tongue 52 protrudes through aperture 55 in door 46 when door 46 is closed, such that bore 54 is outside of enclosure 10 . When the key is turned within keyway 75 to lock rotary shackle padlock 70 , engaging end 74 of shackle 73 passes through bore 54 and then into engaging aperture 76 of rotary shackle padlock 70 , preventing door 46 from being opened.
[0035] Bore 54 has an inner diameter only slightly greater than that of shackle 73 , so hasp means 51 also serves to further reinforce rotary shackle padlock 70 against being pried or slammed.
[0036] Other types of hasp means 51 are well-known to those skilled in the art and will not be discussed further herein.
[0037] In the preferred embodiment 10 illustrated and described herein, lock housing 60 and rotary shackle padlock 70 are disposed on the exterior of enclosure 10 and tongue 52 is attached inside enclosure 10 and protruding outwardly. An advantage of mounting lock housing 60 and rotary shackle padlock 70 on the exterior is that they act as a visual deterrent to thieves, warning the thieves that the secure mailbox will be very difficult to open. Rotary shackle padlocks are known to be difficult to cut or punch and it would be readily apparent to most thieves, even those not familiar with the secure enclosure 10 of the present invention, that lock housing 60 and door 46 further protect rotary shackle padlock 70 against being, destroyed or opened by punching the working part of the lock out.
[0038] Sides 63 of lock lock housing 60 preferably include grip means 66 for helping a person grip lock lock housing 60 , such as the plurality of holes shown in the drawings. Grip means 66 makes it easier for the user to use lock lock housing 60 as a handle for moving door 46 .
[0039] In an alternative preferred embodiment, not illustrated, the relative positions are reversed, such that lock housing 60 and rotary shackle padlock are attached to the inner side of door 46 and engaging end 74 passes through a hasp means located inside enclosure 10 . This embodiment requires that keyway 75 be accessible through a small key port cut through door 46 , unless a rotary shackle padlock with keyless remote operation is employed. This alternative embodiment would be appropriate where visual deterrence is not required or where it is desirable to protect rotary shackle padlock 70 from vandalism damage, such as defacing with acid or epoxy adhesive.
[0040] Secure enclosure 10 of FIG. 1 is well-adapted for receiving and storing of mail. Enclosure 10 includes receiving compartment 30 , including the familiar tunnel 31 that projects outwardly for the convenience of a postman in a vehicle, and a non-secured portal 32 , such as hatch 33 . Enclosure 10 further includes secured compartment 40 for storage of mail until it is retrieved. Mail is retrieved by using door 46 as described above. Door 46 is typically located on rear wall 45 so that access in not blocked by tunnel 31 . Also, secure enclosure 10 may be placed such that tunnel 31 extends over or through a fence such that hatch 33 is available to a delivery person on the street but door 46 is within a fenced yard or court.
[0041] Baffle 90 is disposed between receiving compartment 30 and secured compartment 40 . Baffle 90 is depicted as a pivoting platform, attached to front wall 21 or side walls 23 by pivot 94 . Baffle 90 is balanced such that it is normally horizontal. A postman or other delivery person opens hatch 33 and deposits items onto receiving end 92 of baffle 90 , then lifts receiving end 92 upward. The items slide to drop end 93 of baffle 90 and then into secured compartment 40 . When receiving end 92 is in its normal horizontal position, baffle 90 extends nearly to back wall 22 and blocks access to secure compartment 40 . When receiving end 92 is lifted, receiving end 92 blocks tunnel 31 . Thus, baffle 90 prevents anyone from pulling items out of secured compartment 40 up to hatch 33 . Hatch 33 does not need to be locked, making it convenient for any delivery person to deposit items without needing a key.
[0042] It will be obvious to those skilled in the art that other known types of mechanical baffles may be employed.
[0043] Secure enclosure 10 is also well-adapted for use as a law enforcement dropbox for depositing evidence, firearms, or other items that require secure handling. Modifications to the dimensions can be made to further adapt enclosure 10 for a specific use. For example, if enclosure 10 will be used to store especially heavy or breakable items, it would be desirable to lessen the impact of items falling into secure compartment 40 , such as by adding an inclined platform inside secure compartment 40 to allow items to slide to the bottom of secure compartment 40 from baffle 90 ; by limiting the height of enclosure 10 ; by including a layer of shock-absorbing material such as synthetic viscoelastic foam in the bottom of secure compartment 40 ; or by other means well known to those skilled in the art. Because only persons authorized to remove items from secure enclosure 10 need to have the key to rotary padlock 70 , keys are less likely to be lost, duplicated, or used in an unauthorized manner.
[0044] Although particular embodiments of the invention have been illustrated and described, various changes may be made in the form, composition, construction, and arrangement of the parts herein without sacrificing any of its advantages. Therefore, it is to be understood that all matter herein is to be interpreted as illustrative and not in any limiting sense, and it is intended to cover in the appended claims such modifications as come within the true spirit and scope of the invention.
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Secure enclosure ( 10 ) is useful as mailbox or police evidence dropbox. Items are deposited through unsecured portal ( 32 ), pass past baffle ( 90 ) and are stored in secure compartment ( 40 ). Access to secure compartment ( 40 ) is through door ( 46 ). Lock lock housing ( 60 ) is mounted rigidly on door ( 46 ) and holds rotary shackle padlock ( 70 ) such that rotary shackle ( 73 ) engages hasp ( 51 ) to lock door ( 46 ) but rotary shackle padlock ( 70 ) is protected against twisting, prying, or impact
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BACKGROUND OF THE INVENTION
The invention relates to a method of making rolls of the type used in calenders and analogous machines. More particularly, the invention relates to improvements in methods of making rolls of the type wherein an elongated core is surrounded by an elastomeric envelope and the envelope includes at least one stack of thin discs.
German Pat. No. 10 71 036 discloses a method of making calender rolls which includes welding the discs to each other subsequent to placing of the discs around a core. The discs are made of fleece and contain a bonding agent, such as latex, in a partially vulcanized state. The first step involves the placing of discs around the core and the discs are thereupon pressed against each other with a substantial force. The core and the thus obtained envelope (consisting of pressed-together discs) are thereupon heated for an extended period of time in order to complete the vulcanizing of the bonding agent. The heating step involves subjecting the discs and the partially vulcanized bonding agent to temperatures in the range of 100°-120° C. for a period of 5-8 hours. The thus obtained envelope has a hardness in the range of 90-97 Shore A. A role which embodies an envelope of the just outlined character can be used as a means for squeezing liquids from leather, textile materials and the like or as a counterrole in embossing and like machines.
A drawback of the aforedescribed rolls is that they cannot be put to use in supercalenders and/or compact calenders, for example, in calenders which are used as a means for smoothing the exposed surfaces of webs of paper, webs of fleece, magnetic tapes, webs of textile material and the like. In such calenders, the rolls contain elastic envelopes which surround a solid shaft or a hollow cylinder made of steel or grey cast iron. The hardness of the envelope forming part of a roll for use in a supercalender or a compact calender must exceed the aforementioned values.
European Pat. No. 0 131 083 B1 proposes to use primarily chemical pulp in the discs of rolls of calenders or the like. For example, an envelope which forms part of a roll satisfying the European standards concerning elastic calender rolls contains 80 percent cotton and 20 percent wool. However, it is also known to employ envelopes which contain up to 50 percent asbestos fibers or up to 15 percent carbon fibers. The characteristics of the roll depend on the ratio of various fibers in its envelope. For example, the resistance of an envelope to permanent deformation (marking) can be increased by increasing the percentage of animal wool, i.e., such envelope is less likely to undergo permanent deformation as a result of repeated engagement with pleats, folds or other accumulations of material in a running web of paper or the like. On the other hand, an increase in the percentage of animal wool entails a reduction of hysteresis and attendant pronounced heating simultaneously with a reduction of the ability to stand mechanical stresses. This eliminates such rolls from use under elevated stresses, namely at high speeds and at pronounced line loads.
The ability of a roll to stand elevated temperatures is also an important factor when the envelope develops heat due to hysteresis and also because a roll having an elastic envelope is heated due to transfer of heat from a companion roll which cooperates with the roll having an elastic envelope to define therewith a nip for a running web of paper or the like. Reference may be had to U.S. Pat. No. 2,987,802 which discloses a method of mixing pulp in a paper making machine with a duroplastic substance. The paper web which is obtained from such mixture is heated to a temperature of 290°-300° C. for a period of 6-10 minutes prior to cutting of discs from the web.
OBJECTS OF THE INVENTION
An object of the invention is to provide a method of making an improved elastic cover for use in the rolls of calenders and like machines.
Another object of the invention is to provide a method of making an elastic cover which can stand pronounced mechanical and/or thermal stresses without undergoing permanent deformation.
A further object of the invention is to provide a novel method of making improved rolls for use in calenders and like machines.
An additional object of the invention is to provide a novel and improved method of making discs for use in elastic covers of calender rolls.
Still object of the invention is to provide a novel and improved method of treating stacks of paper discs for the purpose of converting such stacks into elastic covers of rolls for calenders and like machines.
A further object of the invention is to provide an elastic cover which is obtained in accordance with the above outlined method.
Another object of the invention is to provide a novel and improved roll for use in calenders and like machines.
SUMMARY OF THE INVENTION
The invention resides in the provision of a method of making a roll which, when finished, has an elongated core (e.g., a core made of steel) and an elastic cover including a plurality of discs containing a fibrous material and a hardenable plastic substance whose hardening requires a time span exceeding 48 hours. The improved method comprises the steps of placing the discs of the cover next to each other around the core, and subjecting the thus obtained cover to a compressive stress in the longitudinal direction of the core. The step of subjecting the cover to a compressive stress includes starting the compressing step with a delay following the placing step such that the hardening of the plastic substance begins prior to the subjecting step and is terminated within an interval of more than 48 hours following the start of the processing step, i.e., a portion of the aforementioned time span takes place prior and a portion (lasting at least 48 hours) of the time span takes place subsequent to starting of the compressing step.
The subjecting step can be carried out at least substantially without heating of the plastic substance.
The hardening of the plastic substance can begin within a period which immediately precedes and is shorter than the aforementioned interval. The method can be practiced in such a way that the hardening of plastic material takes up a time span including and exceeding the aforementioned interval, and the interval amounts to at least 75 percent of the entire time span. The interval can be longer than one week, e.g., between two and four weeks.
The method can further comprise the step of making the discs in a specific way, namely in a paper making machine and including admixing the plastic substance to paper pulp prior to conversion of pulp into discs. Such method can further comprise making a moist web from the mixture of paper pulp and plastic substance and reducing the moisture content of the web including heating the web for a short period of time to a temperature of approximately 100° C.
Alternatively, the step of making the discs can comprise making a web from pulp, impregnating the web with the plastic substance, and separating discs from the impregnated web.
At least some of the discs can contain between 5 and 40% by weight (preferably between 20 and 30% by weight) of plastic substance.
For example, the plastic substance can contain a water-dispersible epoxy system and a slow accelerator, e.g., an accelerator which contains or consists of polyaminoamine.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved method itself, however, together with additional features and advantages thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments of a calender roll which is obtained in accordance with the improved method and is shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly elevational and partly axial sectional view of a roll which is constructed and assembled in accordance with the method of the present invention;
FIG. 2 is a front elevational view of a disc which is utilized in the cover of the roll shown in FIG. 1; and
FIG. 3 is a fragmentary partly elevational and partly axial sectional view of a modified roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The roll 1 which is shown in FIG. 1 comprises an elongated cylindrical core 2 of steel and an elastic cover or envelope 5 which surrounds the median portion of the core and is assembled of discs 6 of the type shown in FIG. 2. The end portions 3, 4 of the core 2 are designed to be journalled in the frame of a web treating machine, such as a calender, for example, in a manner as disclosed in commonly owned U.S. Pat. No. 5,033,317 granted Jul. 23, 1991 to Rolf Van Haag. The discs 6 contain a fibrous material and a plastic substance which is hardened in accordance with the method of the present invention. The cover 5 is subjected to a compressive stress in the axial direction of the core 2 by two rings 7, 8 which abut the two outermost discs 6 and are maintained in the illustrated axial positions by two nuts 9, 10 mating with externally threaded portions of the core 2. The internal surfaces of the discs 6 are provided with notches 11 (FIG. 2) for a complementary external axially parallel rib (not shown) of the core 2 so that the envelope 5 and the core cannot turn relative to each other.
The discs 6 can be stamped or otherwise removed from a continuous web which is turned out by a standard paper making machine. The major portion of each disc 6 consists of a fibrous material, such as cotton fibers. However, it is equally possible to employ synthetic plastic fibers, mineral fibers, carbon fibers or animal fibers (such as wool) or a mixture of two or more different types of fibers. For example, the range of elasticity of the cover 5 can be enhanced if the discs 6 contain a mixture of cotton fibers with synthetic plastic and/or mineral fibers; this is desirable when the roll 1 is used in a calender for the processing of paper webs because the envelope 5 can readily yield and thereupon reassume its original shape when it encounters a lump or a fold or pleat in a running web. It is further possible to make the disc 6 of a material which includes plastic fleece or synthetic plastic paper without any or with a small percentage of cotton fibers.
The discs 6 further contain between 5 and 40 percent by weight of a hardenable synthetic plastic substance. For example, the plastic substance can be admixed to pulp in the paper making machine prior to conversion of pulp into a web which yields the discs 6. The plastic substance is a cold setting or hardening substance having an accelerating component selected in such a way that the cross-linking speed is very low, namely such that the hardening of the plastic substance is completed within an interval of at least two days (particularly between two days and four weeks) following the application of compressive stress by the rings 7 and 8. The arrangement is preferably such that the interval of hardening of plastic substance following the application of compressive stress is at least 75 percent of the time span which is required to complete the hardening of the plastic substance. Thus, a relatively short portion of such time span elapses prior to and the relatively long interval (not less than 48 hours) of the time span elapses subsequent to the application of compressive stress by the rings 7 and 8.
A presently preferred plastic substance consists of or contains a water-dispersible epoxy system and a slow accelerator, such as polyaminoamine.
Once the roll 1 is assembled in a manner as shown in FIG. 1, it is merely necessary to permit the accelerator of the plastic substance to ensure adequate hardening of the epoxy system (for a period of preferably not less than 48 hours and up to or even in excess of four weeks) and the envelope 5 then exhibits the desirable elastic properties for use in a calender or a like machine. The thus obtained cover 5 is homogeneous and can be used in machines wherein the roll 1 must be rotated at a high speed and/or must transmit and stand elevated pressures. Furthermore, the envelope 5 is capable of resisting pronounced stresses which would cause permanent deformation of the peripheral surface of a standard roll.
It is desirable and important to ensure that the cross-linking take place at or close to room temperature, i.e., that no substantial or pronounced cross-linking reactions take place due to or as a result of heating. Thus, no pronounced temperature changes take place during cross-linking which, in turn, ensures that different reactions (and hence different properties of the material of the cover 5) do not develop during cross-linking. This is important because different properties in different portions of a finished cover could lead to cracks, tears and/or other damage. Moreover, the method is simple because it need not include a heating step during or preparatory to hardening of the plastic substance. All that is necessary is to permit an otherwise finished roll 1 to await complete hardening (not less than 48 hours) of the plastic substance upon completion of the compressing step.
In actual practice, a certain period of time will elapse between the application of plastic substance to the fibrous material and the start of the roll making operation. Since the hardening of the plastic substance is slow, the period between the application of plastic substance to the fibrous material and the making of an cover 5 is a relatively small fraction of the entire time span which is required to ensure adequate hardening of the plastic substance. A very substantial part of the hardening step takes place not only within the discs 6 but also between the abutting surfaces of the discs which are biased against each other by the rings 7 and 8. When the hardening is completed, the resulting cover 5 is a homogeneous body which exhibits a highly satisfactory hardness as well as elasticity such as is necessary to take up anticipated loads as well as excessive loads (i.e., those which could damage or destroy the cover of a conventional roll) without undergoing permanent deformation. Thus, the cover of the improved roll can stand stresses which cause shifting of discs, bulging and/or other damage to a conventional roll. This, in turn, ensures that a roll which is produced in accordance with the improved method does not undergo permanent deformation.
It is already known to regulate the speed of hardening of a cold-hardening plastic substance by properly selecting the nature and the quantity of the accelerator. In accordance with the present invention, the accelerator of the plastic substance is selected in such a way that the making of a starting material (including the fibrous material and the plastic substance), the stamping or other separation of discs 6 from the starting material, the stacking of discs 6 around the median portion of the core 2, and the compressing of discs 6 which form the cover 5 take up only a portion of the entire time span which is required for hardening of the plastic substance. This leaves a sufficiently long interval of time for hardening upon completion of the compressing step. As already mentioned above, the period of hardening prior to completion of the compressing step need not amount to 25 percent of the entire time span for hardening so that the interval of hardening subsequent to the compressing step can amount to not less than 75 percent of the entire time span. The aforementioned interval can last for one full week or even longer, e.g., between two and four weeks.
The presently preferred step of making the discs 6 involves mixing paper pulp in a paper making machine with the plastic substance and thereupon converting the mixture into a web serving as a blank for removal (e.g., by stamping) of discs 6 therefrom. The fact that hardening begins as soon as the plastic substance is admixed to the pulp is of no consequence because the total span of hardening is long and any hardening which takes place prior to completion of the compressing step is still a fraction of the total hardening which is required to complete the making of the cover 5. However, and as also mentioned hereinbefore, the period of hardening prior to completion of the compressing step can be shortened or reduced to zero by the simple expedient of making the discs 6 from paper pulp and by thereupon impregnating such discs with the plastic material, i.e., by ensuring that hardening of plastic material cannot begin prior to stacking of the discs 6 on the core 2.
The interval of hardening upon application of compressive stress can take up to the entire time span which is needed for full hardening of the plastic substance.
FIG. 3 shows a portion of a second roll wherein the solid core 2 of FIG. 1 is replaced with a modified core in the form of a hollow cylindrical shell 102. The cover 105 (consisting of a stack of discs), the rings (only the ring 107 is shown) and the nuts (only the nut 109 is shown) surround the cylindrical shell 102. The latter surrounds and is rotatable relative to a carrier 113 which is non-rotatably installed in bearings 115 provided in the frame of a calender or an analogous machine. The cylindrical shell 102 is rotatable around antifriction bearings 112 and selected portions of such shell can be straightened out or deformed by selected hydrostatic supporting elements 114. Reference may be had again to commonly owned U.S. Pat. No, 5,033,317 to Van Haag, the disclosure of which is incorporated herein by reference.
As already mentioned above, instead of admixing the plastic substance to paper pulp prior to making of a web which yields the discs 6 or 106, it is also possible to make the web from paper pulp and to thereupon impregnate the web with the plastic substance prior to the making of discs 6 or 106. The moisture content of the web can be reduced prior to the making of discs 6 or 106, e.g., by heating the mixture of pulp and plastic substance for a short interval of time to a temperature of approximately 100° C. Such heating takes place prior to compression of the stack of discs 6 or 106.
An important advantage of the improved method is that the material of the discs 6 or 106 need not be heated in the course of the hardening step. In other words, the temperature of the discs need not be raised above room temperature. As used herein, the term "room temperature" is intended to embrace primarily room but also outdoor temperatures.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of my contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
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A roll which has a metallic core and an elastomeric envelope is obtained by assembling the cover from a stack of discs each of which surrounds the core. In order to impart to the cover a desired elasticity, the discs contain a fibrous material and a plastic substance and are pressed against each other in the longitudinal direction of the core. The plastic substance is hardenable within an interval exceeding 48 hours. The pressing step is started with a delay following the step of placing the discs around the core such that the hardening begins prior to compressing and is terminated within an interval not less than 48 hours following the start of the pressing step.
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BACKGROUND OF THE INVENTION
The present invention belongs to the field of molding processes for producing vacuum sealed molds, and in particular, the present invention makes it possible to form the molds which are difficult to mold.
Vacuum sealed molding processes, which have been developed recently as a useful method for making molds, include a step to place a synthetic resin film in tight contact with the surface of the pattern. However, in accordance with the prior art, when the pattern has a deep concave portion or a high convex portion, it is very difficult to stretch the synthetic resin film uniformly over the pattern surface, and therefore the film cannot be applied properly on the bottom or the top surface of the pattern, so that the molds cannot have correct shapes. This presents a great disadvantage.
When performing casting operations using molds by a vacuum sealed molding process, it frequently occurs that the films forming a mold cavity are subjected to the radiation heat of molten metal, and even the film portions not in contact with the molten metal are melted and disappear. If the films are melted in this manner, the charged material loses its original state, which naturally leads to a collapse of the mold. Thus, it is desirable to use a coating material having some shielding effect after the film has melted and disappeared.
SUMMARY OF THE INVENTION
The present invention relates to a molding process in which a heated film is brought into an external pattern while being stretched by an auxiliary pattern and the film is placed in tight contact with the surface of the external pattern using a sucking action, and subsequently a molding flask is assembled to the external pattern to be filled with a charging material so that an internal mold is formed, and on the other hand, a heated film is put on an internal pattern while being stretched by a frame having an annular portion and the film is placed in tight contact with the surface of the internal pattern using a sucking action, and subsequently a molding flask is assembled to the internal pattern to be filled with the charging material so that an external mold is formed, and then said internal and external molds are assembled together so that a complete mold having a deep concave portion or a high convex portion is produced with the use of a vacuum sealed molding process; and the present invention further relates to a film forming auxiliary device in which a coating operation can be performed simultaneously with the forming operation of the film to eliminate a possibility that, when pouring a molten metal into the mold completed as described above and having the films in tight contact therewith, the film portions not in contact with the molten metal are melted by the radiation heat of the molten metal.
An object of the present invention is to provide a molding process for producing vacuum sealed molds having a deep concave portion or a high convex portion such as pots and bathtubs.
Another object of the present invention is to provide a process for placing a film in tight contact with a mold when said vacuum sealed molds are formed.
A further object of the present invention is to provide a film forming auxiliary device for use in vacuum sealed molding processes, which is adapted to perform a coating operation on vacuum sealed molds having a deep concave portion or a high convex portion by the use of the vacuum sealed molds.
These objects and features of the present invention will become more clear by the following description of preferred embodiments taking reference with the attached drawings, in which:
FIGS. 1 through 10 are views showing embodiments of the mold forming steps in accordance with the present invention;
FIG. 1 is a sectional view illustrating a step for heating a film to be placed in tight contact with an external pattern;
FIG. 2 is a sectional view showing a step in which the film is placed substantially along the surface of the external pattern;
FIG. 3 is a sectional view illustrating a state in which the film is completely in tight contact with the external pattern;
FIG. 4 is a sectional view showing a step for molding an internal mold;
FIG. 5 is a sectional view illustrating the internal mold in a completed state;
FIG. 6 is a sectional view showing a step for heating a film to be placed in tight contact with an internal pattern;
FIG. 7 is a sectional view illustrating a step in which the film is placed substantially along the surface of the internal pattern;
FIG. 8 is a sectional view showing a step for molding an external mold;
FIG. 9 is a sectional view illustrating the external mold in a completed state;
FIG. 10 is a sectional view showing a completed mold which can be poured in this state;
FIGS. 11 through 16 are views illustrating a film forming auxiliary device;
FIG. 11 is a partly broken away front view showing an auxiliary pattern device;
FIG. 12 is a partly broken away front view illustrating another embodiment of the auxiliary pattern device;
FIGS. 13 and 14 are sectional views showing steps for forming a film on a pattern having a concave portion; and
FIGS. 15 and 16 are sectional views illustrating steps for forming a film on a pattern having a convex portion.
The present invention will be explained hereunder with reference to an embodiment thereof in which a mold for casting a bathtub is formed.
DETAILED DESCRIPTION OF THE INVENTION
Molding of an internal mold A:
Referring to FIG. 1, a heating means 6 having a heat source such as an electric heater is placed above an external pattern 5 provided therein with a reduced pressure chamber 1 communicating with a vacuum pump (not shown) through a rubber hose 2, the external pattern 5 including a multiplicity of small holes 3 in communication with the reduced pressure chamber 1. A film 8 made of a plastic (such as polyethylene-vinyl-acetate, polystyrene, polyethylene, and the like) and having a thickness of 0.075 - 0.15 mm. is supported at the edges thereof by supports 7 and placed between the heating means 6 and the external pattern 5.
The film 8 is heated by the heating means 6 to a temperature of 80°C - 120°C at which the film 8 shows the best extensibility, followed by the removal of the heating means 6. Then, as shown in FIG. 2, above the film 8 is placed an auxiliary convex member means 9 which has a shape similar to that of an internal mold and to snugly fit into the concave portion of the external pattern 5, and is slightly smaller in volume than said concave portion. The convex member means 9 is inserted into the external pattern 5 with the film 8 being stretched. The supports 7 are lowered so that the surface of the external pattern 5 is covered by the film 8. Subsequently, a communication is established between the reduced pressure chamber 1 in the external pattern 5 and the vacuum pump (not shown) with the result that the film 8 is subjected to the sucking action through the small holes 3 and stretches further to come properly in tight contact with the surface of the external pattern 5.
Then, the supports 7 are removed from the film 8, and the convex member means 9 is taken out from the concave portion of the external pattern 5 (FIG. 3). Subsequently, if necessary, a coating operation is performed on the surface of the film 8 as will be described hereinafter.
FIG. 4 shows a lower molding flask 12 the wall of which has therein a hollow chamber 10 communicating with a vacuum pump through a rubber hose 2a. A suction pipe 11 in communication with the hollow chamber 10 is provided in the lower molding flask 12, a sucking action being performed by the peripheral surface of the suction pipe 11. The lower molding flask 12 is placed on the external pattern 5, and a charging material 13 such as dry sand and the like is supplied into the lower molding flask 12 from above, with a vibration being applied to the lower molding flask 12 and the external pattern 5 by means of a vibrator and the like. Then, the upper surface of the lower molding flask 12 is covered by an impervious film 14. In this embodiment, a space is formed in the central part of the lower molding flask 12 by an auxiliary frame 15, so that the amount of the charging material 13 is saved. The part of the film 14 covering the auxiliary frame 15 is opened as shown at 16 in the figure, and an opening 15a arranged at the bottom of the auxiliary frame 15 is covered by an impervious film 14a. In the construction having the auxiliary frame 15, when supplying sand into the lower molding flask 12, the part beneath the bottom of the auxiliary frame 15 cannot be filled with the sand satisfactorily. To solve this problem, an opening 15 a is provided in the bottom of the frame 15 so that the sand can be supplied through the openings 16 and 15a. Then, the hollow chamber 10 in the lower molding flask 12 is brought into communication with the vacuum pump (not shown) to start the sucking action of the suction pipe 11, as shown in FIG. 5. And the sucking action of the external pattern 5 is terminated to separate the external pattern 5 from the lower molding flask 12. Thus, the molding of the internal mold A is completed.
Molding of an external mold B:
As shown in FIG. 6, a heating means 26 is placed above an internal pattern 25 which is provided with a reduced pressure chamber 21, a rubber hose 22, and small holes 23 in the same manner as the external pattern 5 described previously. A film 28 supported at the edges thereof by supports 27 is placed between the heating means 26 and the internal pattern 25. The film 28 is heated by the heating means 26 to a temperature at which the film shows the best extensibility. Then, the heating means 26 is removed, and the supports 27 are lowered to a plane including the surface of the base of the internal pattern 25 (see FIG. 7). With this operation, the central part of the film 28 comes in contact with the top of the internal pattern 25, and the film 28 is stretched by the downward movement of the supports 27 as shown an imaginary line in FIG. 7. Subsequently, as shown in FIG. 7, an auxiliary member 24 is lowered on the internal pattern 25 by means of a suitable lifting gear and the like, with an auxiliary frame 29 at the lower end of the auxiliary member 24 being placed at the base of the internal pattern 25. At this point, the film 28, which has been stretched between the upper end of the internal pattern 25 and the supports 27 as indicated by the imaginary line in the figure, is further stretched to substantially conform with the shape of the internal pattern 25. Then, the reduced pressure chamber 21 in the internal pattern 25 is brought into communication with a vacuum pump, so that the film 28 comes in tight contact with the internal pattern 25 in the same manner as described previously. Subsequently, the supports 27 are removed from the film 28, and the frame 29 is taken out of the convex portion of the internal pattern 25. If necessary, the surface of the film 28 is coated as will be described hereinafter.
As shown in FIG. 8, an upper molding flask 32 having a hollow chamber 30 and a suction pipe 31 is placed on the internal pattern 25 in the same manner as the molding flask 12 described previously. A charging material 33 such as dry sand and the like is supplied into the upper molding flask 32 from above, with a vibration being applied to the upper molding flask 32 and the internal pattern 25 by means of a vibrator and the like. After this operation, the upper surface of the upper molding flask 32 is covered by an inpervious film 34. In this embodiment, communicating pipes 35a for forming through holes are placed vertically in the upper molding flask 32 before the upper molding flask 32 is filled with the charging material 33, to prevent the destruction of the collapse of the mold cavity during pouring. The film 34 is opened at the parts thereof covering the sprue 35 and the through holes 35a as indicated in the figure by the numerals 36.
Subsequently, the hollow chamber 30 in the upper molding flask 32 is brought into communication with the vacuum pump (not shown), so that a sucking action is applied to the charging material 33 by the suction pipe 31. At the same time, the sucking action of the internal pattern 25 is terminated to separate the internal pattern 25 from the upper molding flask 32. After this operation, the parts of the film 28 covering the sprue 35 and the through holes 35a are opened as indicated by the numerals 28a in FIG. 9. Thus, the molding of the external mold B is concluded. Completion of a mold:
The internal mold A molded in the manner as described above is turned 180°, and the external mold B is placed on the internal mold A. Then, a pouring basin 37 is placed on the pouring basin 35 of the external mold B to complete a mold. (FIG. 10)
With reference to FIGS. 11 through 16, an explanation will be given hereunder on a film forming auxiliary device in which a coating operation can be performed simultaneously with a film forming operation when producing the mold described above by the use of a vacuum sealed molding process.
On a vertically movable fitting plate 51 is mounted a reduced speed motor 53 having a hollow rotating shaft 52 extending vertically through the fitting plate 51. A rotary coupling 54 is connected to the upper end of the rotating shaft 52. The lower portion of the rotating shaft 52 extends rotatably through the fitting plate 51 and has securely fixed to the end thereof an auxiliary convex member 55 (FIG. 11) or an auxiliary concave member 55a (FIG. 12). A suitable number of injection nozzles 56 for coating are provided at desired positions on the auxiliary concave member 55a or the auxiliary convex member 55.
To the nozzles 56 are connected hoses 57 each comprising a set of a rubber hose for supplying a coating material and a rubber hose for supplying compressed air. The hoses 57 are introduced into the hollow rotating shaft 52 through pipes 57a branching off from the lower portion of the hollow rotating shaft 52, and are connected to a communicating port (not shown) in the rotary coupling 54. In the figures, the numerals 58 and 59 indicate respectively a pipe for supplying a coating material and a pipe for supplying compressed air which are in communication with the rotary coupling 54.
Hereunder an explanation will be made on the film forming operation using the convex type auxiliary device shown in FIG. 11. First, a thermoplastic synthetic resin film 61 is supported by supports 63 and placed horizontally above a pattern having a deep concave portion 60 as shown in FIG. 13. The film 61 is heated by a heating means 62 placed above the film 61 to a state in which the film 61 shows a good extensibility, followed by the removal of the heating means 62. Then, as shown in FIG. 14, the auxiliary device is operated, so that the fitting plate 51 is lowered, and the auxiliary convex member 55 is inserted into the pattern 60 from above the film 61 while stretching the film 61.
Subsequently, the supports 63 are lowered to cover the upper surface of the pattern 60 with the film 61, and a reduced pressure chamber 64 in the pattern 60 is brought into communication with a vacuum pump (not shown). As a result of this operation, the film 61 is further stretched with a sucking action being applied thereon and comes properly in tight contact with the surface of the pattern 60. Then, the supports 63 are removed from the film 61, and the fitting plate 51 is raised. During the upward movement of the fitting plate 51, the reduced speed motor 53 is energized and compressed air is supplied to the injection nozzle 56 through the supply pipe 59 and the hollow rotating shaft 52. At the same time, a coating material is supplied to the injection nozzles 56 through the supply pipe 58 and the hollow rotating shaft 52 so that the coating material is discharged from the injection nozzles 56. At this point, the auxiliary convex member 55 is moved upwardly while being rotated with the result that the whole surface of the film 61 is coated substantially uniformly by the coating material discharged from the injection nozzles 56. When the upwardly moving auxiliary member means 55 has reached a predetermined height, the reduced speed motor 53 is deenergized and the supply of compressed air and a coating material is terminated. The auxiliary member means 55 continues to move upwardly until it arrives at the original position thereof.
An explanation will be given hereunder on the film forming operation using the concave type auxiliary device shown in FIG. 12. A film 61 stretched above a pattern having a high convex portion 60a is heated by a heating means 62 to a state in which the film 61 shows a good extensibility as shown in FIG. 15, followed by the removal of the heating means 62. Then, supports 63 are lowered to a plane including the base of the pattern 60a. With this operation, the central part of the film 61 comes in contact with the top of the pattern 60a and is stretched. Subsequently, as shown in FIG. 16, the auxiliary device is operated so that a fitting plate 51 is lowered. The lower end of an auxiliary concave member 55a moves downwardly to reach the base of the pattern 60a, with the film 61 being pressed by said lower end of the auxiliary concave member 55a onto the upper peripheral edge of the pattern 60a. At this point, the film 61, which has been stretched between the top of the pattern 60a and the support 63 as indicated by the imaginary line in the figure, is further stretched to substantially conform with the shape of the pattern 60a. Then, a reduced pressure chamber 64a in the pattern 60a is brought into communication with a vacuum pump (not shown), so that the film 61 comes in tight contact with the pattern 60a in the same manner as described previously. Subsequently, the supports 63 are removed from the film 61, and the fitting plate 51 is raised. During the upward movement of the fitting plate 51, a reduced speed motor 53 is energized, and compressed air is supplied to injection nozzles 56 through a supply pipe 59 so that the injection nozzles 56 operate. Thus, the whole surface of the film 61 is coated substantially uniformly in the same manner as described previously.
Although in this embodiment the auxiliary devices are constructed to be movable vertically, alternatively the patterns 60 and 60a may be constructed to be movable vertically. In such a case, the supports shown in FIG. 13 must move vertically synchronizing with the movement of the pattern 60 when forming the film.
As is clear from the foregoing, in accordance with the present invention it is possible to apply a film surely on a pattern attaining a proper forming of the film without any possibility that wrinkles are produced on the surface of the film applied on an external pattern or an internal pattern, and with the changes in the thickness of film due to the stretching of film being limited to a minimum. Thus, the present invention can accomplish a mold having a deep concave portion or a high convex portion by the use of a vacuum sealed molding process which heretofore has been considered to be very difficult, and enjoys an outstanding advantage that the whole surface of a film can be coated substantially uniformly at the same time that the film is applied properly on a pattern and formed to a desired shape.
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A molding process for casting operations in which castings having a deep concave portion or a high convex portion such as pots and bathtubs are cast using vacuum sealed molds on which films are applied to be in tight contact with them, and a film forming auxiliary device for use in molding such vacuum sealed molds.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/823,674, filed Aug. 28, 2006, which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO APPENDIX
[0004] Not applicable.
BACKGROUND
[0005] 1. Field of the Invention
[0006] The invention relates to medical procedures. More specifically, the invention relates to the use of balloons inserted under tissues for enlargement and optional resection of the tissue.
[0007] 2. Description of Related Art
[0008] Tissues, especially mucosal tissues, form an inner lining of the mouth, nasal passages, esophagus, gastrointestinal tract, and other body passages. These tissues are prone to polyps, lesions, tumors, or other types of protruding growths. Several technologies and methods have evolved to remove such growths. Laparoscopic surgery evolved in the 1990's and assumed an important role in the management or excision of cancerous segments of the bowel or polyp removal. The less invasive approach of laparoscopy reduced hospital time to a few days, and spared the patient a large abdominal incision in place of a few small cuts through which the laparoscopic devices were inserted. Even these procedures require repeat hospital visit for surgery, general anesthesia, two to three day hospitalization, and potential complications related to surgery and anesthesia.
[0009] However, additional advances in less invasive surgical procedures were needed and resulted in development of endoscopic surgery. Endoscopic surgery relies on oral or anal insertion for surgery that can be viewed as a major advance beyond laparoscopy in that it typically can be accomplished at the time of diagnosis, it does not typically require anesthesia, and it avoids the complications associated with body-piercing incision to gain access to the colon or gastric site for tissue removal. Endoscopic mucosal resection (EMR), which is widely practiced in Japan, is gaining acceptance in the rest of the world. However, current endoscopic methods to dissect such growths have restricted access and manipulation of instruments and therefore are cumbersome and time consuming. Typically, five to six hours is required to do the dissection, depending on the type of growth and its protrusion above the tissue surface. Although this is a standard method of treatment of gastrointestinal polyps, it is associated with substantial risk of complications.
[0010] The length of time depends on the growth size and the amount of protrusion above the tissue surface, with more time generally required for a growth closer to the tissue surface, that is, shorter in height. For illustration, FIG. 1 is a schematic cross sectional view of tissues with growths. A mucosal tissue 50 is the tissue typically prone to growths. A submucosal tissue 52 underlies the mucosal tissue, with a muscularis tissue 54 under the submucosal tissue, and a serosa membrane tissue 55 under the muscularis tissue. A growth 56 A, such as a polyp, generally has a head that can be removed by a snare in a snare polypectomy procedure. The snare is positioned to encircle the polyp, then constricted below the head, and excised from the mucosal tissue. However, excision of a larger, flatter, or restricted access growth 56 A, such as a lesion, can be problematic.
[0011] Typically, an endoscope will be guided to the location. The simplest procedure is when the growth is sufficiently protruding above the tissue and shaped appropriately, such as the growth 56 A. A “snare” can be sent through the endoscope to encircle the growth and resect it from the surrounding tissue. A more complicated procedure occurs when the growth is not protruding much, if at all, above the tissue surface, such as growth 56 B. Surgical removal with a knife guided through the endoscope of a minimally protruding growth is more complicated, because the possibility increases dramatically of causing hemorrhaging (up to about 6% of the cases) in the submucosal tissue or even perforating the tissue wall rather than resecting a tissue layer. This possibility is especially true in relatively thin walls, for example, three to five millimeters in thickness of some of the tissues frequently affected. Perforating the wall to expose other tissues and body cavities can lead to significant complications.
[0012] Three factors can make endoscopic resection of growths difficult, such as colonic polyps. These are size, configuration, and location. For instance, sessile polyps greater than two centimeters in diameter, depressed or occupying more than one-third of the wall circumference, extending over more than two folds, or wrapped around a fold in a clamshell fashion, can make polypectomy a challenge. In addition, sessile polyps located behind a fold, within a flexure, or in a tortuous segment of the colon (such as the sigmoid), present a particular challenge even to the skilled endoscopist.
[0013] One recent method of dissecting such growths is to inject a saline solution below the growth, that is, at a submucosal level and “swelling” the tissue. This technique, sometimes references as a “submucosal saline-epinephrine injection polypectomy” provides an increased safety margin when performing a polypectomy, either by the snare technique described above or by cutting the growth with a knife. Further, the growth can be mechanically lifted after the injection to further facilitate removal. Saline injection into the submucosa underneath and surrounding sessile polyps mechanically compresses blood vessels and the epinephrine causes vasoconstriction. In addition, the submucosa is expanded separating the underlying tissue from the mucosa. This increased space provides a “cushion” in preventing thermal, transmural injury to the underlying tissues. Further, some extensive flat polyps, after being elevated by this injection, will be endoscopically resectable when they were not resectable without the injection technique. However, this technique has drawbacks. The “elevated” site is easily deformable upon compression for resection. Further, the elevation dissipates rapidly over time and disappears, requiring repeated injections of saline. Other materials, such as a hypertonic, a 50% glucose solution, or a synthetic ocular lubricant provides a more persistent elevation, but can cause more injuries and increases the perforation risk in the intestinal region due to the small wall thickness. Still further, even with slower absorbing solutions, the mere resection of the tissue exposes the diffused solution to the surface and creates “leaks” in the tissue, sometimes hindering completion of the resection.
[0014] As a further alternative, difficult or larger growths to be resected by piecemeal resection through multiple injections of saline for a localized elevation and removal and then repeated in different areas as needed. In some case, the injection is unnecessary but is performed for safety reasons and because of the constraints of snare size. However, such removal creates certain difficulties for the endoscopist and the pathologist. There is often considerable debris and charring at the polypectomy site, making it difficult to assess the completeness of the excision. This probably explains the variable rates of recurrence; rates as high as 48% have been reported at follow-up due to remnant adenoma tissue. Fragmentation and diathermy artifact also make pathological interpretation and evaluation of resection margins difficult.
[0015] Another proposed procedure is to use a multichannel endoscope and insert a balloon into the submucosal tissue at a particular location through one channel of the endoscope. The balloon is inflated through the endoscope to enlarge the tissue and cause greater protrusion and access. Another channel in the endoscope is used to insert the knife and resect the tissue. The balloon is then deflated and moved to another location until the procedure is accomplished through the endoscope. The disadvantage is that the balloon acts as a “tether” to the endoscope, prohibiting movement of the endoscope to surrounding tissue areas that may need resection, especially in larger growths. Thus, the balloon has to be deflated, and the endoscope relocated, and the balloon reinflated for each portion of the resection. The system also appears limited to a multichannel endoscope to function.
[0016] Thus, for the state of the art, there are no reliable procedures and instrument(s) for the removal of lesion and other undesirable growths particularly those larger than roughly 2 cm in diameter that can be used to successfully 1) present the larger mucosal and submucosal growth to the surgeon that allows for 2) sufficient time to complete the removal, and 3) ensure sufficient margin around an intact cancerous tissue resection. Therefore, innovative procedures, materials, and tools are needed to expand the efficacy and scope of endoscopic removal of larger gastrointestinal lesions and other unwanted growths.
BRIEF SUMMARY
[0017] The present disclosure provides a method, apparatus, and system to facilitate endoscopic insertion of a balloon into tissues, such as submucosal tissues, and optional resection of tissues elevated by the balloon when inflated. The system includes an endoscope, such as a single channel endoscope, with a delivery system for a detachable balloon having a seal. The delivery system includes a conduit suitable for delivering fluid such as gas or liquid to the balloon. The system also includes a knife suitable for resecting at least a portion of tissue that is elevated when the balloon is inflated. The balloon can be inserted under the tissue, such as a submucosal insertion, and inflated. The balloon can then be untethered from the delivery system and deployed submucosally while the endoscope is manipulated around the affected area and the affected tissue knife resected. The endoscope can be retracted from the area. The balloon can be made of biodegradable material that can dissolve or be absorbed over a period of time, can be retractable, or can remain in position for other purposes. The system and method can be applied to other areas and medical procedures, such as insertion into the gastrointestinal tract for esophageal acid reflux control, bladder and incontinence control, and other applications that require insertion of a balloon for a period of time, independently or in combination with removal of tissue. The system and method can also be applied to other therapeutic interventions and diagnostic strategies for disease identification and treatment in other organs.
[0018] The disclosure provides a system for endoscopically inserting a balloon into a layer of tissue, comprising: an endoscope having a least one channel; a balloon delivery system having a catheter with a fluid channel and a balloon on a distal portion of the catheter, the balloon being detachable from the catheter after inflation and adapted to remain inflated after detachment.
[0019] The disclosure also provides a method of endoscopically causing a tissue to protrude, comprising: inserting an endoscope through an opening in a body to a tissue; inserting a balloon delivery system having a balloon through the endoscope at least partially under the tissue; inflating the balloon to cause the tissue to protrude relative to a position of the tissue existing prior to inserting the endoscope; detaching the balloon from the balloon delivery system while the balloon is inflated; and allowing the inflated balloon to remain at least partially under the tissue for a period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] While the concepts provided herein are susceptible to various modifications and alternative forms, only a few specific embodiments have been shown by way of example in the drawings and are described in detail below. The figures and detailed descriptions of these specific embodiments are not intended to limit the breadth or scope of the concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the concepts to a person of ordinary skill in the art as required by 35 U.S.C. § 112.
[0021] FIG. 1 is a schematic cross sectional view of tissues with growths.
[0022] FIG. 2 is a schematic view of an exemplary embodiment of an endoscope system according to the invention.
[0023] FIG. 2A is a schematic cross-sectional enlarged view of portions of the exemplary endoscope system of FIG. 2 .
[0024] FIG. 3 is a cross-sectional schematic view of a portion of a tissue having an unwanted growth thereon.
[0025] FIG. 4 is a cross-sectional schematic view of a catheter inserted into submucosal tissue.
[0026] FIG. 5 is a cross-sectional view of a zone created by the injection of fluid into submucosal tissue.
[0027] FIG. 6 is a cross-sectional schematic view illustrating a balloon inserted into the expanded zone in the submucosal tissue caused by the fluid injection.
[0028] FIG. 7 is a cross-sectional schematic view showing an inflated balloon in the submucosal tissue.
[0029] FIG. 8 is a cross-sectional schematic view of the balloon detached from the endoscope, allowing the endoscope to be manipulated around the growth.
[0030] FIG. 9 is a cross-sectional schematic view showing a removed growth with the balloon in the submucosal tissue.
[0031] FIG. 10 is a schematic flow chart illustrating an exemplary procedure.
DETAILED DESCRIPTION
[0032] One or more illustrative embodiments of the concepts disclosed herein are presented below. Not all features of an actual implementation are described or shown in this application for the sake of clarity. It is understood that the development of an actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related and other constraints, which vary by implementation and from time to time. While a developer's efforts might be complex and time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill in the art having benefit of this disclosure.
[0033] FIG. 2 is a schematic view of an exemplary embodiment of an endoscope system according to the invention. FIG. 2A is a schematic cross-sectional enlarged view of portions of the exemplary endoscope system of FIG. 2 . The figures will be described in conjunction with each other. The endoscope system 2 generally includes an endoscope assembly 4 , as is known to those with ordinary skill in the art. An endoscope assembly 4 of varying sizes can be inserted through portions of a body to illuminate and remotely view portions of the body through which the endoscope assembly is inserted. A side injection port 5 is used to insert various catheters, tools, and other assemblies with the endoscope assembly 4 . The endoscope assembly 4 can be a single channel endoscope or a multi-channel endoscope having two or more channels. Most practitioners use single-channel endoscopes due to their simplicity and lower cost. Thus, one embodiment of the present disclosure uses a single channel endoscope. Other embodiments can use multi-channel endoscopes as desired. The term “endoscope” is used broadly in this application and includes any tool insertable into a body having a channel through which tools and other devises can be placed and used, whether inserted through a natural body orifice or through an artificially created opening, such as through an incision or other procedure, and thus includes a laparoscope modified to be able to convey tools and related instruments for purposes herein. When a distal lens is unavailable, known imaging techniques external to the body can be used for locating the tools internal to the body.
[0034] The endoscope system 2 can further include a balloon delivery system 8 . The balloon delivery system 8 generally includes a conduit 10 having a fluid channel 12 , and a detachable element 14 to deploy the balloon at the location, allowing the endoscope to be manipulated to other locations as necessary. The balloon delivery system 8 can further include a balloon assembly 16 . The detachable element 14 can be used to couple the conduit 12 to the balloon assembly 16 . In at least one embodiment, the detachable element 14 can include a latch to hold the balloon on the endoscope during insertion and inflation. A slide or release mechanism can be operated by the practitioner to push off the balloon and/or release the balloon from the endoscope at the appropriate location. For example, a similar latching assembly sold by Boston Scientific is presently used for releasing surgical clips after actuation with an endoscope, and such teaching can be adapted by one with ordinary skill in the art to the structure and particular needs of the present invention, given the teachings and guidance provided herein.
[0035] In at least one embodiment, the balloon assembly 16 generally includes a balloon and a balloon seal 26 for sealing the balloon after inflation and deployment. The balloon assembly can include a connection conduit 18 , disposed adjacent to the detachable element 14 and a balloon 20 coupled to the connection conduit 18 . The end of the balloon assembly 16 can include a tip 22 . In at least one embodiment, the tip 22 is closed to allow fluid in the balloon assembly 16 to become pressurized and flow through an opening 24 in the connection conduit 18 to inflate the balloon 20 .
[0036] The seal 26 can be self-sealing, such as a check valve, dome valve, and self-sealing septum. The check valve can include such valves as read valves, flapper valves, and other self-sealing valves. In at least one embodiment, the seal 26 can seal against a seat 28 within the balloon assembly 16 .
[0037] The balloon assembly can be guided along a guide wire to a planned location, as described herein. In some embodiments, the guide wire will be external to the balloon assembly. In other embodiments, the guide wire can be internal to the balloon assembly and the balloon assembly can be modified to allow the guide wire to pass therethrough.
[0038] The balloon can be made of medical grade plastic. In some embodiments, the balloon can be made of biodegradable material such as without limitation, polylactic acid materials, glycolides, and other materials that may polymerize and degrade with time in the body. Such materials can include biodegradable polymers including, but not limited to, glycolic acid-based polymers, such as polyglycolide (PGA); lactic acid-based polymers, such as polylactide (PLA); polyanhydrides; polyorthoesters; polyphosphazenes; poly(dioxanone) copolymers; poly(trimethylene carbonate) copolymers; poly(e-caprolactone) homopolymers and copolymers; LPLA; DLPLA; PCL; PDO; PGA-TMC; DLPLG; and polyhydroxybutyrate (PHB) and polyhydroxyvalerate (PHV) polymers and copolymers, such as Biopol(r) (Monsanto Co., St. Louis, Mo.). In other embodiments, the balloon can be made of non-biodegradable material, for example, if the material is to remain intact for an extended period of time. The filling agent of the balloon can be any medically safe material including liquid saline, dextrose solutions, water, gases, such as air or nitrogen, and other fluids. Further, the fluid can be a hardenable material, known to those in the art. The balloon can be provided in different sizes and shapes depending on the size of the tissue to be elevated. Further, the term “balloon” is used broadly to encompass one or more balloons. For example, multiple balloons can be placed in position instead of one larger balloon as may be appropriate for the particular growth to be removed. Further, the balloon can include radio opaque material.
[0039] An additional tool that can be inserted through the side injection port is a knife sheath 30 . The knife sheath 30 generally includes a tip 32 where a retractable knife 34 can extend to cut or abrade various tissues after being guided to the proper location. If the sizes allow, both the knife sheath 30 and the balloon delivery system 8 can be inserted through the injection port at the same time. In some embodiments, insufficient room is available and the balloon delivery system 8 and the knife sheath 30 can be sequentially inserted through the injection port. Advantageously, the balloon delivery system can leave the balloon assembly in location, such as in a submucosal tissue, and be removed from the endoscope assembly 4 . Then, the knife sheath 30 can be inserted through the injection port for resection of the unwanted growth. This aspect alone remarkably differs from known methods and systems in that the knife sheath 30 of the present disclosure is not tethered to a fixed location with the balloon.
[0040] The endoscope assembly 4 generally includes a monitor and lens system 3 for viewing the distal end of the endoscope as it is inserted into the body and guided to the desired location. Further, the endoscope assembly 4 includes a light and power source 6 for providing illumination to the endoscope to view the relevant tissues.
[0041] FIGS. 3 through 9 illustrate at least one series of procedures that can be performed using the endoscope system 2 described above with the endoscope assembly 4 and the balloon delivery system 8 and balloon assembly 16 . The illustrations are schematic only and are representative of only one possibility of using the system. Other steps and methods could be adapted by one with ordinary skill in the art given the disclosure contained herein.
[0042] The disclosed balloon assembly and related systems and methods are exemplary and other and further assemblies and systems can be used and are contemplated. For example and without limitation, other exemplary balloon delivery assemblies and systems include those devices shown in U.S. Pat. Nos. 4,441,495, 5,188,558, 5,304,123, 6,736,793, 6,312,405, and 6,666,828 and US Publication 20060079923, having detachable and sealable balloons. The teaching of such disclosures are incorporated herein by reference.
[0043] Further, variations on the use of the guide wire, including a guide wire external to balloon or internal to the balloon, no guide wire, guide wire at different steps, retracting the guide wire at different steps, and other variations are possible. Such variations are contemplated and are intended to be included within the scope of the claims contained herein.
[0044] FIG. 3 is a cross-sectional schematic view of a portion of a tissue having an unwanted growth thereon. The portion of tissue 48 generally includes a mucosal tissue 50 , a submucosal tissue 52 below the mucosal tissue, and a muscularis tissue 54 below the submucosal tissue. An unwanted growth 56 can occur on the mucosal tissue 50 . Generally, the growth can be a polyp or other tissue that may have a variety of sizes and shapes including a relatively flat surface. The growth can also be a portion of tissue to be stripped during a medical procedure, such as vascular surgery for retrieval of vein grafts. Rounded growths with a head and a stalk can be generally removed through snares and other endoscopic tools known to those with ordinary skill in the art. Flattened growths are more problematic due to accessibility of a larger surface that follows the shape of the underlying tissue. Other types of growths can have similar difficulties in removal or resection. While a variety of growths can benefit from the present disclosure, it is envisioned that the more difficult growths to resect may especially benefit from the present disclosure. Thus, for illustrative purposes, the more flattened growth 56 will be described in the resection procedure, although it is to be understood that the procedure could apply to other types of growths.
[0045] FIG. 4 is a cross-sectional schematic view of an endoscope inserted into submucosal tissue. The endoscope system 10 can be guided through a body cavity such as an esophagus or colon to an appropriate location. A fluid injection catheter 38 with a needle can be disposed down the endoscope to the submucosal tissue so that fluid can be injected into the submucosal tissue 52 . This fluid can include saline and other solutions. In some embodiments, the saline can be dyed with methylene blue. Another liquid besides saline is D50 (50% w/v dextrose). D50 can remain in a concentrated area of the submucosal tissue longer than saline.
[0046] FIG. 5 is a cross-sectional view of a zone created by the injection of fluid into submucosal tissue. The zone 58 raises or protrudes the growth 56 to a higher elevation relative to surrounding tissue. The higher elevation assists in access and resection of the growth 56 from the mucosal tissue 50 . Additional injections can be made at different points through the tissue to create a noncircular, flattened, or nonuniform shaped zone 58 depending upon the size, extent, and shape of the growth 56 . The needle and injection catheter can be removed and a guide wire 40 can be inserted into the endoscope 2 and guided into the zone 58 . The guide wire can provide guidance for various tools, balloons, and other instruments inserted during the procedure.
[0047] FIG. 6 is a cross-sectional schematic view illustrating a balloon inserted into the expanded zone in the submucosal tissue caused by the fluid injection. A balloon assembly 16 can be inserted through the endoscope system 2 with the balloon delivery system 8 . In at least one embodiment, the balloon assembly can be inserted along the guide wire 40 . In some embodiments, the balloon can be inserted independent of the guide wire and thus the illustrated guide wire is not to be exclusive of other options. Further, the balloon can include different sizes and shapes as may be appropriate. The determination of the balloon size and shape can be made after endoscopic review of the growth 56 during the procedure. In some embodiments, the balloon can be inserted directly into the submucosal tissue 52 without the injection of fluid to create a zone 58 . Other embodiments of balloons and balloon assemblies are possible and contemplated.
[0048] FIG. 7 is a cross-sectional schematic view showing an inflated balloon in the submucosal tissue. The balloon delivery system 8 can inflate the balloon assembly 16 when positioned in the selected location. The balloon assembly 16 can retain the zone created by the solution injected into the submucosal tissue. In at least aspect, the balloon can retain the protrusion of the growth 56 .
[0049] FIG. 8 is a cross-sectional schematic view of the balloon detached from the endoscope. The balloon assembly 16 having the inflated balloon can be detached from the endoscope assembly 4 and the balloon delivery system 8 , shown in FIG. 7 . In at least one embodiment, the balloon delivery system 8 can be retracted from the endoscope assembly. In other embodiments, with sufficient room, the balloon delivery system 8 can remain down the endoscope system while other procedures are performed. Further, the balloon delivery system can be retracted and reinserted with one or more other balloon assemblies to be placed in zone 58 or other locations.
[0050] Generally, it will be desirable to remove the growth 56 . Thus, a knife sheath 30 with a knife 34 can be inserted down the endoscope assembly to remove the growth 56 . Advantageously, the endoscope is not tethered to the balloon assembly 16 , so that the endoscope can be moved from the first position 70 to a second position 70 ′ to a third position 70 ″ as appropriate to further resect portions of the growth 56 . The term “knife” is used broadly to include any method of removing material including ablation methods, such as with an argon plasma coagulator, and other ablation tools, high frequency knives, grinders, blades, snares, and other tissue removing devices.
[0051] FIG. 9 is a cross-sectional schematic view showing a removed growth with the balloon in the submucosal tissue. The growth 56 can be removed as a single piece or in multiple pieces in different stages as may be appropriate. In at least some embodiments, the balloon can remain in place in the submucosal layer. In such instances, it may be advantageous to make the balloon assembly out of biodegradable material. In other embodiments, the balloon can be retrieved through the endoscope using various tools, such as forceps and other devices. It may be advantageous to puncture or otherwise deflate the balloon assembly prior to removal so that the fluid contained therein can be allowed to escape and collapse the balloon for easier retrieval.
[0052] In other embodiments, it may be advantageous to simply leave the balloon in position on a more long-term basis. Such instances could include applications where it is desired to maintain a protruding portion of the mucosal tissue 50 . Further, in such more permanent, applications, the balloon assembly could be used for other types of gastrointestinal applications for incontinence, acid reflux, and so forth. In such applications, the procedure may be directed primarily to inserting a balloon and detaching the balloon from the balloon delivery system without necessarily resecting tissue. As one exemplary and nonlimiting application, the balloon could be asserted into an esophageal submucosal tissue above the stomach to restrict the size of the esophagus and reduce acid reflux damage in the esophagus. The present disclosure uniquely offers a detachable balloon that can be inserted submucosally and left in position in an inflated condition using an endoscopic procedure to access areas of the body not generally accessed.
[0053] The concepts disclosed herein using a detachable balloon inserted endoscopically can also be used not only in surgical situations that require separation of cell layers like endometrial stripping but also for therapeutic procedures, such as procedures where there is use for contained bulking agents such as gastroesophageal reflux disease (GERD), acid reflux, bowel and urinary incontinence and vesicoureteral reflux, subcutaneous dissection, tamponade in closed spaces, a lithotripsy target, subfacial, submusclar dissection, or as a prosthesis. A detachable balloon that can be deployed in situ can assist in subcutaneous dissection for plastic and reconstructive surgery, and vascular surgery for retrieval of vein grafts. An endoscopically detachable balloon can also provide intervertebral disc prosthesis or a joint cartilage or fluid prosthesis. As another example, in lithotripsy, a balloon can be deployed above or below a stone in the bile duct, ureter, or bladder with radioopaque contrast for the lithotripsy technician to aim and destroy the radiolucent stones therebetween. Further, a deployed balloon with radioopaque contrast can provide for focused radiotherapy of tumors by marking the tumor above and below with a balloon in the esophagus, stomach, pancreas, colon, bronchus, kidney, bladder, and other body tissue and organs. Furthermore, the deployed balloon can be designed such that it contains therapeutic ingredients like drugs, cells, peptides or enzymes under the mucosa and can be left in situ to provide local or regional therapeutic effects. For example, it can be conceived that following surgical resection of cancerous tissue, a balloon containing chemotherapeutic agent is deployed and left close to the resection site, so that there is localized delivery to prevent recurrence. Such a balloon can also be constructed with a slow-release material and be filled with antimetastatis and/or anti-angiogenesis agents; this kind of delivery will greatly aid the release of larger doses of therapeutic agents more effectively, since the deployed balloon is close to the site of disease. This kind of delivery reduces the systemic effects and will also help deliver large doses of therapeutic agents more effectively.
[0054] FIG. 10 is a flow chart illustrating one non-limiting example that is similar to the procedures that have been described above. Step 80 includes passing an endoscope into the UGI tract or colon. Step 82 includes injecting a saline solution with an injection catheter into the submucosal tissue to create a “space” and lift a lesion. Step 84 includes inserting a balloon catheter into the submucosal saline space. Step 86 includes inflating a balloon in the submucosal tissue, detaching the balloon, and removing the catheter. Step 88 includes inserting a needle knife to cut on the periphery of the elevation until the lesion is removed.
[0055] The invention has been described in the context of various embodiments and not every embodiment of the invention has been described. For example, the mucosal tissues have been described, but it is contemplated and understood that the invention may be used on other body tissues and such use is included within the scope of the claims. Apparent modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, the Applicant intends to protect all such modifications and improvements to the full extent that such falls within the scope or range of equivalent of the following claims.
[0056] The various methods and embodiments of the invention can be included in combination with each other to produce variations of the disclosed methods and embodiments, as would be understood by those with ordinary skill in the art, given the understanding provided herein. Also, various aspects of the embodiments could be used in conjunction with each other to accomplish the understood goals of the invention. Also, the directions such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of the actual device or system or use of the device or system. Unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, should be understood to imply the inclusion of at least the stated element or step or group of elements or steps or equivalents thereof, and not the exclusion of a greater numerical quantity or any other element or step or group of elements or steps or equivalents thereof. The device or system may be used in a number of directions and orientations. Further, the order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. The term “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, directly or indirectly with intermediate elements, one or more pieces of members together and can further include without limitation integrally forming one functional member with another in a unity fashion. The coupling can occur in any direction, including rotationally. Additionally, the headings herein are for the convenience of the reader and are not intended to limit the scope of the invention.
[0057] Further, any references mentioned in the application for this patent as well as all references listed in the information disclosure originally filed with the application are hereby incorporated by reference in their entirety to the extent such may be deemed essential to support the enabling of the invention. However, to the extent statements might be considered inconsistent with the patenting of the invention, such statements are expressly not meant to be considered as made by the Applicant.
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The present disclosure provides a method and system to facilitate endoscopic insertion of a balloon into tissues, such as submucosal tissues, and optional resection of tissues elevated by the balloon when inflated. The system includes an endoscope with a delivery system for a detachable balloon having a seal. The balloon can be inserted under the tissue, such as a submucosal insertion, and inflated. The balloon can then be untethered from the delivery system and deployed submucosally while the endoscope is manipulated around the affected area and the affected tissue knife resected. The endoscope can be retracted from the area. The balloon can be made of biodegradable material that can dissolve or be absorbed over a period of time. The system and method can be applied to other areas and medical procedures that require insertion of a balloon for a period of time.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related in subject matter to co-pending application Ser. No. 216,227, filed Dec. 15, 1980, entitled "Cuttings Cleaning Method", said copending application being assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a cuttings washer method for use in drilling and similar operations for a subterranean well.
2. Description of the Prior Art
During the drilling of a subterranean well, a drilling fluid or mud is circulated within the well bore to cool and lubricate the drilling bit and to remove drilling cuttings from the bottom of the well. At the well head, the cuttings are removed, and the drilling fluid is recirculated. When an oil base drilling fluid is used, however, residual oil clinging to the cuttings may contaminate the environment, such as the ocean or sea, or the like. To avoid such contamination, and, in some situations, to comply with some government regulations, it is therefore desirable to wash such drilling cuttings before disposing of them, particularly from an offshore drilling rig.
Equipment for washing cuttings is commercially available. In known systems, cuttings are deposited in a tub containing a wash solution and are agitated therein. The cuttings are then deposited on a horizontal vibrating screen. Wash solution and oil contaminants are shaken off the cuttings particles and through the screen. The vibratory motions impel the cuttings particles off the edge of the screen into the ocean or other suitable depositary.
Depositing the cuttings in a washing tub, removing them after agitation, and depositing them on a shaker is relatively time consuming, hence in some drilling and related operations, even two of such systems operating at the same time have been unable to keep up with the drilling rate.
SUMMARY OF THE INVENTION
The disadvantages of the prior art are overcome with the method and apparatus of the present invention, in which drilling cuttings may be washed at least twice while traveling in a continuous path. Oil-contaminated cuttings are deposited on an inclined vibrating screen. A spray of washing solution which may include a surfactant, is directed upon such cuttings with sufficient force to effectively coat the cuttings with the solution. The vibratory motion moves the cuttings downwardly on the inclined screen and agitates the cuttings to remove the solution and oil contaminants through the screen. After traveling down the screen and being shaken to reduce the moisture content, i.e., the entire fluid content of the treated matter, to less than about ten percent, the cuttings fall off the lower edge of the screen onto another inclined, vibrating screen. Again the cuttings are sprayed and coated with a washing solution, and shaken to remove the washing solution and any remaining oil contaminants. Advantageously, the second and subsequent washing solutions may be more dilute then the first.
The washing solutions are recovered separately below each screen, and recirculated for reuse in spraying the cuttings. During recirculation, the wash solutions may be cleaned by a centrifuge, to remove any fine cuttings particles which have fallen through the screen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one of two series-operated vibrating screens used in the cuttings washer assembly.
FIG. 2 is a schematic block diagram showing the operation of the cuttings washer assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a typical drilling operation, drilling fluid which is circulated from the hole is separated from cuttings and particles it carries before being recirculated through the well bore. Solids control equipment, generally indicated at 10, for removing particles from the drilling fluid may comprise a desilter, a centrifuge, a cuttings shaker, and a mud cleaner. Before the removed particles are discarded oil or other hydrocarbons clinging to or otherwise associated with the particles is removed by the cuttings washer assembly.
The cuttings washer assembly comprises two inclined, vibrating shaker screens 12 and 14, nozzles 22 and 37 for spraying the cuttings with a washing solution, and recirculating and cleaning means for the washing solution.
The vibrating screens 12 and 14 are of the type disclosed in U.S. Pat. No. 3,014,587, to Philippovic. In general, as illustrated in FIG. 1, the inclined vibrating screen 12 is actuated by an unbalanced rotary motor 16 attached to the screen 12. The screen 12 may be secured to a supporting structure by means of hollow, elastomeric isolators 18. The isolators 18 may be pneumatically expanded to tune the apparatus to achieve the desired vibratory patterns. The apparatus may thus be tuned so that the vibrations toward the top of the inclined screen tend to retard the movement of particles down the incline, thus assuring adequate time for washing and screening. Alternatively, the screen 12 may be secured to the structure by means of coiled springs, solid shock absorbers, or the like. Towards the bottom of the incline the vibratory motions assist the movement of particles down the incline of the screen 12, to effectively pitch washed particles over the lower edge 13 of the screen 12.
As illustrated in schematic form in FIG. 2, two of such vibrating screens are aligned in series. A chute 20 is disposed above the upper screen 12 for feeding particles from the solids control equipment 10 onto the upper portion of the vibrating screen 12. The screen 12 is disposed above the screen 14 and so arranged that the particles shaken off the lower edge 13 of the screen 12 fall onto the upper portion of the inclined screen 14. In an offshore drilling rig, the screen 14 may be so arranged that washed particles pitched off the lower edge of the screen 14 fall into the ocean.
Above the upper portion of the inclined screen 12, and adjacent the chute 20, are a plurality of suitably mounted spray nozzles 22, oriented to direct a forceful spray of washing solution onto cuttings particles deposited on the screen 12. The screen mesh is of a size that the cuttings paticles remain on top of the screen while the wash solution and rinsed off oil and other hydrocarbons pass freely though the screen. A tank 24 is disposed beneath the vibrating screen 12 to recover washing solution which passes through the screen 12. A pump 26 draws solution from the tank 24 through a line 28, and recirculates the washing solution through a line 30 to the spray nozzles 22. Some fine particles will inevitably pass through the screen 12 and into the wash solution in the tank 24. To avoid the necessity of frequent changing of the wash solution as it becomes contaminated with such fine drilled solids, a centrifuge or hydrocyclone 32 is provided. A portion of the output of the pump 26 is diverted through a line 34 to the hydrocarbon and/or centrifuge 32, and thence through a line 36 to the tank 24.
Similarly, a second set of nozzles 37 and a tank 38 are associated with the second inclined vibrating screen 14. A single pump could be employed to recirculate washing solution from tanks 24 and 38 through nozzles 22 and 36. However, two separate recirculation pumps may advantagously be employed, as illustrated schematically in FIG. 2. A second pump 40 withdraws water through a line 42 from the tank 38, and recirculates the wash solution through a line 44 to spray nozzles 37. A portion of the output of the pump 40 associated with the screen 14 is diverted through a line 46 through the hydrocyclone centrifuge 48 and thence through a line 50 to the tank 24. Thus two different wash solutions may advantageously be used. For example, the wash solution associated with the screen 12 may be a highly potent detergent solution, and the solution associated with the screen 14 may be a more dilute rinse solution.
To use the cuttings washer assembly, drilled cuttings particles separated from the drilling fluid by the solids control equipment 10 are deposited through the chute 20 onto the inclined vibrating screen 2, adjacent its upper edge. A high velocity spray of washing solution is directed onto the cuttings from the nozzles 22. Preferably, the nozzles 22 produce a cone shaped spray pattern which will distribute the wash solution throughout the deposited cuttings. The solution may typically comprise calcium chloride water and a surfactant, although other components and additives may be utilized. The spray must be introduced onto the cuttings with sufficient force and in sufficient amount to effectively remove hydrocarbon contaminants from the cuttings. The fluid pressure, flow rate, and nozzle configuration may be varied to achieve this result, in known ways.
The vibratory motion of the screen 12 propels the cuttings particles down the incline, and agitates the particles to remove oil and other hydrocarbons and wash solution from the particles. Satisfactory results are achieved when the particles are retained on the vibrating screen 12 until their moisture content is less than about ten percent, by weight. As the particles are exposed to the wash solution, a low moisture content indicates that hydrocarbon contaminants have also been substantially removed from the particles.
As the particles approach the lower edge 13 of the screen 12, the vibratory motion of the screen 12 pitches the particles onto the screen 14, adjacent the upper edge of the screen 14. Here the process of washing the particles with a spray of washing solution and agitating the particles to remove wash solution and hydrocarbons is repeated. Washed cuttings particles are propelled off of the lower edge of the screen 14 into the ocean, or may otherwise be disposed.
It should be noted that a single shaker with one longer, vibrating screen could be employed, while still using two sets of nozzles, and two separate wash solutions. With such an apparatus, it would merely be necessary to divide the screen into two separate treatment zones by placement of the two sets of nozzles and tanks. Again, the screen would have to be long enough to permit sufficient agitation under the spray to substantially coat all particles with wash solution and sufficient agitation beyond the spray to substantially reduce the moisture content. A screen length of about 12 feet would be appropriate in a single screen apparatus. Moreover, the screen assembly 12 itself may be subdivided into two or more screening units, in series.
The vibratory pattern of any particular area of the screen depends upon the distance of that area from the motor, the weight distribution of the screen assembly, the speed of the motor, and tuning of the screen insolators. As disclosed by the aforementioned Philippovic patent, the screen may be tuned to retard the downward motion of particles on the screen in some areas and to assist the flow of materials down the incline in other areas. However, as larger screens are employed, it becomes increasingly difficult to tune the system. To avoid unwanted vibrations that could impede the flow at the lower edge of a screen, it has been found preferable to use three or more shorter screens, in series, as described above.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are comtemplated which can be made without departing from the spirit of the described invention.
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Particulate matter is deposited on an inclined vibrating screen. A spray of wash solution is directed onto the cuttings. As the cuttings move down the incline, the vibration agitates the wash solution and hydrocarbon contaminants from the cuttings. The solution is recovered below the screen. Washed cuttings are deposited onto a second inclined vibrating screen unit, where the procedure may be repeated. Recovered washing solution is cleaned and recirculated.
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BACKGROUND OF THE INVENTION
This invention concerns devices for rapidly releasing fluid under pressure from a reservoir. So called "air bag" safety cushion devices used in auto vehicles rely on very rapid inflation of an air bag at the moment a serious collision occurs. Testing and development of these systems require numerous test inflations to be carried out, but since pyrotechnic devices are typically employed in actual air bag inflations, such tests are costly and require licensed facilities.
It is difficult or impossible to simulate the gas flow in such systems with reservoirs opened with conventional valving due to the very high rates of flow occurring almost instantaneously when an air bag system is activated.
There are other applications where a very rapid opening of a fluid passage would be desirable, preferably with a simple, reliable device.
There has heretofore been employed various bursting pieces associated with pressure release discs, but these have been relatively bulky members partially blocking flow in the discharge passage.
SUMMARY OF THE INVENTION
The present invention comprises a frangible sealing disc or diaphragm installed in a passage extending from the high pressure reservoir. A puncturing pin is mounted on the downstream side of the disc inclined at an angle so that its longitudinal axis intersects the center of the disc, the disc distended as by preforming and/or the exertion of the pressure in the reservoir towards its downstream side. A selectively operable driving means is associated with the pin to enable driving of the pin to force a sharpened end into the distended center of the disc. Penetration of the center of the disc by the sharpened end causes rupturing along radial lines prescored into the disc.
The rupturing disc releases fluid under pressure from the reservoir very rapidly which has been found to closely simulate the flow characteristics of typical gas generators used in air bag restraint systems.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a transverse sectional view of the device according to the present invention.
FIG. 2 is a plan view of the rupture disc incorporated in the device shown in FIG. 1.
DESCRIPTION
In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
FIG. 1 shows a release conduit 10 in communication with a pressure reservoir 12, shown diagrammatically. The conduit 10 is sealed by a diaphragm 14 having its periphery clamped between flange 16 of conduit 10 and flange -8 of a housing 20, these flanges secured together with threaded fasteners 22.
The diaphragm 14 is disc shaped and may be of various materials such as metal or plastic, designed with a thickness to be of sufficient strength to normally withstand whatever pressure exists in reservoir 12. The diaphragm 14 is scored with radially extending score lines 24 (FIG. 2) which intersect at the center 26 of the diaphragm 14. The diaphragm 14 is also formed with a dished or distended bulge feature 28 located on the downstream side as installed.
The housing 20 has an internal cavity 21, and is secured to a discharge conduit 30 by means of mating flanges 32, 34 and threaded fasteners 36
The discharge conduit 30 receives flow from cavity 21 of the housing 20, and directs outflow to a downstream device 38 which utilizes the outflow, such as an air bag installation to be test deployed.
An elongated pin 40 is installed extending through a sidewall of the housing 10, inclined at an acute angle as shown so that its longitudinal axis intersects the bulged center 36 of the diaphragm 14. The sharpened tip 42 of the pin 40 is directed towards the diaphragm 14, but normally held retracted as shown in FIG. 1 by a compression spring 44 contained in a plunger housing 46 engaging a plunger head 48 of the pin 40 to urge it to the retracted position shown. The housing 46 is vented at 50 to insure free movement of the pin 40 in the housing 46.
An actuator 52 is provided, selectively operable to drive the pin 40 so to cause the sharpened end 42 of pin 40 to penetrate the center 36 of the diaphragm 14. A suitable actuator may take many forms, such as a pneumatic device, or a mechanical spring operated device as are used to drive firing pins in firearms. Penetration of the center 36 of diaphragm 14 causes the diaphragm 14 to burst under the pressure contained in the reservoir -2, tearing open along the score lines 24, the segments peeling back in flower petal fashion against the interior of the housing 20, to allow immediate release of the gas under pressure in the reservoir 12. The spring 44 causes retraction of the pin 40 so that a substantially unimpeded flow path is afforded for discharge of the fluid under pressure in the reservoir 12.
It has been found that this device provides a discharge flow characteristic similar to the gas generators used in air bag systems in that a very rapid valvelike action is achieved.
At the same time the device is simple and reliable and may be manufactured at low cost.
Variations in thickness and material of the diaphragm 14 may be used to vary the discharge flow characteristics for a particular application.
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A device is disclosed for very rapidly releasing fluid under pressure from a reservoir in which a sharpened pin is driven at an angle into the center of a sealing diaphragm to release the fluid under pressure from the reservoir.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to an apparatus for handling tubulars. More specifically, but not by way of limitation, this invention relates to an elevator apparatus and method for lifting tubular members on a rig.
[0002] Most oilfield tubular connections have a larger outer diameter than the tubular body. This difference in diameter creates a shoulder that can be utilized for lifting the tubular. To lift up the tubular, a tool called an elevator wraps around the tubular body. Upon hoisting the elevator having been wrapped around the tubular, the upper section of the elevator makes contact with the corresponding shoulder of the connection. The contact area between the elevator and shoulder creates an interference providing a lifting surface for the tubular.
[0003] Elevators are comprised of a body, one or more hinged doors and a latch. To close the elevator around the tubular, it is lowered adjacent to the tubular (usually suspended from the traveling block) and the two portions are hingedly closed around the tubular below the connection. The latch closes after the portions come together and locks it shut.
[0004] Automation of tubular handling devices is a useful technique to incorporate safety and efficiency in the handling of tubular members. Prior art devices have attempted to automate the handling of tubular members with elevators. However, these prior art devices suffer from several deficiencies such as reliability, cost of manufacture, repair, maintenance, simplicity of operation, etc.
[0005] Most existing remote operated elevators are comprised of an elevator of conventional design, utilizing hydraulic or pneumatic cylinders, attached to the elevator, to offer the feature of remote operation. These mounted cylinders create operational and ergonomic issues that must be addressed to assure proper functionality.
[0006] Therefore, an object of the present invention is to provide an apparatus and method for handling a tubular member. Another object is to provide an elevator apparatus and method that can be activated remotely. Yet another object is an elevator apparatus that can be remotely opened or closed. Still yet another object is an elevator apparatus and method that can latch or unlatch remotely. These objects and many other objects will become apparent from a reading of the present disclosure.
SUMMARY OF THE INVENTION
[0007] An elevator apparatus is disclosed. The apparatus includes a circular member comprising a first and a second portion and a hinge pin means operatively associated with the first portion and the second portion, for pivoting the first portion relative to the second portion. The elevator apparatus further includes a first rotary actuator for activating the hinge pin so that the first and second portion pivot to form a circular member, a latch mechanism for latching the first portion and the second portion, and a second rotary actuator for actuating the latch mechanism.
[0008] In one preferred embodiment, the first rotary actuator comprises: a first cylinder; a first rack disposed within the cylinder, the first rack being responsive to a pressure within the cylinder; and a first roller having teeth disposed thereon, wherein the first rack and the teeth are engaged and wherein the first roller is connected to the hinge pin means.
[0009] The first cylinder, in the most preferred embodiment, is a hydraulic or pneumatic pressure cylinder receiving pressure from a source such as a hydraulic or pneumatic control unit. Also, in the most preferred embodiment, the second rotary actuator comprises: a second cylinder; a second rack disposed within the second cylinder, with the second rack being responsive to a pressure within the second cylinder; and a second roller having teeth disposed thereon, wherein the second rack and teeth are engaged and wherein the second roller is connected to a first pin so that lateral movement of the second rack causes extension of the first pin.
[0010] The second roller, in one preferred embodiment, is connected to a second pin offset from the first pin and wherein lateral movement of the second rack causes extension of the second pin in a direction opposite from the first pin.
[0011] The apparatus may further comprise an indicator means for detecting the extension of the first pin. In one preferred embodiment, the indicator means comprises a relay switch that is controlled by the position of the first pin.
[0012] In another preferred embodiment, the first pin has a first position that is recessed within an aperture within a housing and a second position that extends from the housing, and wherein the indicator means comprises a projection that is positioned within the aperture and a relay switch operatively connected to the projection, and wherein upon movement of the first pin from the recessed position to the extended position, the projection is lifted from the aperture which trips a relay switch.
[0013] A method of lifting a tubular member on a drilling rig is also disclosed. The method comprises suspending an elevator apparatus from the rig. The elevator apparatus includes: a first portion and a second portion; a hinge pin member operatively associated with the first portion and the second portions, for pivoting the first portion relative to the second portion; a hinge rotary actuator for moving the hinge pin; and, a latch member for latching the first portion and the second portion in order to form a circular member about the tubular.
[0014] The method further comprises surrounding the elevator apparatus about the tubular member, with the tubular member being suspended in a rotary table on the rig with a slip device or in a more horizontal position from the v-door, pipe rack or catwalk, and activating the hinge rotary actuator so that the first portion and the second portion pivots about the hinge pin. The method further includes latching the first portion and the second portion—together thereby forming the circular member, releasing the tubular member from the slip device, and lifting the tubular with the elevator apparatus. In one preferred embodiment, the method also includes detecting whether the first portion and the second portion are latched.
[0015] The method may further comprise suspending the tubular member within the rotary table on the rig, and unlatching the first portion from the second portion by activating a latch rotary actuator operatively associated with the latch member. Next, the hinge pin is activated via the first hinge rotary actuator, and the first portion and the second portion is pivoted in order to separate and open up the two portion.
[0016] In one preferred embodiment, the hinge rotary actuator comprises: a pressure cylinder; a rack disposed within said cylinder and responsive to a pressure; a roller having teeth thereon, with the teeth engaging the rack. In this embodiment, the step of activating the hinge rotary actuator comprises: selectively applying a pressure in the cylinder; moving the rack in response to the pressure; rotating the roller; and pivoting the hinge pin thereby separating the first portion from the second portion.
[0017] The second rotary actuator, in one preferred embodiment, comprises: a pressure cylinder; a rack disposed within the cylinder and responsive to a pressure; a roller having teeth thereon, with the teeth engaging the rack; and wherein the step of activating the door rotary actuator(s) comprises: selectively applying a pressure to the cylinder; moving the rack in response to the pressure; and rotating the roller so that the latching pin contracts so that the first and the second portion are no longer latched together.
[0018] An advantage of the present invention includes the device that can be remotely controlled. Another advantage is that the door mechanism and latch mechanism is dependable and can be activated numerous times. Yet another advantage is that the device provides a safety means to determine if the device is latched.
[0019] Another advantage is that the design incorporates rotary actuator(s) solidly affixed to the hinge boss area/areas, which is directly attached to the hinge pin/pins. Yet another advantage is that the design reduces the size and complexity of conventionally designed units. By minimizing the fabricated attachment areas and hydraulic/pneumatic cylinders, it also reduces the risk of failure in the attachment and linkage areas.
[0020] A feature of the elevator apparatus includes a rotary actuated hinge. Another is the use of a rotary actuated latch. Still yet another feature is the rotary actuator uses rack and pinion, and wherein the movement of the rack is initiated via a pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of the elevator apparatus of the present invention.
[0022] FIG. 2 is the elevator apparatus shown in FIG. 1 wherein the elevator apparatus has been pivoted to the open position.
[0023] FIG. 3 is a perspective view of the elevator apparatus seen in FIG. 1 depicting a partial cut-away illustration of the rotary actuator for the hinge means.
[0024] FIG. 4 is a perspective view of the rotary actuator for the hinge means seen in FIG. 3 .
[0025] FIG. 5 is a perspective view of the opened elevator apparatus and the latch means in the unlatched position.
[0026] FIG. 6 is a perspective view of the rotary actuator for the latch means seen in FIG. 5 .
[0027] FIG. 7 is a partial perspective view of the closed elevator apparatus depicting a cut-away illustration of the latch means.
[0028] FIG. 8 is a sequential view of the closed elevator apparatus seen in FIG. 7 depicting the closed latch means.
[0029] FIG. 9 is a schematic illustrating a drilling rig, with an elevator apparatus suspended from the drilling rig derrick.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring now to FIG. 1 , a perspective view of the elevator apparatus 2 (sometimes referred to as the apparatus 2 ) of the present invention will now be described. In the most preferred embodiment, the apparatus 2 has a first semi-circular half 4 (also referred to as the first portion 4 ) and a second semi-circular half 6 (also referred to as second portion 6 ), and wherein the first semi-circular half 4 and the second semi-circular half 6 are hinged together via hinge pin 8 . The hinge pin 8 will be turned by the hinge rotary actuator 10 (sometimes referred to as the first rotary actuator 10 ). The hinge rotary actuator 10 includes an internal rack and pinion that are housed within a pressure cylinder 12 that will be described later. The rotary actuator is commercially available from Parker Hannifin Corp. under the name Parker Rotary Actuator.
[0031] FIG. 1 further shows the latch rotary actuator 14 (sometimes referred to as the second rotary actuator 14 ). The latch rotary actuator 14 includes an internal rack and pinions that are housed within a pressure cylinder 16 that will be described later. As noted earlier, rotary actuators are commercially available. FIG. 1 further depict the eyelets 18 , 20 for attaching a cable to the apparatus 2 in order to suspend the apparatus 2 from a derrick of a drilling rig, as readily understood by those of ordinary skill in the art.
[0032] A handle 22 is attached so that a roughneck can aid in opening, closing and/or handling the apparatus 2 . The internal portion of the apparatus 2 is configured to receive a tubular member, such as a drill pipe. FIG. 1 depicts that each of the semi-circular halves 4 , 6 have an inner concave surface which in turn extends to the top radial surface 24 , 26 , respectfully, and wherein the lower section of the connection will rest on the radial surfaces 24 , 26 as understood by those of ordinary skill in the art. FIG. 1 further shows the wedge member 28 , which is attached to the first portion, as well the brackets 30 , 32 of the hinge boss, which are attached to the second portion 6 . The wedge member 28 contains a cylindrical end portion 34 , and the brackets 30 , 32 contain apertures. As shown in FIG. 1 , the hinge pin 8 is configured to be inserted into the cylindrical end portion 34 , and bracket apertures. The control unit 36 for delivering a hydraulic fluid or pneumatic pressure to the hinge rotary actuator 10 and the latch rotary actuator is depicted. The hydraulic control unit 36 is commercially available. The control unit 36 is remotely controlled by an operator.
[0033] Referring now to FIG. 2 , the elevator apparatus 2 is shown in FIG. 1 , wherein the apparatus 2 has been pivoted to the open position. It should be noted that like numbers appearing in the various figures refer to like components. Hence, the operator would have activated the latch rotary actuator 14 so that the apparatus 2 is unlatched. Additionally, the hinge rotary actuator 10 has also been activated so that the hinge pin 8 has rotated thereby separating the first semi-circular half 4 from the second semi-circular half 6 . In this way, a tubular can be inserted into the apparatus 2 , or the tubular can be taken-out of the apparatus 2 .
[0034] FIG. 3 is a perspective view of the apparatus 2 seen in FIG. 1 depicting a partial cut-away illustration of the hinge rotary actuator 10 for the hinge means 8 . More specifically, the hinge rotary actuator 10 comprises the pressure cylinder 12 and the rack 40 , wherein the rack contains the teeth 42 , and the roller 44 . As seen in FIG. 3 , the roller 44 contains teeth 46 that will engage with teeth 42 . The roller 44 has the stem 48 which is connected to the hinge pin 8 . The brace means 50 connects the hinge rotary actuator 10 to the apparatus 2 , and in particular to the first semi-circular half 4 and to the hinge pin(s)
[0035] The hinge rotary actuator further has a first end 52 connected to the cylinder 12 and a second end 54 connected to the cylinder 12 , wherein end 52 can allow a hydraulic fluid in and the end 54 can allow hydraulic fluid out . . . thereby providing for the later movement of the rack 40 . The hydraulic fluid (or pneumatic pressure) is controlled from the control unit 36 as seen in FIG. 1 . As the rack 40 moves from one end to the other end, rotational movement is imparted to the roller 44 which in turn causes the hinge pin 8 to rotate. FIG. 3 further illustrates the housing 56 which sealingly encases the roller 44 and rack 40 as shown. The housing 56 forms part of the cylinder 12 so that the roller 44 and rack are sealingly encased. A plurality of protective bars 58 surround the cylinder 12 . The bars 58 are tie rods and used to keep the cylinder/end caps together and is common in most cylinders. As per the teachings of this invention, the operator will control, via the selective application of hydraulic or pneumatic pressure, the opening and closing of the apparatus 2 with the control unit 36 , such as seen in FIG. 1 .
[0036] Referring now to FIG. 4 , a perspective view of the hinge rotary actuator 10 for the hinge pin 8 will be described. The stem 48 is connected to the hinge pin 8 . Hence, as the stem 48 is turned, the hinge pin 8 also turns. FIG. 4 also shows the opening 60 in the first end 52 and the opening 62 in the second end 54 , wherein the openings 60 , 62 allow for the input and output of the hydraulic fluid for supplying pressure to the rack 40 (not seen in this view) in order to move the rack laterally. As noted earlier, the lateral movement of the rack 40 causes the rotation of the stem 48 .
[0037] FIG. 5 is a perspective view of the opened elevator apparatus 2 and the latch means in the unlatched position. More specifically, FIG. 5 depicts the latch rotary actuator 14 that contains a rack and roller (not seen in this view). The latch rotary actuator 14 is commercially available from Parker Hannifin Corp. under the name Parker Rotary Actuators, as previously described. The latch means generally comprises a pin housing 66 , that contains the pin means, and wherein the pin housing 66 is operatively attached with the latch rotary actuator 14 , and wherein the latch rotary actuator 14 extends and contracts a set of pins (not seen in this view), as will be more fully described. The pin housing 66 is mounted to the first semi-circular half 4 .
[0038] The pin housing 66 will cooperate and engage a receptacle member 68 . The receptacle member 68 has a prong member 70 that contains a first prong 72 and a second prong 74 . The first prong 72 has an aperture 76 and the second prong 74 has an aperture 78 . The pins from the pin housing 66 will engage the apertures 76 , 78 , as will be more fully explained below. FIG. 5 further depicts the indicator means 80 for indicating whether the pin means have engaged the apertures 76 , 78 .
[0039] Referring now to FIG. 6 , a perspective view of the latch rotary actuator 14 will now be described. The latch rotary actuator 14 has a pressure cylinder 84 that will contain the rack and pinion (not seen in this view). The latch rotary actuator 14 contains a first end 86 with the opening 88 and a second end 90 with the opening 92 , and wherein the openings provide an inlet and outlet for the hydraulic pressure. The latch rotary actuator 14 further contains the housing 94 , operatively associated with the cylinder 84 , which sealingly houses the rack and pinion. Also, FIG. 6 depicts the roller 96 that contains the teeth 98 . The roller 96 is operatively associated with the pinion as noted in the discussion of the hinge rotary actuator. A set of pins is included, namely the pin 100 and the pin 102 , and wherein the pin 100 contains the teeth 104 and the pin 102 contains teeth (not seen in this view). The teeth on the pins 100 , 102 will engage the teeth 98 so that movement of the roller 96 effects lateral movement of the pins 100 , 102 . The pins 100 , 102 are offset relative to the roller 96 , and when activated, the pins 100 , 102 travel in opposite directions. In other words, pin 100 is on one side of roller 96 and pin 102 is on the other side of roller 96 . In the extended position, the pins 100 , 102 will engage the apertures in the prongs of the receptacle member 68 thereby latching the apparatus 2 .
[0040] FIG. 7 is a partial perspective view of the closed elevator apparatus 2 depicting a cut-away illustration of the latch means. More specifically, the pins 100 , 102 have been recessed within the pin housing 66 due to the linear actuation of the roller 96 . In the view of FIG. 7 , the elevator 2 is unlatched. FIG. 7 shows how the prongs 72 , 74 are disposed about the housing extension 106 , and wherein that extension 106 contains cavities 108 , 110 for placement of the pins 100 , 102 .
[0041] The indicator means 80 is also shown. The indicator means 80 has a pivoting arm 112 that contains the projection 114 . As seen in FIG. 7 , the projection 114 is disposed through the aperture 78 since the pin 102 is recessed within the aperture 108 . The pivoting arm 112 is connected to the relay switch housing 116 via member 118 . In the position seen in FIG. 7 , the relay switch is connected, and therefore, a light is activated and wherein the operator can tell that the latch is in the open position by the light. The relay switch is commercially available from Rexroth Bosch Group under the name Directional Valve.
[0042] Referring now to FIG. 8 , a sequential view of the closed elevator apparatus 2 seen in FIG. 7 depicting the closed latch means will now be described. In other words, the apparatus 2 is latched. More specifically, the rotation of the roller 96 has caused the pins 100 , 102 to extend through the apertures 76 , 78 of the receptacle member 68 thereby latching the apparatus 2 . Additionally, the pin 102 has caused the projection 114 to pivot upward (via the pivoting arm 112 ). Hence, the pivoting arm 112 will cause the relay switch (located within the switch housing 116 ) to cause the light to go off, which in turn informs the operator that the apparatus 2 is now latched. Other types of signals are possible, including sound and electromagnetic radio signals.
[0043] In order to unlatch the apparatus 2 , the operator may simply activate the latch rotary actuator 14 , and in particular the rack, which in turn will cause the roller 96 to rotate thereby contracting the pins 100 , 102 . Next, the hinge rotary actuator 10 (seen in FIGS. 3 and 4 ) can be activated in a similar fashion, i.e. the rack moves thereby causing the roller and stem to rotate the hinge pin 8 , which would open the apparatus 2 .
[0044] As seen in FIG. 9 , when the apparatus 2 is in the latched position, the apparatus 2 can be used to lift, lower, and/or suspend a tubular 122 from a rig 124 , with the tubular 122 being suspended within a subterranean well 126 .
[0045] Although the present invention has been described in terms of specific embodiments, it is anticipated that alterations and modifications thereof will no doubt become apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations and modifications as fall within the true spirit and scope of the invention.
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An elevator apparatus and method. The apparatus includes a circular member comprising a first and second semi-circular half and a hinge pin(s) for pivoting the first and second semi-circular half together. The elevator apparatus further includes a hinge rotary actuator(s) for activating the hinge pin(s) so that the first and second semi-circular half pivot to form the circular member, a latch rotary actuator for latching the first semi-circular half and the second semi-circular half. In one preferred embodiment, the hinge rotary actuator(s) comprises: a first cylinder; a first rack disposed within the cylinder, the first rack being responsive to a pressure within the cylinder; and a first roller having teeth disposed thereon, wherein the first rack and the teeth are engaged and wherein the roller is connected to the hinge pin.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of windows and specifically to a brake shoe and pivot assembly for a window counterbalance.
2. Description of the Related Art
Double hung windows are provided with counterbalances for maintaining a sash in an elevated position. Springs or weights connected to the sash to act as the counterbalance. Many window sashes are adapted for tilting inwardly for cleaning. The sash tilts on a pivot assembly at the bottom of the sash. Spring operated tilt latches at the top of the sash retain the sash in the vertical position and are released for pivoting of the sash.
The pivot assembly commonly is associated with a brake that firmly maintains the sash in place when the sash is tilted. Examples of such pivots and brakes are shown in U.S. Pat. Nos. 4,610,108 to Marshik, 5,069,001 to Makarowski, 5,139,291 to Schultz, 5,237,775 to Hardy and 5,243,783 to Schmidt et al, all incorporated herein by reference. The pivot assembly is typically fastened to the sash with screws or otherwise, as shown in U.S. Pat. Nos. 5,251,401 and 5,371,971 to Prete.
SUMMARY OF THE INVENTION
The present invention provides a pivot assembly for a window assembly having a window sash with a notch defining a pair of opposed tracks and having a brake assembly slidably disposed in a frame of the window assembly. The pivot assembly includes a rigid body and a pivot bar projecting from the body. The pivot bar has an end adapted for being received in the brake assembly. A flange extends from the body and has walls spaced from walls of the body so as to define a pair of opposed channels. The assembly is slidable into the window sash and the channels are adapted for receiving the opposed tracks of the window sash therein.
The flange and body define a generally I-shaped cross section. The flange walls are flexible for accommodating deformations and thickness variations of edges of the track received in the channels. The walls of the body are sloped for accommodating deformations and thickness variations of edges of the track received in the channels. The body is generally parallelepipedic and includes a longitudinal bore receiving the pivot bar therein, wherein the bore is stepped so as to define a lip and a stop, the pivot bar is provided with a detent engaging the lip, and an end of the pivot bar engages against the stop to limit longitudinal movement of the pivot bar and retain the pivot bar in the body.
A detent projects from the body and is adapted for engaging a wall of the window sash for retaining the pivot assembly therein. The body is generally parallelepipedic and further comprises a longitudinal bore receiving the pivot bar therein. The bore is stepped so as to define a lip and the pivot bar is provided with a detent engaging the lip to limit longitudinal movement of the pivot bar and retain the pivot bar in the body. The bore is stepped so as to define a stop and an end of the pivot bar engages against the stop to limit longitudinal movement of the pivot bar and retain the pivot bar in the body. A flange projects from the pivot bar and is adapted for engaging in the brake assembly. The flange is spaced from an end of the pivot bar to define a nose.
The invention also provides a pivot and brake assembly for a window assembly. The invention includes a brake assembly having a housing slidably disposed in a frame of the window assembly; a brake movable to engage the frame so as to resist movement of the housing in the frame; a cam disposed in the housing and rotatable for moving the brake.
The pivot and brake assembly also includes a pivot assembly having a rigid body; a pivot bar projecting from the body and having an end received in the cam so that pivoting of the pivot bar rotates the cam; and a flange extending from the body and having walls spaced from walls of the body for defining a pair of opposed channels, the assembly being slidable into a notched window sash of the window assembly and the channels being adapted for receiving opposed tracks of the window sash therein.
The cam includes a central passage in which the pivot bar is received, the bore having a lip therein, and the pivot bar includes a flange projecting from the pivot bar and engaging the lip to limit longitudinal movement of the pivot bar and retain the pivot bar in the cam. The flange is spaced from an end of the pivot bar to define a nose and the cam is provided with a back wall for engaging the nose to limit longitudinal movement of the pivot bar and retain the pivot bar in the cam. The pivot bar is eccentric and the cam includes an eccentric passage in which the pivot bar is received, the bar and passage mating so as to limit rotation of the bar relative to the cam.
The invention also provides a window assembly including a frame having two spaced, opposing, generally parallel slide channels. A sash has two spaced, generally parallel stiles and spaced, generally parallel header and footer rails assembled to form a generally rectangular shape. Each of said stiles is adapted for sliding along a corresponding one of the slide channels, and said footer rail has a hollow construction and a notch at each end thereof, each notch defining a pair of opposed, generally parallel tracks. A pair of brake assemblies as described above are slidably disposed in the respective slide channels. The brake is movable to engage the slide channel so as to resist movement of the housing in the slide channel. A pair of pivot assemblies as described above are slidable into the notch of the sash and the channels receiving opposed tracks of the respective window sash notch therein. A counterbalance is disposed in each of the slide channels and attached to the corresponding brake assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a double hung window assembly;
FIG. 2 shows an exploded perspective view of a lower corner of a sash and a pivot assembly;
FIG. 3 shows an end view of the pivot assembly;
FIG. 4 shows a side view of the pivot assembly;
FIG. 5 shows a sectional side view of the pivot assembly taken from line 5--5 of FIG. 3;
FIG. 6 shows a side view of a pivot bar;
FIG. 7 shows an end view of the pivot bar;
FIG. 8 shows a top view of the pivot bar;
FIG. 9 shows an exploded perspective view of a brake assembly;
FIG. 10 shows a sectional view of a cam taken from line 10--10 of FIG. 9;
FIG. 11 shows an elevational view of brake assembly installed in a window frame;
FIG. 12 shows the elevational view of FIG. 11 in a locked position; and
FIG. 13 shows a top sectional view of the window frame taken from line 13--13 of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a double hung window assembly 10 includes an upper sash 11 and a lower sash 12 that are slidable in a window frame 14. The lower sash 12, for example, includes vertically disposed stiles 16 and horizontally disposed rails 18 including an upper header rail and a lower footer rail. The window frame includes vertical jambs 20 defining opposed vertical slide channels 22 or tracks. Brake assemblies 24 are slidable in respective slide channels 22. Lower corners of the sash 12 are provided with pivot assemblies 26 that are associated with respective brake assemblies 24 to define pivot and brake assemblies. The brake assemblies 24 are supported by respective counterbalances, such as balance springs 28 disposed in the slide channels 22. Tilt latches 30 are disposed in upper corners of the sash 12 for releasably retaining the upper end of the sash in the slide channels 22.
Referring to FIGS. 2 through 5, the pivot assembly 26 includes a housing 32 and a pivot bar 34 located therein. The housing 32 includes a body 36 having a longitudinal bore 38. The bore 38 shown is generally rectangular, but other shapes are suitable as is apparent from the following description of the pivot bar 34. The bore 38 is stepped, that is, different parts of the bore have different cross-sectional dimensions and shapes. One end of the bore defines a mouth 40 slightly wider than the pivot bar 34 to facilitate installation and allow slight flexing thereof. A main part 42 of the bore is sized to snugly retain the pivot bar 34 therein. Another end of the bore is circular in cross section and defines a stop 44 against which the pivot bar 34 abuts. Adjacent the stop, a bottom wall is recessed to define a lip 46.
The bottom of the housing 32 is provided with a flange 48 or pair of flanges spaced above the body 36 and defining a pair of walls 50. The flange 48 and body 36 define a generally I-shaped cross section. The bottom of the body 36 has sloped walls 52. The walls 50, 52 define channels 54 that are wider toward the center of the body. A retaining detent 56 projects from the top of the body near one end.
Referring to FIGS. 2 and 5, the pivot bar 34 has a U-shaped cross section of formed metal. One end of the pivot bar is provided with laterally extending flanges 60. A detent 62 projects from a bottom wall of the pivot bar near another end. The pivot bar 34 is located within the bore 38 of the housing 32 so that the pivot bar detent 62 engages behind the lip 46 to prevent longitudinal movement of the pivot bar in one direction, as shown in FIG. 5. An end of the pivot bar 34 engages the stop 44 to prevent longitudinal movement of the pivot bar in another direction. The pivot bar projects from the housing 32 so that the flanges are spaced from the housing.
Other configurations of the pivot bar are also suitable. For example, referring to FIGS. 6-8, the pivot bar 34a can be cast as a bar having a rectangular cross section with rounded corners. The Flanges 60a extend from long edges of the bar and have ends 64 defining segments of a single circle. The flanges 60a can be set back from the end of the bar to define a longitudinally projecting nose 63. The detent 62a projects from one of the long edges near an end of the pivot bar 34a. The pivot bar 34a fits in the bore 38 similarly to the pivot bar 34 previously discussed. For other configurations of the pivot bar, the bore of the housing is correspondingly sized and shaped to accommodate the pivot bar.
Referring to FIG. 2, the lower end of the sash stile 16 is provided with a notch 66 or slot to allow passage of the pivot housing 32 therethrough. A second notch 67 or slot is cut in a lower wall of the lower rail 18 to define a pair of opposed tracks 68 or rails. The second notch 67 is as long as the housing 32. The pivot housing 32 is installed in the notch 66 so that the tracks 68 are received in the channels 54. The detent 56 (FIG. 4) engages behind an outer wall of the stile 16 immediately above the notch 66 to retain the housing 32 in place.
As a result of forming and welding the sash 12 and cutting the notches 66, 67, the tracks 68 have inconsistent thickness along their length and are deformed somewhat at their edges. The width of the channels 54 at their openings is such that the tracks snugly fit therein. The sloped walls 52 provide a larger space to accommodate the deformations and inconsistent thickness of the track edges. The channels 54 are deep enough that the walls 50 of the flange 48 are somewhat flexible for accommodating the deformations and inconsistent thickness of the track edges.
Referring to FIGS. 9-12, the brake assembly 24 includes a housing 70, a cam 72, and a movable or deformable brake 74, such as a shoe or spring. The cam 72 has a central passage 76 provided with a lip 78 (FIG. 10) and a lateral opening 80. The passage 76 has a height slightly greater than the thickness of the pivot bar 34a permitting insertion of the pivot bar therein, as shown in FIG. 10. The pivot bar 34, 34a and central passage 76 are eccentric so that they mate, thereby limiting rotation of the pivot bar relative to the cam. The lip 78 is spaced from an internal back wall 82 such that one of the flanges 60a is received behind the lip. The back wall 82 limits longitudinal travel of the pivot bar 34a in one direction by engaging the nose 63 and the lip 78 limits longitudinal travel of the pivot bar 34a in another direction by engaging the flange 60a. A flange 84 is provided on the cam 72 for retaining the cam in the housing 70.
Referring to FIGS. 11-13, the cam 72 and brake 74 are installed in the housing. The housing is slidably disposed in the slide channel 22. Rotation of the cam 72 with the pivot assembly causes outward movement or expansion of the brake 74, as shown in FIG. 12. The brake engages walls of the slide channel 22 to prevent movement of the brake assembly 24. Thus, when the window sash 12 is tilted as shown in FIG. 1, the pivot and brake assembly 24, 26 locks the sash in place. When the sash is in the vertical position, as shown for the upper sash 11, the brake is in the nonlocking retracted position of FIG. 11 and the sash is vertically slidable. Numerous variations of such brake assemblies are suitable, examples of which have been previously cited above.
The present disclosure describes several embodiments of the invention, however, the invention is not limited to these embodiments. Other variations are contemplated to be within the spirit and scope of the invention and appended claims.
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A brake is disposed in a window frame. The brake includes a cam that causes the brake to engage the frame to resist movement of the brake. The cam is operated by a pivot assembly mounted in a sash of the window. A body of the pivot assembly slides into a notch in the sash and is retained by a detent. The pivot assembly includes an eccentric pivot bar that is received in an eccentric passage of the cam. The pivot bar engages a stop in the body and has a detent that engages a lip in the body.
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BACKGROUND OF THE INVENTION
This invention relates to an exhaust silencer system for a two-cycle engine and more particularly to an improved arrangement for silencing the exhaust gases of a ported two-cycle engine.
Although two-cycle engines are widely used for a variety of applications because of their simplicity and their high power output per displacement, there are some disadvantages with such engines. One problem particularly prevalent with two-cycle engines is the noise associated with their exhaust. This noise is a result of several factors, one of which is the fact that the exhaust gases are discharged to the atmosphere during each rotation of the crankshaft as opposed to every other crankshaft rotation as with a four-cycle engine. In addition, the porting of the engine causes the exhaust gases to emanate from the exhaust port quite rapidly and this itself gives rise to significant silencing problems.
In addition, two-cycle engines are normally employed in relatively confined applications such as outboard motors, motorcycles or the like wherein the provision of a large and complex exhaust silencing system is not possible. As a result, there is some objection to the use of two-cycle engines even in these applications due to the difficulty in silencing.
It has been proposed to silence the exhaust gases of a two-cycle engine by providing an expansion chamber into which the exhaust gases can expand before the exhaust port is opened. However, the previously proposed constructions have been such that the communicating passageway that communicates the cylinder with the expansion chamber is not fully opened before the exhaust port is opened. As a result, the full utilization of the expansion chamber cannot be employed.
Furthermore, the prior art systems have had the disadvantage that the communication passageway is open after the exhaust port is closed and when the piston is still traveling toward its top dead center position. As a result, these type of devices tend to reduce the effective compression ratio of the engine and, accordingly, its power output.
In addition to the aforenoted defects, those systems which have been previously proposed have necessitated the formation of the expansion chamber either in the cylinder head in whole or in part and also have not afforded an opportunity to provide any cooling for the expansion chamber.
It is, therefore, a principal object of this invention to provide an improved exhaust silencer system for a two-cycle engine.
It is a further object of this invention to provide an exhaust silencer system for a two-cycle engine that includes an expansion chamber and a communicating port that communicates the expansion chamber with the cylinder but which will not have the defects of the prior art constructions.
It is a further object of this invention to provide an improved exhaust silencing system utilizing an expansion chamber that communicates with the cylinder but wherein the compression ratio of the engine is not adversely affected.
It is a further object of this invention to provide an exhaust silencer for a two-cycle engine employing an expansion chamber and wherein the expansion chamber communicates completely with the cylinder before the exhaust port opens.
It is a further object of this invention to provide a silencing system for a two-cycle engine including an expansion chamber and a valve that can be tailored to control the expansion chamber so as to not adversely affect other conditions of the engine and also to achieve maximum silencing.
It is a still further object of this invention to provide an expansion chamber silencing device for a two-cycle engine wherein the expansion chamber is cooled so as to assist in silencing.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in an exhaust silencer system for a ported two-cycle internal combustion engine comprising a cylinder that receives a piston, an exhaust port in said cylinder opened and closed by the associated piston and having an initially opened position, a fully opened position, a beginning closing position and a fully closed position. An expansion volume is provided that communicates with the cylinder through a communication port. Means are provided for controlling the communication port between an initially opened position before the exhaust port is in its initially opened position and at least one of a fully opened position before the exhaust port is in its initially opened position or in a fully closed position before the exhaust port is in its fully closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an outboard motor attached to the transom of a watercraft which is shown partially and in cross-section and which outboard motor includes an exhaust silencing system constructed in accordance with a first embodiment of the invention.
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 3.
FIG. 3 is a cross-sectional view taken along a horizontal plane and on an enlarged scale through the power head of the outboard motor.
FIG. 4 is a port timing diagram of this embodiment of the invention.
FIG. 5 is a schematic cross-sectional view taken through a two-cycle, crankcase compression, internal combustion engine constructed in accordance with another embodiment of the invention.
FIG. 6 is a port timing diagram showing one method in which the embodiment of FIG. 5 may be operated.
FIG. 7 is a port timing diagram showing another method by which the embodiment of FIG. 5 may be operated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, an outboard motor constructed in accordance with an embodiment of the invention is identified generally by the reference numeral 11. The invention is described in conjunction with an outboard motor because the invention has particular utility with two-cycle, crankcase compression, internal combustion engines as are normally used with outboard motors. It is to be understood, however, that the invention is capable of use in other applications for such two-cycle engines.
The outboard motor 11 includes a power head consisting of a two-cycle, crankcase compression, internal combustion engine 12 and a surrounding protective cowling which is shown in phantom and is identified by the reference numeral 13. In the illustrated embodiment, the engine 12 is of the two cylinder inline type. It should be readily apparent, however, to those skilled in the art how the invention can be utilized in conjunction with other cylinder numbers and configurations.
The engine 12 has a crankshaft, to be described, that is coupled to a drive shaft 14 which is journaled for rotation about a vertically extending axis within a drive shaft housing 15. This drive shaft 14 extends into a lower unit 16 to drive a propeller shaft 17 through a conventional bevel gear type forward, neutral, reverse transmission 18. A propeller 19 is affixed to the propeller shaft 17 in a known manner for propelling the associated watercraft, which is partially shown and is identified generally by the reference numeral 21.
The outboard motor 11 is affixed to the transom of the watercraft 21 by means of a swivel bracket 22 and clamping bracket 23 which afford tilt and trim movement of the outboard motor 11 as well as steering movement of it in a known manner.
The engine 12 is water cooled and coolant for the cooling system is drawn through an underwater inlet 24 formed in the lower unit 16 by a water pump 25 that is driven by the drive shaft 14 and which is positioned between the lower end of the drive shaft housing 15 and the upper end of the lower unit 16.
The construction of the outboard motor as thus far described may be considered to be conventional and since the invention relates to the engine and particularly to the exhaust silencing arrangement therefor, further description of the outboard motor is believed to be unnecessary.
Referring now additionally to FIGS. 2 and 3, the engine 12 includes a cylinder block 26 in which a pair of cylinder bores are formed by liners 27. Pistons 28 reciprocate in these cylinder bores and are connected by means of connecting rods 29 to a crankshaft 31, aforereferred to. The crankshaft 31 is journaled within a crankcase chamber 32 formed by a skirt portion 33 of the cylinder block 26 and a crankcase member 34 that is affixed to the cylinder block 26 in a known manner.
A cylinder head 35 is affixed to the cylinder block 26 at the end opposite the crankcase member 34 and is formed with combustion chamber recesses 36. Spark plugs 37 are carried by the cylinder head 35 for firing the charge in the combustion chamber recesses 36 in a known manner.
As is typical with two-cycle engine practice, the individual crankcase chambers 32 associated with each of the cylinders formed by the liners 27 are sealed from each other in an appropriate manner. A fuel/air charge is delivered to each of these chambers 32 by one or more carburetors 38. The carburetors 38 draw fresh air from within the protectice cowling 13 through an air intake device 39 and discharge it into the crankcase chambers 32 through a manifold 41 in which reed type check valves 42 are provided so as to prevent reverse flow when the pistons 28 are approaching their bottom dead center position.
The charge compressed within the crankcase chambers 32 is transferred to the area above the pistons 28 on their descent through one or more scavenge passages 43. This compressed charge is then fired by the spark plugs 37, as aforenoted, and is discharged to the atmosphere through an exhaust system that includes an exhaust port 44 formed in the cylinder liner 27 and which communicates with an exhaust manifold 45 formed at least in part in the cylinder block 26. A cover plate 46 is affixed over the exhaust manifold 43 and is formed with a cooling jacket 47 that receives coolant from the engine cooling jacket in a well known manner.
In accordance with the invention, an expansion chamber 48 is formed by the cylinder block 26 and the cover plate 46 adjacent the cooling jacket 47. As a result, exhaust gases which are delivered into the expansion chamber 48 in the manner to be described will be cooled by the engine coolant so as to further assist in silencing. The expansion chamber 48 communicates with the respective combustion chambers or cylinders formed by the liners 27 through ports 49 which are disposed vertically above the exhaust ports 44. As a result of this vertical disposition above the exhaust ports 44, the expansion chamber 48 will communicate completely with the cylinder before the exhaust ports 44 open. This will insure good silencing.
The timing of the port opening may be best seen in FIG. 4 wherein the direction of rotation occurs in a clockwise direction. As may be seen, when the piston 28 moves downwardly, first the communication ports 49 will be initially opened, then they will be fully opened before the exhaust port begins to open. The exhaust port then moves to its fully opened position, its initial closing position and its fully closed position before the communication prt 49 begins to close. Of course, this construction, therefore, presents some loss of effective compression ratio but does achieve optimum silencing.
FIG. 5 shows another embodiment of the invention wherein the general components are the same as those of the previously described embodiment. For that reason, those components which are basically the same have been identified by the same reference numerals and have only been shown schematically.
In this embodiment, an expansion chamber 101 communicates with the cylinder bore through a communication port 102. The port 102 is opened and closed, not by the piston 28 per se but rather by a shutter valve 103 that is operated by means of a solenoid 104 or other form of servo motor. The solenoid 104 is operated by a control device 105 which receives an input signal from a crank angle sensor 106 and opens and closes the shutter valve 102 in accordance with any of a plurality of predetermined types of strategies. One such strategy may achieve initial opening of the communication port 102 and full opening of the communication port 102 through movement of the shutter valve 103 before the exhaust port 44 opens and closure in accordance with the same sequence as shown in FIG. 4 and provided for by the embodiment of FIGS. 1 through 4. Of course, such an arrangement would have the disadvantages as aforenoted. That is, the effective compression ratio would be reduced.
One prefered method of operation of the embodiment of FIG. 5 is shown in FIG. 6 which is a timing diagram corresponding generally to the timing diagram of FIG. 4 but, of course, with the different port timing. In this embodiment, the communication port 102 is opened initially by operation of the shutter valve 103 before the exhaust port 44 begins to open. However, the full opening of the communication port 102 may be deferred by delaying the rate of opening of the shutter valve 103 until after the exhaust port has become partially opened but not fully opened. The shutter valve 103 can then be actuated so as to begin closing of the communication port 102 before the exhaust port 44 begins to close with the communication port 102 being fully closed before the exhaust port 44 is fully closed. With such an arrangement, loss of compression ratio will be avoided while obtaining the advantages of the previously described embodiment.
FIG. 7 shows another mode of operation wherein the communication port is not only initially opened but fully opened before the exhaust port begins to open. In this way, then the advantages of the embodiment of FIGS. 1 through 4 insofar as maximum effective silencing can be achieved. However, in the mode of operation of this embodiment, the communication port 102 will begin to be closed after the exhaust port begins to close but will be fully closed before the exhaust port is fully closed thus providing the advantages of the method of operation of FIG. 6.
It should be readily apparent from the foregoing description that the described embodiments of the invention and their modes of operation are very effective in achieving good exhaust silencing with a two-cycle ported internal combustion engine without all of the disadvantages of the prior art. Of course, the embodiments disclosed are only preferred embodiments and various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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An exhaust silencing system for a two-cycle ported engine including an expansion chamber that communicates with the cylinder through a communication port that is opened before the exhaust port of the engine is opened so as to permit the exhaust gases to expand and reduce the noise of the engine. The communication port is either fully opened before the exhaust port is initially opened so as to achieve maximum silencing and/or is fully closed before the exhaust port is fully closed so as to avoid loss of effective compression pressure.
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TECHNICAL BACKGROUND
[0001] The present invention relates generally to the method of forming a molded three-dimensional construct comprised of at least one fibrous thermoplastic component, and more particularly, to a method of controlling the thermal history of a homogeneous or layered fibrous pre-form comprised at least in part of thermoplastic staple length fibers such that the physical properties of the molded three-dimensional compound are significantly enhanced.
BACKGROUND OF THE INVENTION
[0002] A considerable number of consumer durable articles are constructed, in part or whole, from components that have been formed from a generic base material into a contoured or three-dimensional shape by the application of heat and pressure. Typical base materials are selected from those polymeric and malleable metallic compositions exhibiting the capability to be thermoformed and yet retain the imparted shape upon removal from the molding apparatus for a period of time corresponding to the service life of the end-use article. Where the component is desired to be of a minimum thickness, sheet or film stock in single layer, laminate layer, or composite layer form, may be selected from the broadest range of base material compositions. However, when a component is desired to have a durable and stable loftiness or thickness without the weight penalty accrued from a construct comprising a quantity of laminated sheets, the range of suitable base materials is significantly reduced.
[0003] Components that have a significant thickness and are adversely affected by the weight penalty of a substantially solid construction are typified by automotive interior panels, appliance facings, domestic furnishings, and acoustic dampening shields. In place of solid base materials, alternate materials are selected whereby the composition includes entrained or encapsulated air volumes, such as that formation found in chemical catalyst foams and foamed thermoplastics, or a substructure of open interstices, as found in bulked fibrous mats.
[0004] Foams have been a very popular solution as a base material in the thermoforming of three-dimensional molded components. As is well known in the art, various open and closed cell foams have been employed as a base material. The formation of these foams comes at the cost of the creation of hazardous and toxic gases which must be properly controlled and vented from the workspace and require complex mixing and molding equipment. Further, it has been found that when such foams are used in the formation of laminate or composite constructs, hereafter referred to as compound molded constructs, the serviceable life-span is insufficient due to thermal- and photo-degradation with a corresponding performance loss of the foam layer. In recent years, there has been a general impetus in the art to find alternate materials as the environmentally deleterious fabrication side products and limited component performance of foam, in conjunction with issues of non-recyclability, have been found unacceptable and difficult to remedy.
[0005] Fibrous base materials have come into favor as a replacement for foams due to the ability to blend differing staple length, denier and polymeric composition fibers in the pre-formed mat so as to alter, or otherwise “tune”, the performance of the molded construct to the end-use application. Staple fibers can be selected from different deniers and staple lengths as well as mono-component or multi-component thermoplastic composition. It is also possible to include non-thermoplastic fibers into the thermoplastic blend, such as thermoset and natural fibers, to act as reinforcing elements and render a thermoformed three-dimensional compound composite having improved physical performance. However, such constructs exhibit a loss in composition homogeneity and, as a result, may only be recycled into same-composition constructs.
[0006] Developments in new light-weight, durable molded articles have resulted in a greater concern directed to the quantity of fibrous base material required to form the necessary components, the ultimate weight of that component with regard to performance, and the impact on the overall article weight. For example, in constructs such as interior automotive panels, the weight of the panel directly impacts upon the weight and ultimate efficiency of vehicle manufacture and operation, as well as, the resistance of the molded panel to deform or “sag”. In constructs such as acoustic dampening shields, as used in sound attenuation and abatement in theaters, a lighter weight article would require less hardware to hang or otherwise affix said panel.
[0007] The formation of fibrous material directly into a molded construct is a well known practice to those skilled in the art. A blend of fibers formed in to a precursor mat, followed immediately by thermoforming, is routinely practiced in the creation of component level constructs. U.S. Pat. No. 4,840,832 to Weinle, et al., is particularly representative of the state of the art, and is hereby incorporated by reference. The method disclosed by Weinle is appropriate when a heavy weight precursor mat is used, however, when the weight of the mat is decreased, and importantly, the thermal mass is decreased, the performance of the molded construct falls off to an unacceptable level. U.S. Pat. No. 6,322,658 to Byma, et al, discloses a composite headliner bonded together by differentially heating each layer to a predetermined temperature, inserting the layers into a mold, and then compressing the layers together. This method, however, does not allow for the optimal performance of physical properties, such as toughness and structural stability.
[0008] The present invention contemplates a method of forming a three-dimensional molded fibrous component whereby the thermal history of a homogeneous or layered fibrous pre-form, comprised in least in part of thermoplastic staple length fibers, is controlled such that the physical properties of the resulting compound construct are significantly enhanced. The present invention further contemplates that the improved physical properties as result of the practice of the disclosed method allow for a significant reduction in the basis weight of the resulting construct.
SUMMARY OF THE INVENTION
[0009] Herein is disclosed a method of controlling the thermohysteresis of a homogeneous or layered fibrous pre-form, comprised at least in part of thermoplastic staple length fibers, such that the physical properties of the resulting molded three-dimensional compound construct are significantly enhanced. In particular, the thermohysteresis is the result of a specific thermal history comprising the treatment of a fibrous pre-form with an elevated temperature incubation period followed by a cooling period. A so-treated fibrous pre-form can be subsequently molded by conventional thermomolding methods to render improved toughness, strength and structural stability to a resulting molded construct.
[0010] An initial fibrous pre-form comprising a thermoplastic fiber is manufactured by conventional fiber lay-down technologies, such as carding followed by cross-lapping or air-laying. The fibrous pre-form is then subjected to an elevated temperature incubation period whereby at least a portion of the fibrous component comprising the pre-form reaches a molten state and fiber to fiber bonds are initiated. Upon cooling from the molten state, two related mechanisms are believed to occur. First, the fiber-to-fiber bonds solidify and form a durable integration of the fibrous material into a unified pre-form. Second, as the polymer component fibrous material returns to a cooled state, the molecular structure of the polymer component has been affected to yield an ultimate construct of enhanced physical properties. The combined effects of the two mechanisms are a fibrous pre-form that exhibits an elevated level of strength, which when reheated and molded into a three-dimensional construct by the application of heat and pressure, results in a construct having a higher performance level than a construct molded from an untreated pre-form.
[0011] The thermohysteretic effect so described is further enhanced by introducing a compression step after the initial elevated temperature incubation period and the cooling period. By this method, the heated pre-form is transferred to a compression molding station and the heated pre-form compressed to a depth in the range of less than the full fibrous pre-form thickness, but greater than or equal to the full molded construct thickness, then cooled by either active or ambient means. A final molded construct is then formed by re-heating the compressed pre-form to a second elevated temperature and compressing to the final depth and contour.
[0012] It is also envisioned that the elevated temperature incubation of the entire uncompressed fibrous pre-form is replaced by a means whereby only the outer surfaces of the fibrous pre-form are subjected to an elevated temperature. Suitable means for heating preferentially the outer surfaces of the fibrous pre-form include radiant heat sources. Once the outer surface of the fibrous pre-form has been heated, the pre-form may be cooled with or without a partial depth compression step.
[0013] The thermal history of the ultimate construct may also be controlled by means of maintaining thermal environment of the fibrous pre-form between the initial heating step and the final molding step. Such means for controlling the thermal environment include the use of one or more thermal isolation layers and the application of active heating elements well known in the art.
[0014] A thermal isolation layer may be fabricated from those materials having insulative properties, such as found in fluorocarbon based polymers, ceramics, and thermoset resins, in either a unitary sheet form or as a coating on the molding surface. A method employing the thermal isolation layer involves the temporary superimposing of a thermal isolation layer on the upper and lower surfaces of fibrous pre-form. The sandwiched fibrous pre-form is then subjected to an elevated temperature incubation period whereby at least a portion of the fibrous component comprising the pre-form reach a molten state. The heated and sandwiched pre-form is then transferred to a compression molding station and the heated pre-form compressed to the full depth of the final molded component. The molded pre-form is then removed from the mold and the thermal isolation layers detached, if required, revealing the completed three-dimensional molded component.
[0015] A compound construct is also envisioned by the above methods whereby a plurality of previously formed woven fabric, nonwoven fabric, or film facing layers, either alone or in conjunction with an adhesive, may be positioned in face to face juxtaposition with the fibrous pre-form during an intermediate compression step.
[0016] The present method has been practiced for controlling the thermohysteresis of a polyester sheath/core binder fiber and matrix fiber blend during the formation of a three-dimensional molded construct as well as three-dimensional molded compound constructs to obtain enhanced physical properties. As will be appreciated, the technique can be employed for enhancing the physical properties of the ultimate molded construct fabricated whereby a wide variety of fibers, fiber blends and facing layers are employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings which are particularly suited for explaining the invention are attached herewith; however, it should be understood that such drawings are for explanation purposes only and are not necessarily to scale. The drawings are briefly described as follows:
[0018] [0018]FIG. 1 is a diagrammatic view of an apparatus for compressing a fibrous pre-form prior to molding;
[0019] [0019]FIG. 2 is a schematic view of the apparatus depicted in FIG. 1, whereby the apparatus is in operation;
[0020] [0020]FIG. 3 is a schematic view of the preferred means for mechanically needling the fibrous pre-form;
[0021] [0021]FIG. 4 is a schematic view of the preferred means for an indicative commercial process line.
[0022] [0022]FIG. 5 is a cross-sectional photomicrograph at 7.5x magnification depicting the fibrous interstitial structure of Comparative Example 1;
[0023] [0023]FIG. 6 is a top plan photomicrograph at 5.5x magnification depicting the surface topography of Comparative Example 1;
[0024] [0024]FIG. 7 is a cross-sectional photomicrograph at 7.5x magnification depicting the fibrous interstitial structure of Example 3;
[0025] [0025]FIG. 8 is a top plan photomicrograph at 5.5x magnification depicting the surface topography of Example 3; and
[0026] [0026]FIG. 9 is a cross-sectional photomicrograph at 7.5x magnification depicting the fibrous interstitial structure and outer nonwoven facing layers of Example 1.
DETAILED DESCRIPTION
[0027] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0028] Application of the present invention begins with a fibrous pre-form comprising staple length fibers. The staple length fibers may be selected from those composed in part or whole of thermoplastic polymers. Suitable deniers for the fiber are typically in the range of about 1 to 20, with the range of 3 to 15 being preferred. Thermoplastic polymers suitable for this application include polyolefins, polyamides, and polyesters. The thermoplastics may be further selected from homopolymers, copolymers, and other derivatives including those thermoplastic polymers having incorporated melt additives or surface active agents. The profile of the fiber is not a limitation to the applicability of the present invention. It is anticipated that fibrous component of the fibrous pre-form comprise greater than about 50% by weight thermoplastic fibers so as to render the fibrous pre-form receptive to thermoforming procedures. The remainder of the fibrous component can be comprised of thermoset polymeric fibers and natural fibers.
[0029] A preferred embodiment of the present invention is the use of a blend of at least two different types of staple fibers. The first staple fiber type is a bi-component fiber having a polyester core component and a co-polyester sheath component. At an appropriate elevated temperature, the co-polyester sheath melts and flows into the fiber-to-fiber junctions and initiates fiber bonding, this type of fiber being referred to as a binder fiber. The second staple fiber type is a large denier polyester fiber, referred to as a matrix fiber. The purpose of the large denier polyester fiber is to impart resilience to the structure while being bonded by the binder fiber and maintaining polymeric homogeneity in the fibrous pre-form.
[0030] The staple length fibers are formed into a mat in order to facilitate handling during molded construct fabrication. Staple length fibers may be laid down into a fibrous batt by conventional methodologies such as the use of one or more cards. By employing fiber redistribution equipment downstream of the card or cards, fibers comprising the batt can be distributed and/or oriented such that fibrous batt is imparted with the benefit of the fiber directionality. Use of a cross-lapper has been found to be particularly beneficial in that the uniform distribution of the fibers oriented away from a 90° relative departure angle within the fibrous batt provides for potential improvement of machine direction and cross direction strength performance.
[0031] A fibrous batt has little inherent integrity, requiring a light to moderate consolidation of the fibrous batt into a fibrous pre-form mat. Mechanically needling, as shown in FIG. 3, has been the most preferred method as the mechanical entanglement can be readily adjusted depending on the processability requirements and yet does not introduce adhesive binders or other materials into the construction. A particular representative mechanical needling process includes the use of a compression belt to reduce the excessive bulk of the fibrous batt to a height suitable for mechanically needling, typically greater than 10:1 compression rate being used. The mechanical needling occurs in two incremental steps including the use of a pre-needler having less than about 100 punches per square inch with a Foster type needle and needler having greater than about 100 punches per square inch with a triangular type needle. Once formed into a mat, the fibrous pre-form may be either wound into a roll or cut into sheets for later processing. In order to thermally treat the fibrous pre-form, the fibrous pre-form is placed in either an elevated temperature environment or in contact with an elevated temperature surface. Whether in continuous or finite dimension sheet form, the fibrous pre-form can be treated with a continuous flow of heated air in a convection oven. Once the fibrous pre-form sheet has reached a predetermined elevated temperature, the sheet is optionally compressed, then allowed to cool. A compression operation can be in either the form of a flat, crenulated or fluted surface based on either a press platen for finite dimension sheets or as a nip in appropriately formed calender rolls for continuous roll material.
[0032] Cooling of the heated fibrous pre-form below its activation temperature can occur by either active or ambient means. Depending upon processing constraints, including line speed and equipment footprint, selected cooling means are employed appropriate to those constraints. When employing a high line speed whereby the residence time will be necessarily short, an active cooling environment would expedite processing. Alternately, if finite dimension sheets are to be formed, the residence time in conveying, sorting, and stacking may be sufficient for ambient temperature cooling.
[0033] The particular apparatus employed in the compression of the prototypical fibrous pre-forms of the present invention is depicted in FIG. 1. A hydraulic ram 15 is affixed to base 10 , the base further comprising uprights 11 for securing upper platen 12 . Attached to the hydraulic ram 15 is lower platen 14 . Lower platen 14 moves relative to upper platen 12 by actuating the hydraulic ram 15 and applying pressure as measured by gauge 17 . To prevent full depth compression of the fibrous pre-forms, key-stock spacing shims 13 and 16 are interposed between lower platen 14 and upper platen 12 to create a chamber of finite height determined by the key-stock selection. Upper platen 12 and lower platen 14 can also be independently heated, for hot-press forming the construct, when an elevated surface temperature is desired.
[0034] The application of the compression apparatus is shown in FIG. 2. In Panel A, a pre-heated fibrous pre-form 20 A having a first thickness is placed between the spacing shims. The hydraulic ram is actuated, raising the lower platen until such point the spacing shims impact upon the upper platen, as shown in Panel B. The platens are allowed to remain in this position and at the predetermined pressure for a finite duration. In Panel C, the expiration of this finite duration results in releasing the hydraulic ram, thus lowering the lower platen. The now compressed fibrous pre-form 20 B, having a second thickness less than the first thickness, is then removed.
[0035] Once the thermally treated fibrous pre-forms have been fabricated, conventional forming technologies can be employed to yield improved performance molded constructs.
[0036] It is within the purview of the present invention that a compound construct can be formed during the thermal cycle process. Compound constructs are molded fibrous pre-forms that further comprise one or more layers of thin preformed materials as facing layers. The combination of a facing layer or facing layers on a fibrous pre-form results in a molded construct exhibiting better physical performance than the core exhibits alone. It is proposed that the facing layers in conjunction with the fibrous pre-form result in the performance characteristics of a structure often referred to as an “I” beam composite. Suitable materials for the facing layer include woven fabrics, nonwoven fabrics, and films.
EXAMPLES
[0037] It is hereby declared that the resultant molded constructs prepared by the following examples are within a standard deviation of 10% in respect to construct basis weight and part depth.
Comparative Example 1
[0038] A thermoformed material was fabricated utilizing a standard heavy weight fibrous pre-form. The fibrous pre-form consisted of 25% by weight 15.0 denier by 3.0 inch staple length polyester matrix fiber with approximately 10 crimps per inch, as available as Kosa fiber type 295, blended with 75% by weight 4.0 denier by 2.5 inch staple length carbon doped co-polyester/polyester sheath/core binder fiber with approximately 10 crimps per inch, as Kosa fiber type C58. The weight of the pre-form was 1765 grams per square meter (gsm).
[0039] The heavy weight fibrous pre-form was placed into a Lab-Line Instruments' Laboratory convention oven, model Imperial IV, and heated for 10 minutes at 180° C. Upon completion of the incubation period, the heated pre-form was immediately transferred to a Carver Press, Model C, as shown in FIG. 1 and FIG. 2. Two 3.2 mm key-stock spacing shims were previously set in position on the left-hand and right-hand side of the lower platen and the heated pre-form was set in between these shims. The platens were at an ambient temperature of approximately 22° C. The hydraulic ram was then actuated until such point the lower and upper platens made contact on the spacing shims. At this point, the hydraulic ram continued applying pressure to the spacing shims until a pressure level of at least 1000 pounds per square inch was reached. The mold was allowed to remain in this position for 1.75 minutes.
Comparative Example 2
[0040] A similar material as described in Example 1, whereby in the alternative, a compound construct utilizing a light weight fibrous pre-form and an upper and lower layer of previously constructed nonwoven fabric/adhesive were applied. The approximate weight of the pre-form was 700 grams per square meter. A nonwoven fabric was employed as an outer facing. The nonwoven fabric consisting of a polyester/co-polyester carded staple fiber unified into a cohesive fabric by the application of through air thermal bonding and had a final basis weight of 144 gsm. An adhesive film was also employed to further enhance adhesion of the nonwoven layer to the fibrous pre-form. The adhesive film was a type 5209 polyester based adhesive film as supplied by Bemis Associates, Inc. of Shirley, Mass.
[0041] A layered pre-form was set in the convection oven and incubated at 180° C. for 7 minutes. The layered pre-form consisted of a first layer of carded staple, through air bonded nonwoven, a first layer of polyester based adhesive film, the light weight fibrous pre-form, a second layer of polyester based adhesive film, and a second layer of carded staple, through air bonded nonwoven. Upon completion of the incubation period, the heated, layered pre-form was placed in the Carver Press. A 5 mm spacing shim was employed and a duration at compression of 2.0 minutes.
Comparative Example 3
[0042] A similar material as described in Comparative Example 1, whereby the weight of the fibrous pre-form was 1711 gsm, the pre-form was incubated at 180° C. for 10 minutes and was cold pressed at an excess of 1000 pounds per square inch on 5.0 mm spacing shims for 1.75 minutes.
Comparative Example 4
[0043] A similar material as described in Comparative Example 3, whereby the weight of the fibrous pre-form was 945 gsm, the pre-form was incubated at 180° C. for 4.25 minutes and was cold pressed at an excess of 1000 pounds per square inch on 5.0 mm spacing shims for 1.25 minutes.
Comparative Example 5
[0044] A similar material as described in Comparative Example 2, whereby the weight of the fibrous pre-form was 684 gsm. The layered fibrous pre-form further comprised an upper and lower thermal isolation layer in contact with the nonwoven layer, positioned away from the fibrous pre-form layer. The thermal isolation layer consisted of a nominal 0.9 mm thickness fluorocarbon polymer sheet available as a Teflon product from the Du Pont Corporation. The entire layered fibrous pre-form with thermal isolation layers was elevated to the temperature of 180° C. for 7 minutes before molding. Spacing shims of 7.3 mm were employed to compensate for the additional thickness of the two thermal isolation layers and, again, a compression duration of 2.0 minutes was employed.
Comparative Example 6
[0045] A similar material as described in Comparative Example 5, whereby two nonwoven layers consisting of 144 gsm thermally bonded polyester/co-polyester staple fiber were affixed to outer surfaces of the fibrous pre-form without the use of an adhesive binder layer. Spacing shims of 7.3 mm were used.
Comparative Example 7
[0046] An un-insulated fibrous mat was treated in a continuous process whereby the surface was heated to a sufficient temperature to activate the binder while under compression of or about 3 mm. It was then cooled below the activation temperature and the pressure released.
Example 1
[0047] A thermoformed material fabricated by the present invention comprised a layered fibrous pre-form as described in Comparative Example 2, whereby the layered fibrous pre-form was initially heated at 180° C. for 4.25 minutes, then cooled to 22° C., then layered as described. The entire layered fibrous pre-form with thermal isolation layers was elevated to the temperature of 180° C. for 7 minutes before molding. Spacing shims of 7.3 mm were employed to compensate for the additional thickness of the two thermal isolation layers and, again, a compression duration of 2.0 minutes was employed.
Example 2
[0048] A thermoformed material fabricated by the present invention comprised a fibrous pre-form as described in Comparative Example 4, whereby the fibrous pre-form was initially heated a 180° C. in a convection oven for 4.25 minutes. The heated pre-form was then compressed in excess of 1000 pounds per square inch on 5.0 mm key-stock shims for 1.75 minutes. The compressed pre-form was then allowed to cool to 22° C. under ambient conditions. The cooled, compressed fibrous pre-form was then compressed on 5.0 mm shims between heated platens, the platens being at about 190° C., for a duration of 1.0 minute.
Example 3
[0049] A thermoformed material similar to Example 2, whereby the heated pre-form was instead compressed using 7.2 mm key-stock shims followed by cooling and hot press forming on 5.0 mm shims.
Example 4
[0050] A thermoformed material similar to Example 2, whereby a 700 gsm fibrous pre-form was initially heated for 3.0 minutes at 180° C., then cooled to 22° C. Two nonwoven facing layers consisting of 144 gsm thermally bonded polyester/co-polyester staple fiber, where subsequently applied, and the compound construct compressed on 5.0 mm shims at 180° C. for 1 minute.
Example 5
[0051] A thermoformed material similar to Comparative Example 1, whereby rather than heating in a convection oven, the outer surfaces of the fibrous pre-form were placed in direct contact with an elevated temperature radiant heat source of at least 180° C. until such time the fibers at the face of the fibrous pre-form are integrated. This surface topography is depicted in the untreated material as shown in FIG. 5 versus the treated material in FIG. 7. The surface heated fibrous pre-form is then allowed to cool at an ambient temperature of 22° C. The pre-form is then heated for 7 minutes at 180° C. in a convection oven. Thermal isolation layers were utilized in conjunction with 7.3 key-stock shims, as previously described, while the heated pre-form was then compressed in excess of 1000 lbs. for 2 minutes.
Example 6
[0052] A thermoformed material similar to Comparative Example 6, whereby the outer surfaces of the fibrous pre-form were exposed to an elevated temperature radiant heat source of 180° C. for 1 minute, cooled to an ambient temperature of 22° C., then used as the pre-form in conjunction with the nonwoven facing layers and thermal isolation layers. The adhesive layers were deleted.
Example 7
[0053] An insulated fibrous mat was treated in a continuous process whereby the surface was heated to a sufficient temperature to activate the binder while under compression of or about 3 mm. It was then cooled below its activation temperature and the pressure released.
Example 8
[0054] A fibrous mat was treated in a continuous process whereby the surface was heated to a sufficient temperature to activate the binder while under compression of or about 3 mm. It was then cooled below its activation temperature and the pressure released. This pre-form was then thermoformed with two adhesive coated facing layers of through-air bonded, carded fibers and an additional aesthetic layer.
Example 9
[0055] A fibrous mat, and two adhesive coated facing layers, were treated in a continuous process whereby the surface of the mat reached a temperature sufficient to activate the binder component while under compression of or about 3 mm. The construct was then cooled below the activation temperature and the pressure released. This pre-form was then thermoformed with an additional aesthetic layer.
[0056] Each of the above materials was tested for performance after being allowed to rest at an ambient temperature of 22° C. for at least 24 hours. Data provided in Tables 1-5 show the results of performing a three-point flex test derived from ASTM D-790 on 3 inch by 6 inch samples. Testing parameters include the use of a Model 1122 Instron utilizing a 50 pound compression cell. The nosepiece consisted of a 0.3 cm radius by 5.5 cm width. The test span consisted of two 1.2 cm diameter rests separated by 9.53 cm. Table 5 reflects the results of an indicative commercial scale process line.
[0057] Table 1 and Table 3 both illustrate two constructs developed in a comparative manner, wherein one construct was developed utilizing two thermal isolation layers and the other construct was developed devoid of the thermal isolation layers. The constructs that were developed utilizing the thermal isolation layers showed an improvement in stiffness over those constructs developed devoid of the thermal isolation layers. Table 2 shows two constructs also developed in a comparative manner at a lower basis weight, however, the construct in Example 5 comprises additional fabric layers which in turn increases the stiffness of the construct. Table 4 embodies data reflective of an indicative commercial line process, wherein the stiffness improvement is fully exhibited.
TABLE 1 Part Identification Basis Weight Part Depth Stiffness Comparative Example 2 1154 4.9 1.9 Example 1 1189 5.4 6.8
[0058] [0058] TABLE 2 Part Identification Basis Weight Part Depth Stiffness Comparative Example 5 684 5.2 0.64 Example 5 693 5.4 0.73
[0059] [0059] TABLE 3 Part Identification Basis Weight Part Depth Stiffness Comparative Example 6 965 5.5 5.8 Example 6 993 5.5 6.8
[0060] [0060] TABLE 4 Part Identification Basis Weight Part Depth Stiffness Comparative Example 7 1317 5.1 7.9 Example 7 1488 5.4 9.4 Example 8 1408 5.1 9.2 Example 9 1419 5.2 9.2
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A method is disclosed of controlling the thermohysteresis of a homogeneous or layered fibrous pre-form, comprised at least in part of thermoplastic staple length fibers, such that the physical properties of the resulting molded three-dimensional compound construct are significantly enhanced. In particular, the thermohysteresis is the result of a specific thermal history comprising the treatment of a fibrous pre-form with an elevated temperature incubation period followed by a cooling period. A so-treated fibrous pre-form can be subsequently molded by conventional thermomolding methods to render improved toughness, strength and structural stability to a resulting molded construct.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 08/100,487, filed Jul. 30, 1993, now U.S. Pat. No. 5,503,550 and entitled Gas Log Fire Place.
FIELD OF THE INVENTION
The present invention relates to fireplace devices and, more particularly, to a gas-fired, simulated log fireplace insert incorporating an automatic flue damper for controlling the operational state of a chimney vent (open/closed) in response to gas combustion and an externally mounted carbon monoxide detector for terminating or inhibiting gas combustion in response to an unsafe level of detected carbon monoxide. The invention is aesthetically attractive, extremely safe to operate and capable of acting as a significant source of heat.
BACKGROUND OF THE INVENTION
Many people, especially those who reside in cold climates, enjoy having a wood burning fireplace in their homes. Unfortunately, a tremendous degree of manual labor must be expended to provide the requisite firewood associated therewith. Further, the problems associated with lighting the fire, the fire hazard from sparks and the removal of ashes are often disliked by the owners of wood burning fireplaces. As such, a wide variety of gas-fired substitute units have been developed which provide many of the same aesthetic properties of wood burning fireplaces without the concomitant problems.
Typical gas-fired fireplace units normally comprise a natural gas inlet line that leads to a gas manifold located within the firebox of the fireplace. The inlet line passes through the firebox containment bricks or metal liners and will normally include at least one main flow valve and a valved tap for a standing pilot. These valves and any associated electronic controls are placed either in the containment material or within the firebox itself. To complete the unit, a number of simulated, ceramic logs are placed atop the manifold. When the device is lit, flames from the manifold pass upwardly through the logs, thereby simulating the typical flame pattern of a traditional wood burning fireplace.
Although this type of fireplace installation eliminates many of the above-detailed disadvantages of wood burning fireplaces, it suffers from a plethora of problems relative to the lighting and combustion of the gas supply.
In many states, standing pilot lights are being made illegal due to the associated fire hazard. In addition, the standing pilot light is economically unsatisfactory due to its continuous depletion of fuel. One recently employed method of avoiding a standing pilot light has been the addition of a wall switch actuated piezo electric igniter for the pilot, wherein the electronics for the igniter are placed within the firebox containment region. This alleviates the standing pilot problem with newer units that have double wall or similar containment areas that can receive the electronic components. However, there are no similar solutions available for retrofit units that are placed in existing brick fireplaces that do not have double wall or similar construction that can receive the electronic components. By making the electronics part of the fireplace, the prior art also prevents the unit's use as a significant heat source due to the deleterious effect the higher heat output would have on the electronic components. A typical prior art device of this type can produce a heat output on the order of 28,000 BTU's.
Many of the newer gas-fired fireplace units also include an electronically controlled gas inlet valve. This allows a user to simply flip a switch to automatically light the entire unit (both the pilot and the manifold). A problem arises since a fireplace is unlike typical home appliances in that it requires a movable damper in its flue. If a user turns on the unit without first manually opening the damper, a potentially serious and hazardous overheating condition can result since the combustion gases cannot escape up through the flue.
SUMMARY OF THE INVENTION
In order to avoid the disadvantages of the prior art, the present invention incorporates an automatic flue damper and an externally mounted carbon monoxide detector into a retrofitted, gas-fired, simulated log fireplace insert system. These features provide an improved unit that can be readily and safely retrofitted into an existing fireplace.
The present invention includes a gas burner apparatus that is designed to be installed (retrofitted) into a conventional fireplace or prefabricated fireplace of brick or other refractory material construction. As known in the art, such conventional brick or prefabricated fireplaces generally include a square or rectangular firebox area having a floor composed of brick or the like and three surrounding brick walls, wherein the brick walls extend upward, thereby forming the flue and chimney of the fireplace. Normally, the fireplace flue is located at the top of the firebox area and includes a manually controlled damper.
The gas log fireplace system of the present invention includes a gas manifold that is attached to the home's gas-line by an inlet pipe. The inlet pipe extends out of the firebox via a hole which has been suitably established in one of the brick walls that surround the firebox. The outer portion of the inlet pipe extends exterior to the brick containment and includes an electrically actuated flow valve and a tap for a pilot light that also includes an electrically actuated flow valve. A computerized igniter/controller module is also located exterior to the firebox brick containment and is used to actuate the valves and ignite the pilot. A wall mounted switch is provided which allows a user to control the igniter/controller in a simple manner. Unlike prior art retrofit devices of this type, a standing pilot light is not required.
An additional feature of the invention that greatly enhances the safety of the unit is a temperature actuated electrical switch which is mounted at a distance from the manifold. The temperature actuated switch is connected to the igniter/controller by heat resistant wiring and is located above the gas manifold proximate the flue.
The temperature actuated switch is used to detect conditions that would be caused by the unit operating when the flue is closed. When the unit is operating normally with the flue open, the air temperature in the region of the flue opening is less than 400° F. However, if the unit is operating with the flue closed, the temperature in the same region will exceed 400° F. Should the latter condition occur, the temperature actuated switch automatically initiates a disruption in the electrical power supplied to the igniter/controller, thereby causing the main flow and pilot valves to move to their closed, no-flow position. This completely shuts down the unit.
The use of a temperature actuated electrical switch in lieu of other mechanisms is critical due to the harsh conditions normally found in the area of the firebox. Mechanical devices can become easily jammed by soot, tar and ash buildup. The electronic nature of the temperature actuated switch allows it to operate even if its exterior becomes coated with the same products.
As described above, an overheating condition may occur when a manually actuated damper is inadvertently maintained in a closed position during combustion. As such, the gas log fireplace system of the present invention incorporates an automatic, thermostatically controlled, electric damper (such as the SL19 manufactured by FLAIR INTERNATIONAL CORPORATION) which is adapted to automatically close when the burner is off and to fully open when combustion is required. The automatic damper closes when the burner is off to prevent loss of heated air to thereby save energy. The automatic damper also includes an interlock for preventing burner operation unless the damper is in an open position. More specifically, the interlock is adapted to interrupt the electrical power supplied to the main flow and pilot valves (either directly or through the igniter/controller) when the damper is closed, thereby causing the main flow and pilot valves to move to their closed, no-flow positions. Further, the damper is spring loaded and will return to an open position in response to a power failure, thereby enabling the normal chimney draft to effectively vent any unburned gas that may have accumulated. Secondary to the above considerations, the automatic damper advantageously increases the efficiency of the gas log fireplace system by reducing heat loss due to the natural draft of an associated chimney. Generally, during the installation of the automatic damper, the pre-existing manually operated damper is either completely removed or permanently locked in its open position.
A thermally actuated vent damper, such as those manufactured by AMERI-THERM may also be incorporated into the gas log fireplace system of the instant invention. More specifically, the thermally actuated vent damper includes four bi-metal quadrants that are adapted to remain in mutually closed positions when the gas burner is not in operation. Upon ignition of the gas burner via the electrically actuated main flow and pilot valves, the hot flue gases reach the damper, causing the bi-metal quadrants to rapidly extend to an open position, thereby allowing the hot flue gases to safely flow upwards through the chimney.
The thermally actuated vent damper is mounted to a galvanized steel sheet metal hood which has been suitably secured to an upper portion of the firebox area, wherein the vent damper is adapted to project upward into the throat of the flue. As with the automatic damper described above, the pre-existing, manually operated damper must be completely removed or secured in a permanently open position within the flue. Again, the thermally actuated vent damper increases the efficiency of the gas log fireplace system by preventing back drafts of cold air from flowing down the chimney into the living area of a house, by reducing any cooling of the firebox area of the fireplace and by reducing the loss of heated room air.
The present invention provides an externally mounted carbon monoxide detector, such as the COSTAR Carbon Monoxide Detector Model 12S-i, for terminating or inhibiting gas combustion in response to an unsafe level of detected carbon monoxide. More specifically, the carbon monoxide detector includes a chemi-optical sensor for activating an alarm relay after sensing an unsafe level of carbon monoxide over a predetermined period of time. For example, a relatively low level of 50 parts per million of carbon monoxide will activate the alarm relay in approximately eight hours. Correspondingly, higher detected levels of carbon monoxide will necessarily activate the alarm relay after a shorter period of time. In response to the activation of the alarm relay, an optional audible alarm will sound and the igniter/controller will initiate the closure of the main flow and pilot valves. After the carbon monoxide level has decreased to an acceptable, safe level as determined by the carbon monoxide detector, the igniter/controller will permit the reactivation of the main flow and pilot valves via the wall mounted switch. Alternately, in response to the activation of the alarm relay, the electrical power supplied to the igniter/controller may be interrupted by an appropriately wired switch member or the like, thereby causing the main flow and pilot valves to move to their closed, no-flow states. Again, after the dangerous carbon monoxide level has decreased sufficiently, the carbon monoxide detector will reestablish electrical power to the igniter/controller.
The instant invention can be easily retrofitted into an existing fireplace. In an alternate embodiment, the automatic damper includes a shape which conforms to the flue for ease of installation during the retrofit. The existing flue can be used and the wall switch for the igniter/controller and the carbon monoxide detector can be conveniently located within the living area of the home. Further, the valves and computerized igniter/controller are located exterior to the fireplace firebox and brick containment materials and in this way are not exposed to the deleterious high heat conditions found in the region of the firebox. Advantageously, in this type of installation, the unit can be used as a significant source of heat with a heat output of up to approximately 38,000 BTU's. More specifically, by externally placing the controlling apparatus of the present invention a distance away from the high temperatures of the fireplace's firebox area, larger pipes may be utilized to increase the gas flow to the burner, thereby increasing the heating capacity of the system.
The gas log fireplace system of the present invention can meet all codes and requirements for pilotless devices. It can be sized to provide both aesthetic appeal and significant heating capacity. The utilization of a plurality of independently operating safety systems, including a remote temperature actuated switch, an automatic damper and a carbon monoxide detector, provide the gas log fireplace system of the present invention with a factor of safety unequaled by the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will become readily apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 provides a frontal view of the gas log fireplace system of the present invention with portions shown in schematic form;
FIG. 2 is a front view of the pilot ignition unit;
FIG. 3 is a side view of the fireplace illustrated in FIG. 1;
FIG. 4 illustrates the mounting of a thermally actuated vent damper within the fireplace flue;
FIG. 5 illustrates the thermally actuated vent damper of FIG. 4 with the bi-metal quadrants in their closed positions; and
FIG. 6 illustrates the thermally actuated vent damper of FIG. 4 with the bi-metal quadrants in their open positions.
FIG. 7 is a side view of the rectangular damper system.
FIG. 8 is a top view of the rectangular damper system in a chimney flue.
FIG. 9 is an isometric view of hanger for the rectangular damper enclosure.
FIG. 10 is an isometric view of the rectangular damper system in a chimney flue.
FIG. 11 is a side view of the rectangular damper system in a fireplace.
FIG. 12 is a frontal view of the gas log fireplace system with the rectangular damper system.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, there is illustrated a gas log fireplace system, generally designated as 1, that is retrofitted into a pre-existing, conventional fireplace 2, wherein like reference numerals refer to like components throughout the drawings.
As illustrated in detail in FIGS. 1 and 3, the gas log fireplace system of the present invention is connected to the home gas line 3 by an inlet pipe 4. A conventional manual shut-off valve 6 is utilized to link the home gas line 3 to the inlet pipe 4. The inlet pipe 4 extends to a valve unit 10 comprising two electrically actuated gas flow control valves 12 and 14.
Pilot gas flow control valve 12 is positioned between the main gas inlet 4 and pilot tube 16. The pilot tube passes through the firebox containment material, brick or its equivelant, 18 and leads to the pilot light unit 20. The firebox brick containment material 18 extends upwardly and forms the walls of the flue and chimney.
Inlet gas flow control valve 14 selectively joins inlet pipe 4 to the manifold input pipe 22. This pipe also passes through the containment material 18 and extends to a manifold assembly 24 that includes a plurality of closely spaced gas outlet orifices 26. These orifices lie beneath a plurality of synthetic ceramic logs 30 that are maintained in position by stanchions 32. At least one of the gas outlet orifices 26 is disposed adjacent the pilot light unit 20.
Located between the end of the manifold inlet pipe 22 and the entrance to the manifold assembly 24 is a modified mixer orifice 33. The mixer orifice is substantially identical to a standard LP (liquid petroleum) mixer orifice in that it includes a center orifice and a plurality of air inlet holes that are adjustably covered by a manually movable nut. The standard mixer orifice is modified by drilling out the orifice with a #35 drill bit until it has a diameter of approximately seven sixty-fourths of an inch. This is significantly greater than its original diameter. By utilizing such a mixer orifice, one can use natural gas as a fuel and adjust the air fuel mixture to the gas outlet orifices 26 to significantly improve the burn characteristics of the system.
The electrically actuated gas flow control valves 12 and 14 are electrically coupled via wiring harness 34 to an igniter/controller module 40 that is located exterior to the insulating brick containment material 18. The module 40 provides the electrical power required to move these valves between their closed and open positions. The pilot light unit 20 is also electrically connected by the wiring harness 34 to the igniter/controller module 40, via wire 78.
The igniter/controller module 40 is coupled by wires 42 to a 24 volt transformer 44. The transformer is connected to the house electric lines by wires 46. In a typical installation, the module 40 is a HONEYWELL model Y86 unit or the like.
A temperature actuated switch 50 is located adjacent the fireplace chimney flue 52 and is electrically connected to the ignition/controller module 40 via a loop in one of the wires 42. Preferably, the flue 52 encloses an automatic, electric damper 54. As is readily apparent in FIG. 1, the temperature actuated switch 50 is wired in series with the module 40. Consequently, an open circuit produced by the temperature actuated switch 50 will interrupt the electrical power supplied to module 40. Preferably, the temperature actuated switch 50 is a MARS Company model 39043 or the like. It includes a manual reset switch with a button 48.
A manually operated switch 60, illustrated schematically in FIG. 1, provides the user with a simple control over the gas log fireplace system. The switch is electrically connected to the module 40 via the wires 46 that lead to the transformer 44. Preferably, the switch 60 would be installed on a wall within a few feet of the fireplace.
As detailed above, the flue 52 incorporates an automatic, electric damper 54 for controlling the passage of air therethrough in response to the combustion of the gas exiting the gas outlet orifices 26 in the manifold 24. The damper 54 includes a rotatable damper vane 80, which is adapted to pivot between an open and closed position about pivot member 82, and a damper controller 84 (including a motor) for regulating the operational rotation of the damper vane 80. The damper controller 84 is suitably coupled to a 24 volt transformer 86 via wires 88, with transformer 86 connected to the house electric lines by wires 90. Further, the damper 54 is electrically connected by a wiring harness 92 to the igniter/controller module 40. When gas combustion is required, the igniter/controller module provides the automatic damper with an "open" signal. In response thereto, the damper vane 80 is rotated to its open position by damper controller 84. Thereafter, gas combustion is initiated as detailed below. When gas combustion ceases, the damper 54 is returned to a closed position, thereby preventing the passage of air through the flue 52. The damper controller further includes an interlock (not shown) for preventing burner operation unless the damper vane 80 is in the required operational open position. Such a condition may occur if the damper vane is blocked open by debris or the like or in response to an inoperative or malfunctioning damper vane closing mechanism.
As illustrated in FIGS. 4, 5 and 6, a thermally actuated vent damper 94 may be utilized in lieu of the automatic, electric damper described above. The thermally actuated vent damper 94 includes a plurality of bi-metal quadrants 96 mounted therein that are adapted to remain in mutually closed positions when the gas burner is not in operation, thereby preventing the flow of air through the flue 52. After the gas has been ignited, the hot flue gases come into contact with the bi-metal quadrants 96 which rapidly flex to their open positions as illustrated in FIG. 6, allowing the flue gases to pass upwards through the chimney. Preferably, the thermally actuated vent damper 94 is mounted upon a galvanized steel sheet metal hood 98 which has been suitably secured to an upper portion of the fireplace's firebox area.
An alternative, rectangular damper system 110 is shown in FIGS. 7 and 8. The rectangular damper system 110 includes a motor 114 coupled by an electric motor drive shaft 116 to the damper panel drive shaft 117.
The electric motor drive shaft 116 is coupled to the damper panel drive shaft 117 with a key 119. The electric motor 114, electric motor drive shaft 116, and key 119 are components of the FLAIR SL19 motorized vent damper. If the electric motor 114, or the coupling between the motor 114 and damper panel drive shaft 117, fails, the damper panel 120 will be displaced to its open position by a spring 118. This spring 118 is connected to both the damper panel drive shaft 117 and the damper housing 112. The spring 118 is mounted around the damper panel drive shaft 117 like in the FLAIR SL19 unit. A damper housing 112 encloses the damper panel 120. The rectangular damper system 110 is placed in a flue 124 with a rectangular cross section in a lieu of a mechanical damper. Any pre-existing mechanical damper in the flue 124 is disconnected or removed upon insertion of the damper system 110. Regions of the flue 124 about the damper system 110 are filled with thermal insulation 122 to prevent heat loss.
References are now made to FIGS. 9 and 10. The damper housing 112 is mounted in the flue 124 with damper housing mounting hangers 130. Hanger lips 132 on each end of the hangers 130 lock into the damper housing 112 and mount over the lip of a firewall 140 or smoke hood 150, or is attached to the flue 124 by masonary screws.
The damper panel 120 is centrally mounted on the damper panel drive shaft 117 within the damper housing 112. The damper panel 120 has damper panel ends 142 that are bent at about fifteen degree angles. Damper housing flanges 144 are attached to the center of the damper housing walls 146 parallel to the flue walls. The flanges 144 are also bent at about a fifteen degree angles.
When the fireplace system 1 commands the damper system 110 to open, the damper panel 120 is rotated by the electric motor 114 so that the damper panel 120 is parallel to the firewalls 140. As a result maximum exhaust gas flow is permitted through the damper system 110. When the fireplace system 1 commands the damper system 110 to close, the damper panel 120 is rotated by the electric motor shaft 116 to a position perpendicular to that of the firewalls 140. In this closed position the damper panel ends 142 mate with the bent damper housing flanges 144 to provide a tight seal to reduce heat loss through the flue to the environment.
FIG. 11 is a side view of the fireplace 2 with a rectangular damper system 110. FIG. 12 is a frontal view of the rectangular damper system 110 with the fireplace system 1.
References are now made again to FIG. 1. A carbon monoxide detector 100, mounted within the living area of the home exterior to the fireplace 2, is provided to terminate or inhibit gas ignition and/or combustion in response to an unsafe level of detected carbon monoxide. The carbon monoxide detector 100 includes an alarm relay 102 which is activated after an unsafe level of carbon monoxide is detected by a carbon monoxide sensor 104 over a predetermined period of time. In response to the activation of the alarm relay 102, an alarm signal is transmitted to the igniter/controller module 40 over wire 106, thereby initiating the shut down of the pilot gas flow control valve 12 and inlet gas control valve 14. After the sensor 104 has determined that the level of carbon monoxide within the living area has decreased to a safe level, the alarm signal is terminated, thereby allowing the igniter/controller module 40 to reinitiate gas combustion in response to the actuation of switch 60.
The pilot light unit 20 is shown in greater detail in FIG. 2. The unit comprises a pilot light outlet nozzle 70 and a sparkplug igniter 72. There is also a thermocouple type heat sensor located within an igniter/sensor rod 74. The igniter 72 would be connected at tip 76 to the module 40 by a heat resistant wire 78 (see FIG. 1) which runs to the wiring harness 34.
In operation, the manual shut-off valve 6 would normally be in an open condition whereby gas is allowed to pass to the valve unit 10. To start the unit, the operator would actuate switch 60 to its "on" position. This would cause the module 40 to open pilot gas flow control valve 12 which allows gas to flow through pipe 16 to the pilot light outlet nozzle 70. At the same time, the module 40 sends an intermittent electric current through wire 78 to initiate a sparking of the igniter 72. Once the pilot lights, a small current will be created between the pilot light unit and ground due to the heat of the pilot flame acting on the thermocouple. The igniter/controller module 40 senses this current and then performs two functions. First, it stops sparking the igniter. Next, the module sends a signal to the inlet gas control valve 14 which causes the valve to open.
After valve 14 opens, gas begins to flow through the manifold input pipe 22 into the manifold 24. The gas exits the manifold through the orifices 26. The exiting gas is initially ignited by the pilot and, once lit, the burning of the gas is sustained until the unit is shut down. The burning gas rises upward and passes through and around the ceramic logs 30, thereby simulating a wood fire.
When the user desires to turn the unit off, he or she merely places switch 60 in its "off" (open circuit) position as illustrated in FIG. 1. This causes the module 40 to stop emitting "open" signals to valves 12 and 14, thereby immediately moving these valves to their closed position. The flame is extinguished as the last of the gas is exhausted and the unit is then in its shutdown condition.
During normal operating conditions when the automatic damper 54 is open, the heat from the fire will pass upwardly through the flue, thereby minimizing the temperature to which the top of the firebox is heated. However, if the automatic damper malfunctions and remains closed when the unit is in operation, the above temperature conditions increase significantly.
The air heated by the burning gas and the resultant gas combustion products will continue rising toward the flue even if the damper therein is closed. Instead of flowing upwards through the chimney, the gases will collect at the top of the firebox and spill outwardly into the living area of the home.
Due to the change in air/gas flow within the firebox, the top of the firebox proximate the flue is heated to a temperature significantly greater than 400° F. Should this occur, the temperature actuated switch 50 is tripped to its open circuit position. In this mode, electrical current cannot pass through the switch 50 to the igniter/controller module 40, thereby simulating the "off" position of switch 60. The electrically actuated valves 12 and 14 immediately move to their closed position and the unit shuts down.
The temperature actuated switch 50 includes a manual reset button 48 that it can be operated by the user to reset the switch. Once reset, the switch will again allow the passage of electrical current to the module 40. Since manual resetting of the switch 50 is required prior to operation of the unit, the user would be alerted to the fact that the automatic damper 54 has malfunctioned so that appropriate repairs and the like may be performed.
To retrofit an existing brick or masonry fireplace with a gas log fireplace system in accordance with the invention, the following procedure is normally followed.
Initially, the fireplace is fully cleaned and the irons are removed. Next, exterior access to the firebox area of the fireplace is obtained by drilling a hole through the insulating brick containment material 18 of one of the brick walls that surround the firebox.
Next the fireplace is modified for optimum use of the gas burner apparatus. After completely removing the pre-existing manually operated damper or permanently locking it in an open position, the automatic electric damper 54 is installed in the fireplace flue 52 and is suitably wired to the electrical wiring of the home and to the igniter/controller 40. Further, the temperature actuated switch 50 is installed within the firebox proximate the flue opening and connected in series with the module 40.
The gas flow control valves 6, 12 and 14 and the igniter/controller module 40 are installed exterior to the fireplace 2 in a location where they will not be exposed to temperatures substantially higher than the ambient room temperature. In practice, the valves and module are normally located two or three feet from the fireplace in either an adjacent wall or cabinet or within the basement of the home. Similarly, the carbon monoxide detector 100 is installed exterior to the fireplace 2 on a ceiling or wall at least 5 feet above the ground and wired to the igniter/controller module.
The igniter/controller module 40 is then connected to the home's electrical wiring and the gas flow control valves are connected to a source of natural gas. At this time, pipes 16 and 22 and wire 78 are appropriately connected and are extended through the hole in the insulating brick containment 18 into the firebox area.
The gas burner apparatus including the manifold assembly 24, pilot light unit 20 and mixer orifice 33 are then placed within the firebox area of the fireplace. Appropriate connections are made to pipes 16 and 22 and wire 78 is connected to the pilot light unit 20. All of the connections are then tested. Once complete, the gas burner apparatus is ready for use.
A back draft diverter screen 108 may be incorporated into the fireplace system of the present invention to prevent a downwardly directed back draft of air from directly contacting the gas burning apparatus while the damper 54 is in an open state. More specifically, as illustrated in FIG. 3, the back draft diverter 108 may be secured to the back wall of the wood burning fireplace 2 directly under the flue 52.
In order to reduce the formation of carbon deposits on the plurality of synthetic ceramic logs 30 during the operation of the gas burning apparatus, and thereby increase the cleanliness of the resultant gas combustion products, the logs 30 may be arranged so that the flames extending upward from the manifold assembly 24 do not impinge thereon. Such a log arrangement is illustrated in FIG. 3.
FIGS. 3 and 11 disclose a hearth opening modification shield 180. The hearth modification opening shield 180 is a sheet metal lip that may be mounted across the front upper opening of the fireplace mouth. If the fireplace has difficulty drawing off the gas products of combustion, the adjustable hearth opening modification shield 180 may be used. The hearth opening modification shield 180 fits across the entire upper front of the hearth mouth. The shield 180 may be lowered or raised depending on draw needs by adjustable bolts through which pressure screws 131 are mounted. The shield fits up behind glass doors between the masonary and the back of the glass doors. Optionally, the shield may be mounted with masonary screws or industrial glue.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.
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A gas-fired, simulated log fireplace insert incorporating an automatic flue damper for controlling the operational state of a chimney vent (open/closed) in response to gas combustion, an externally mounted carbon monoxide detector for terminating or inhibiting gas combustion in response to an unsafe level of detected carbon monoxide and a temperature actuated switch, disposed within the firebox area of the fireplace proximate the flue, for terminating gas combustion in response to excessive fireplace temperatures caused by a malfunctioning damper.
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This invention relates to shower-bathtub combinations, and more particularly to shower-bathtub combinations having sliding doors.
BACKGROUND OF THE INVENTION
A shower-bathtub combination, hereinafter called a shower-bathtub, is well known in the art. Shower-bathtubs typically have a rectangular configuration and are usually installed adjacent to three walls in a bathroom. The two short sides of the shower-bathtub being adjacent to walls which Applicant refers to as short walls and a long side being adjacent to a wall which Applicant will refer to as the long inside wall. The shower-bathtub can be used to take either a tub bath or a shower. A shower door or a shower curtain is typically provided to furnish a fourth outside shower wall to prevent water from splashing out of the shower-bathtub when the shower is being used.
Shower curtains typically are flimsy, tend to gather mold and need to be cleaned regularly. Moreover, they are also relatively ineffective in preventing all water from splashing out of the shower. However, there is no ugly track along the top of the outside wall of the bathtub.
Prior art shower doors, are typically not as flimsy as shower curtains and are less likely to gather mold, but they also have serious faults. Usually shower door assemblies have two sliding doors and are sold with a track system that permits the doors to slide horizontally. This track system usually comprises a top track and a bottom track. Two rollers are typically attached at the top of each of the two doors and the rollers roll in the top track. Some sort of roller or tab is normally attached at or near the bottom of the door which runs in the bottom track which is normally mounted on the top of the outside side of the bathtub portion of the shower-bathtub. A dam is normally part of the bottom track and runs along the bottom of the doors and outside of the doors to force water running down the inside of the doors to flow into the shower-bathtub. The track along the top of the outside side of the bathtub is generally considered ugly and detracts from the beauty of a well-designed bathtub.
What is needed is a better shower door assembly.
SUMMARY OF THE INVENTION
The present invention provides an improvement to a sliding door system for a shower-bathtub installed adjacent to three walls of a bathroom. The improvement comprises an upper track that has the following elements: (1) at least two wheel supports, (2) at least two wheel stays positioned above the two wheel supports, and (3) at least two lower bearing supports positioned at least five inches below the two wheel supports. The upper track is rigidly attached to the two short walls of the shower-bathtub and provides enough support so that the presence of a lower track is unnecessary. In a preferred embodiment, the outside wall of the bathtub and the two short shower walls comprise molded dams.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a preferred embodiment of the present invention.
FIG. 1A shows the lower dam molded into the top edge of the outside side of the tub.
FIG. 1B shows a vertical dam molded into the outside edge of one of the two short shower walls.
FIG. 2 shows a side view of a preferred embodiment of the present invention.
FIG. 3 shows a top view of a preferred embodiment of the present invention.
FIG. 4 shows a cross section view of the upper track.
FIG. 5 shows a lengthwise view of the inside of the upper track and how to mount a shower door onto the upper track.
FIG. 6 shows how a wheel from the wheel attachment assembly rolls on the upper track.
FIGS. 7 and 8 show the rubber mount.
FIG. 9A shows the doors sliding on the lower track.
FIG. 9B shows a top view of the lower track insert and insert housing.
FIG. 10 shows a side view of another prefered embodiment of the present invention.
FIG. 11 shows a top view of another preferred embodiment of the present invention.
FIG. 12 shows a perspective view of another preferred embodiment of the present invention.
FIG. 13 shows a perspective view of another preferred embodiment of the present invention showing water runoff channels.
FIG. 14 shows a perspective view of another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 presents a perspective view of a shower-bathtub that could utilize a preferred embodiment of the present invention. Also, FIG. 2 presents a side view and FIG. 3 presents a top view of the shower-bathtub. In the preferred embodiment, shower-bathtub 1 is formed from a fiberglass mold in the usual manner. FIG. 4 shows the principal features of the present invention. Glass sliding doors 10 rollingly hang from upper aluminum track 12 as shown in FIG. 4. Sliding doors 10 are made from 1/4 inch thick tempered glass. Side dams 16 and 17 and lower dam 18 are located on the front side of shower-bathtub 1 and function to prevent water from leaking outside of shower-bathtub 1 while it is in operation. Rubber mounts 13 rigidly mount track 12 to left wall 14 and right wall 15.
Upper Track
A detailed cross sectional view of upper aluminum track 12 is presented in FIG. 4 and a lengthwise view of the inside of track 12 is presented in FIG. 5. Upper aluminum track 12 is fabricated using 1/16-inch thick aluminum. Aluminum track 12 has wheel support 19 located 11/4-inches below the top of track 12. Also, wheel stay 25 extends 1/2-inch down from the top of track 12 and functions to prevent wheel 20 from falling off wheel support 19. Lower bearing support 26 is a U-shaped groove at the bottom of track 12 and functions along with bearing 29 attached to door 10 with bracket 28 to prevent rocking motion of sliding doors 10. In this preferred embodiment groove 26 is about 6 inches below wheel support 19. This distance could be increased to provide increased resistance to rocking motion of the doors, but the distance between support 19 and groove 26 should not be less than 5 inches. Wheel stays 25 have cutouts 27, as shown in FIG. 5. Cutouts 27 function to allow loading of doors 10 onto track 12, also shown in FIG. 5.
Mounting Upper Track to Shower-Bathtub
Upper track 12 is mounted to shower-bathtub 1 with rubber mounts 13 as shown in FIGS. 2 and 3. A more detailed view of the mounting assembly is given in FIGS. 7 and 8. As shown in FIG. 7, rubber mount 13 fits snuggly in the cross section of track 12. Rubber mount 13 is made of rubber having a durometer hardness of 0.80. A side view of rubber mount 13 is given in FIG. 8. Rubber mount 13 is a solid piece of rubber that has two parts: track support section 13B and wall insertion section 13A. Track support section 13B extends 3/8 inch into track 12. Wall insertion section 13A extends 3/8 inch into shower-bathtub 1. For extra support, mount 13 is rigidly secured to the short walls of shower-bathtub 1 by means of screws 30. Screws 30 are screwed into wall 14,15 at a 30-degree angle for maximum support.
Connecting Sliding Doors to Upper Track
Wheel attachment assembly 21 is rigidly connected to the top of doors 10 by tightening screw 22 against clamping section 22A, as shown in FIG. 4. Wheel attachment assembly 21 is available from Alumax with offices in Magnolia, Ark., part number 8239. Wheels 20 are made of plastic and have a diameter of 3/4-inch. Doors 10 are mounted so that wheels 20 roll on wheel support 19 as shown in FIG. 4 and FIG. 6. There is a 1/16-inch clearance in-between wheels 20 and wheel stay 25 so that wheels 20 may freely roll on wheel support 19 without skidding against wheel stay 25, as shown in FIG. 4 and FIG. 6. L-bracket 28 is glued to doors 10 as shown in FIGS. 4 and 5. Rotationally attached to L-bracket 28 is bearing 29. Bearing 29 is 1/4 inch in diameter.
To load doors 10 onto track 12, doors 10 are lined up underneath track 12 so that wheel assemblies 21 are directly underneath cutouts 27. Doors 10 are then raised up to track 12. Bearing 29 is then slid at an angle into lower bearing support 26 as shown in FIG. 4. Then, wheels 20 are placed on wheel support 19 at a position directly underneath cutouts 27. This procedure is repeated with the second door 10 until both doors are loaded onto upper track 12 as shown in FIG. 4. In this preferred embodiment, the bathtub is a molded fiberglass shower-bathtub and the top surface of the outside wall of the bathtub is molded in the shape shown in FIG. 1A to form a dam along the top edge of the outside side of the tub. Also, the outside edges of the two short shower walls are molded in the shape shown in FIG. 1B to form vertical dams. The doors slide inside these dams.
Second Preferred Embodiment
The major advantage of upper track 12 over prior art systems is that lower bearing support 26 of track 12 sufficiently prevents rocking of doors 10 so that a lower track mounted on the top outside edge of the bathtub is unnecessary. This is highly desirable because lower tracks in prior art shower door assemblies are aesthetically unpleasing and are a collector of mold and bacteria. Nevertheless, some users may still desire a lower track for redundancy. FIGS. 9A and 9B show how a lower track may be used with the present invention. FIG. 9A shows a side view of the inside of lower dam 18. Lower track 31 contains two U-shaped plastic strips 31A. U-shaped strips 31A are glued to lower dam 18 and extend the length of lower dam 18. Glued to the bottoms of each door 10 are insert housings 32. A top view of insert housing 32 is presented in FIG. 9B. Slidingly connected to insert housings 32 are lower track inserts 33 and 34. Insert housings 32 and lower track inserts 33 and 34 are both made from molded hard plastic. Friction force between insert housings 32 and lower track inserts 33 and 34 is sufficient to hold lower track inserts 33 and 34 in place and engaged with lower track 31 as shown in FIG. 9A to provide maximum support for doors 10. However, the friction force is also sufficiently weak so that finger force is enough to push lower track inserts 33 and 34 downward so that doors 10 can be easily installed or removed from lower track 31.
Other Embodiments
In the first preferred embodiment, shower-bathtub 1 was a solid fiberglass mold that consisted of rear and side walls, and left, right and lower dams. However, it is possible to add the present invention to an existing bathtub 101, as shown in FIG. 10 and FIG. 11. In this preferred embodiment, left dam 16 and right dam 17 are rigidly connected to existing walls 100 with glue. Caulking is then applied to the seam formed at the connection to prevent moisture from seeping through. Likewise, lower dam 18 is glued to the outside top of bathtub 101. Again, caulking is applied to prevent moisture from seeping through the connection. Upper track 12 is mounted to walls 100 as previously described.
Another embodiment is available to deal with a problem presented by the embodiment described in FIG. 1 in that the FIG. 1 embodiment is too large to fit through many bathroom doors. Therefore, in order to get it into the bathroom, a wall would need to be torn down and then rebuilt. The embodiment shown in FIG. 12 solves this problem. Here, shower-bathtub 1 is molded into two halves; upper half 151 and lower half 150. By splitting shower-bathtub 1 into two halves, it can be more easily moved into a small bathroom through a normal size door. Once inside the bathroom, upper half 151 is lowered into position on top of lower half 150. Caulking is then placed over the seam to prevent moisture from leaking through.
Although the previous embodiments have discussed utilizing the present invention with a shower-bathtub, it is also possible to apply to present invention to showers that are stand-alone. In other words, by reference to FIG. 1, if the bathtub section of shower-bathtub 1 was omitted, doors 10 and side dams 16 and 17 could be extended in length and lower dam 18 would extend upward from the floor 400 of shower 402, as shown in FIG. 14.
A further embodiment is seen by reference to FIG. 13. Side dams 16 and 17 are molded with water runoff channels 16A and 17A. Channels 16A and 17A are angled so as to direct water flow back into the tub. This aids in the prevention of mold build-up or water damage that could occur if water droplets were to stick to the side of dams 16 or 17.
The present invention has been described utilizing upper track 12 with sliding doors 10 and molded lower dam 18 and side dams 16 and 17. However, some users may prefer a shower curtain rather than sliding doors 10. A further embodiment is achieved by removing upper track 12 with sliding doors 10 and instead combining a shower curtain with molded lower dam 18 and side dams 16 and 17.
Although the above-preferred embodiments have been described with specificity, persons skilled in this art will recognize that many changes to the specific procedures disclosed above could be made without departing from the spirit of the invention. Therefore, the scope of the invention is to be determined by the appended claims and their legal equivalents.
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An improvement to a sliding door system for a shower-bathtub installed adjacent to three walls of a bathroom. The sliding door system includes an upper track that has the following elements: (1) at least two wheel supports, (2) at least two wheel stays positioned above the two wheel supports, and (3) at least two lower bearing supports positioned at least five inches below the two wheel supports. The upper track is rigidly attached to the two short walls of the shower-bathtub and provides enough support so that the presence of a lower track is unnecessary. In a preferred embodiment, the outside wall of the bathtub and the two short shower walls comprise molded dams.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing a multilayer ceramic circuit board with copper, which comprises a glass-ceramic insulator having a low dielectric constant and a conductor having a low electrical resistance.
2. Description of the Related Art
Multilayer ceramic circuit boards have been produced by using either a high melting point metal such as molybdenum or tungsten, or a noble metal such as gold. Recently, it is desired to use copper as a conductor, because its electric resistance is lower than the former and its price is cheaper than the latter. The lower melting point of copper enables the use of a glass-ceramics having a softening point far lower than alumina. It is, of course, necessary to fire the glass-ceramics in an inert atmosphere in order to prevent oxidizing of the copper. On the other hand, it is desirable that the organic materials are completely burnt out without leaving residual carbon, which may derive from a binder resin, a plasticizer, a deflocculant, and a solvent. These organic materials bring the following improvements in the behavior of a ceramic slurry and green sheet:
(a) The solvent dissolves the other organic materials to distribute them uniformly in the slurry, to disperse the ceramic paricles in the slurry, and the solvent evaporates from the green sheet formed by doctoring the slurry and leaves micropores in the green sheet.
(b) The deflocculant forms a thin coating film on the surface of the ceramic particles, to distribute them uniformly in the formed slurry and stabilize their distribution due to the occurrence of steric hindrance and electric repulsion between the ceramic particles. Thus, it is possible to form a green sheet in which the ceramic particles are uniformly distributed without flocculation.
(c) The binder dissolves in the solvent and enhances its viscosity to form a thixotropic slurry. Thus, it is possible for the ceramic particles to bind with each other in a green sheet.
(d) The plasticizer structurally expands the binder and improves distribution of the binder in the slurry. Thus, it is possible to obtain a flexible green sheet.
Although these organic materials exhibit such desirable effects in forming a ceramic slurry and green sheet, one of them, i.e., a deflocculant, is sometimes eliminated in order to decrease the total amount of organic materials, thereby decreasing the residual carbon after firing.
Nakamura et Kamehara to Fujitsu Ltd., disclose in Japanese Examined Patent Publication No. 52-5523 to produce a ceramic board by firing a green sheet prepared from a ceramic slurry which comprises alumina particles, a deflocculant, i.e., sorbitan sesquioleate or sorbitan trioleate, a hydrophobic binder, and a plasticizer, first in normal atmosphere at 400° C. to 600° C. to eliminate the binder and then at 1300° C., and finally in a hydrogen atmosphere at 1600° C.
Honda to Fujitsu Ltd., discloses in Japanese Unexamined Patent Publication No. 51-127112 a process for producing a multilayer glass circuit board by laminating conductor paste-printed glass green sheets prepared from a glass slurry which comprises glass powder, a binder, e.g., polymethacrylate or polyvinylbutyral resin, a plasticizer, e.g., dioctyl phthalate, dibutyl phthalate, a deflocculant, e.g., nonyl phenol ethylene oxide adduct (registered trade name "Tergitol NPX" available from Union Carbide Ltd.), a solvent, e.g., methyl ethyl ketone and other adduct, e.g., polyethylene glycol; prefiring the laminated structure at about 500° C. in a reducing atmosphere, and then firing the structure in vacuum.
Tormey et al reports in MIT Industrial Liaison Program Report 6-15-84, 1984 to use a fish oil or glycerol trioleate as a deflocculant in a ceramic slurry.
Herron et al to IBM Ltd., disclose in U.S. Pat. No. 4,234,367 to produce a ceramic circuit board in an atmosphere of water vapor containing hydrogen in a ratio of H 2 :H 2 O 10 -4 to 10 -6 .5 by firing a ceramic structure, which comprises copper as a conductor, spodumene or cordierite as a ceramic insulator, polyvinylbutyral as a binder, and dioctyl phthalate or dibutyl phthalate as a plasticizer. However, there is no reference in the description to a deflocculant. In addition, polyvinyl butyral is not thermally depolymerizable and does not completely burn out at a temperature lower than 1000° C. in an non-oxidizing atmosphere. Thus, the inventors consider that of the above fired board will inevitably deteriorate the mechanical and electrical properties due to its porous structure and to residual carbon.
Kamehara et al to Fujitsu Ltd., disclose in U.S. Pat. No. 4,504,339 a method for producing a multilayer glass-ceramic structure having copper-based conductors therein for use as a circuit board. In this method, a multilayer structure consists of layers of a thermally depolymerizable resin and glass-ceramic containing preferably 40 percent to 60 percent by weight of Al 2 O 3 and layers of a copper-based paste. The structure is fired in an inert atmosphere containing water vapor, the partial pressure of which is 0.005 to 0.3 atmosphere, preferably at 550° C. to 650° C. The structure is then sintered in a nitrogen atmosphere containing no water vapor, preferably at about 900° C.
However, if the firing temperature in the inert atmosphere containing water vapor is higher than 650° C., the residual carbon is trapped in the closed pores in which H 2 O vapor is present. The carbon then reacts with the H 2 O to form CO 2 . This phenomenon results in bloating of the glass-ceramic. Thus, Kamehara et al teach the composition of a firing atmosphere and usage of a thermally depolymerizable resin, e.g., polymethyl methacrylate, but do not describe the use of a deflocculant in the organic materials, and a silica rich SiO 2 -B 2 O 3 type glass in the ceramics.
A slurry without a deflocculant is generally poor in the dispersion property of ceramic particles in the solvent containing a binder and a plasticizer, and green sheets formed from such a slurry exhibit the same demerit as the slurry. In addition, a fired multilayer structure formed by laminating such green sheets exhibits deviation of the shrinkage rate and the mechanical strength in one and the same structure.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a process for producing a multilayer ceramic circuit board with copper, which exhibits minimum residual carbon in the ceramic without oxidation of the copper conductor.
It is another object of the present invention to provide a process for producing a multilayer ceramic circuit board with copper, which exhibits minimum deviation of the shrinkage rate and the mechanical strength of the ceramic structure.
It is still another object of the present invention to provide a process for producing a multilayer ceramic circuit board with copper by laminating and firing ceramic green sheets which exhibit minimum surface roughness.
It is yet another object of the present invention to provide a process for producing a multilayer ceramic circuit board with copper by laminating and firing ceramic green sheets which were formed by doctoring a ceramic slurry, in which ceramic particles exhibit minimum flocculation.
There is provided according to the present invention a process for producing a multilayer ceramic circuit board with copper comprising the steps of:
forming green sheets by doctoring a slurry which comprises 100 parts by weight of glass ceramic particles, 5 to 20 parts by weight of a thermally depolymerizable resin binder, 2 to 10 parts by weight of a plasticizer, and up to 2 parts by weight of a fatty acid ethylene oxide adduct deflocculant, the glass ceramic comprising 20 to 70% by weight of alumina; and 30 to 80% by weight of SiO 2 -B 2 O 3 type glass;
forming via holes through said green sheets;
screen-printing a copper paste on said green sheets;
laminating said green sheets; thereby forming a multilayer structure; and
firing said multilayer structure in a nonoxidizable atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the relationship between the amount of residue of various deflocculants and a heating temperature.
FIG. 2 shows the relationship between the viscosity of supernatant from slurries which contain various deflocculants and a settling time.
FIG. 3 shows the relationship between the viscosity of slurry and the amount of oleic acid ethylene oxide adduct.
FIG. 4 shows the relationship between the surface roughness of the green sheets and the amount of various deflocculants.
FIGS. 5A and 5B are microphotographs showing the surface of a green sheet which contains oleic acid ethylene oxide adduct.
FIGS. 5C and 5D are microphotographs showing the surface of a green sheet which contains no deflocculant.
FIG. 6 shows the firing profile for producing a multilayer ceramic circuit board with copper.
FIG. 7 shows the relationship between the standard deviation of bending strength of fired ceramic substrates and the amount of oleic acid ethylene oxide adduct.
FIG. 8 shows the relationship between the deviation shrinkage rate of a fired ceramic substrate and the amount of oleic acid ethylene oxide adduct.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the deflocculants, fatty acid ethylene oxide adducts having relatively small molecular weight of 150 to 800 can be used, due to its solubility in an organic solvent and the flexibility of formed green sheets, preferably unsaturated fatty acid ethylene oxide adducts, most preferably oleic acid ethylene oxide adducts, due to its relatively small molecular weight which leaves only a small amount of residue at heating.
Useful thermally depolymerizable binder resins may be polymethacrylate ester, polytetrafluoroethylene, poly-α-methyl styrene, and the mixture thereof, because these are depolymerized and burn out at a temperature lower than 900° C. in an inert gas containing water vapor, the partial pressure of which is in the range of 0.005 to 0.3 atmospheric pressure. The SiO 2 -B 2 O 3 type glass comprises a first component having a softening point higher than the melting point of copper, and as a second component at least one of noncrystallizable and crystallizable glasses having a softening point lower than the melting point of copper.
The noncrystallizable glass may be borosilicate or aluminoborosilicate, and the crystallizable glass may be cordierite or spodumene.
The firing steps may comprise prefiring the multilayer structure in an inert atmosphere containing water vapor, the partial pressure of which is 0.005 to 0.3 atmosphere, first at a temperature of 350° C. to 450° C. whereat the binder resin is thermally depolymerizable, second at a temperature of 650° C. to 900° C. whereat the residual organic substance which did not burn out in the first step reacts with water vapor to be eliminated; and firing the multilayer structure in an inert atmosphere without water vapor at a temperature higher than 950° C. and lower than the melting point of copper.
Fatty acid ethylene oxide adduct deflocculants easily burn out in an inert atmosphere, thereby little residual carbon is left without oxidizing conductor copper in the fired multilayer ceramic circuit board. The obtained ceramic board exhibits excellent electric and mechanical properties for mounting electronic elements. In addition, fatty acid ethylene oxide adduct deflocculants improve uniformity in the distribution of ceramic particles in green sheets, thereby improving uniformity in the bending strength and shrinkage rate of the fired ceramic structure, which meets the requirement of enlarging the size of multilayer ceramic circuit boards. Unsaturated fatty acid ethylene oxide adducts, such as oleic acid ethylene oxide adduct, linolic acid ethylene oxide adduct and linoleic acid ethylene oxide adduct, are, generally, more preferable than saturated fatty acid ethylene oxide adducts, such as stearic acid ethylene oxide adduct, because the former exhibits larger solubility in an organic solvent than the latter. Oleic acid ethylene oxide adduct is most preferable, because this adduct leaves little amount of residue at heating, due to its relatively small molecular weight.
The present invention will be more fully understood from the following examples, in reference to the drawings.
EXAMPLE 1
The burn out characteristics were estimated by referring to various deflocculants, i.e., oleic acid ethylene oxide adduct (1), sorbitan trioleate (2), a phosphate ester (registered trade name "Niko Frontier A 229E" available from Daiichi Kogyo Seiyaku Ltd.) (3), stearic acid amid ethylene oxide adduct (4), and a glycerol ester of a fatty acid (5).
Those deflocculants were heated alone in a nitrogen atmosphere at a heating rate of 10° C./minutes, and the amount of residue was determined by means of differential thermal analysis.
As shown in FIG. 1, oleic acid ethylene oxide adduct (1) exhibits no residue after heating at 500° C. and a fish oil (5) exhibits remaining residue even at 1,000° C.
EXAMPLE 2
Slurries were prepared by mixing the following components in a ball mill for 20 hours.
______________________________________Ceramic 600 gα-alumina (diameter 3 to 4 μm) 200 gSilica-boron oxide type glass A 200 g(melting point ca. 1,500° C.)Silica-boron oxide type glass B 200 g(melting point ca. 800° C.)Solvent 650 gMethyl ethyl ketone 550 gAcetone 100 gBinder, polyacrylate 70 gPlasticizer, dibutyl phthalate 20 gDeflocculant (molecular weight 480) 0-12 g______________________________________
The deflocculation characteristics of ceramic slurry, which contained one of the various deflocculants described in Example 1 in an amount of 6 g per 600 g ceramic, i.e., 1.0 part by weight of deflocculant per 100 parts by weight of ceramic, was determined by taking a sample of supernatant flowing from an exit 1.0 cm deep from the surface of the slurry having a total height of 10.0 cm after allowing it to settle for a predetermined period of time, and by measuring the rotation viscosity of the supernatant by a Brookfield viscosimeter. The results are shown in FIG. 2.
The supernatant of a slurry containing oleic acid ethylene oxide adduct (1) maintains its original viscosity after 100 hours of settling, and thus exhibits a dispersion property superior to a slurry containing sorbitan trioleate (2) or a glycerol ester of a fatty acid (5).
EXAMPLE 3
Slurries similar to those described in Example 2, except that the oleic acid ethylene oxide adduct (1) was used alone in an amount of 0 to 12 g per 600 g ceramic, i.e., 0 to 2 parts by weight of deflocculant per 100 parts by weight of ceramic. The rotation viscosity of the sample slurries was determined by a Brookfield viscosimeter immediately after preparation of the slurries. As shown in FIG. 3, the viscosity exhibits minimum value when 0.5 to 2 parts by weight of deflocculant are contained.
EXAMPLE 4
Ceramic green sheets were prepared from slurries similar to those described in Example 2.
The surface roughness of the ceramic green sheets was determined by a surface roughness contact measuring device. As shown in FIG. 4, the green sheet which contains 1 to 2 parts by weight of oleic acid ethylene oxide adduct (1) per 100 parts by weight of ceramic, i.e., 6 to 12 g per 600 g of ceramic, exhibits minimum surface roughness. Glycerol ester of a fatty acid (5) and sorbitan trioleate (2) exhibit a deflocculating effect similar to polyethylene glycol oleate (1). Conversely, a phosphate ester (3) contributes nothing to deflocculation of the slurry, and stearic acid amid ethylene oxide adduct (4) causes a deterioration in the deflocculation.
EXAMPLE 5
A ceramic green sheet was prepared from a slurry similar to that described in Example 3 except that the amount of oleic acid ethylene oxide adduct (1) was 9 g, i.e., 1.5 parts per weight of deflocculant per 100 parts by weight of ceramic. FIGS. 5A and 5B are microphotographs showing the surface roughness of the ceramic green sheets at magnifications of 500 and 3,000, respectively. FIGS. 5C and 5D are microphotographs similar to those showin in FIGS. 5A and 5B, except that no deflocculant was contained in the green sheets, taken at the same magnifications as in FIGS. 5A and 5B, respectively. The roughness of the green sheets evidently is decreased by adding the oleic acid ethylene oxide adduct (1).
EXAMPLE 6
Ceramic green sheets were prepared as described in Example 5 to form 0.3×15×15 mm sheets. Copper balls 0.2 mm in diameter were passed through the sheets to form via holes, and patterns of copper paste were screen-printed on the sheets to form conductor patterns. Thirty layers of the thus formed sheets were laminated and pressed under 25 MPa at 130° C. for 30 minutes to form a green multilayer structure, which was subjected to the firing conditions shown in FIG. 6. Thus, prefiring was carried out in a nitrogen atmosphere containing water vapor, the partial pressure of which was 0.07 atmosphere, first at 400° C. for 8 hours, and then at 800° C. for 8 hours, to burn out the organic materials. The prefired multilayer structure was sintered in a nitrogen atmosphere without water vapor at 1,010° C. for 8 hours. The obtained multilayer ceramic circuit board with copper exhibited the following properties. The electric sheet resistance of the copper conductor was 1.1 mΩ/□ , the bending strength, the density, the dielectric constant, the amount of residual carbon, and the brighteners of the ceramic insulator were 1,800 kg/cm 2 , 99,0%, 4.9, less than 30 ppm, and 80%, respectively.
EXAMPLE 7
Multilayer ceramic structures were produced similar to those described in Example 6, except that no conductor was contained therein and the amount of oleic acid ethylene oxide adduct (1) was varied to 0 to 2 parts per 100 parts by weight of ceramic. As shown in FIG. 7, the standard deviation of the bending strength between the ceramic structures decreases to near 20 MPa in the case where more than 0.5 parts by weight of oleic acid ethylene oxide adduct was contained.
EXAMPLE 8
A multilayer ceramic structure similar those described in Example 7 was subjected to a firing shrinkage test. Deviation of the shrinkage rate in one and the same board was minimum, as shown in FIG. 8, in the case where 0.5 to 2 parts by weight of oleic acid ethylene oxide adduct was contained per 100 parts by weight of ceramic.
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A process for producing a multilayer ceramic circuit board with copper including the steps of:
forming green sheets by doctoring a slurry which includes 100 parts by weight of glass ceramic particles, 5 to 20 parts by weight of a thermally depolymerizable resin binder, 2 to 10 parts by weight of a plasticizer, and up to 2 parts by weight of a fatty acid ethylene oxide adduct type, deflorculant. The glass ceramic includes 20 to 70% by weight of alumina, and 30 to 80% by weight of SiO 2 -B 2 O 3 glass. The process further includes the steps of forming via holes through the green sheets, screen-printing a copper paste on the green sheets, and laminating the green sheets, thereby forming a multilayer structure and firing the multilayer structure in a non-oxidizable atmosphere.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to the following commonly owned copending U.S. patent application:
[0002] Ser. No. ______ (Attorney Docket No. RPS920020179US1) entitled “Method and Apparatus For Imbedded Pattern Recognition Using Dual Alternating Pointers” filed ______, and
[0003] Serial No. ______ (Attorney Docket No. RPS920020181US1) entitled “Method and Apparatus For Performing Fast Closest Match In Pattern Recognition” filed ______, which are hereby incorporated by reference herein.
TECHNICAL FIELD
[0004] The present invention relates in general to pattern recognition systems and in particular to methods and systems for reducing the storage required for reference patterns (RPs) containing repeating substrings (RSs).
BACKGROUND INFORMATION
[0005] Recognizing patterns within a set of data is important in many fields, including speech recognition, image processing, seismic data, etc. Some image processors collect image data and then pre-process the data to prepare it to be correlated to reference data. Other systems, like speech recognition, are real time where the input data is compared in real time to reference data to recognize patterns. Once the patterns are “recognized” or matched to a reference, the system may output the reference. For example, a speech recognition system may output equivalent text to the processed speech patterns. Other systems, like biological systems may use similar techniques to determine sequences in molecular strings like DNA.
[0006] In some systems, there is a need to find patterns that are imbedded in a continuous data stream. In non-aligned data streams there are some situations where patterns may be missed if only a single byte-by-byte comparison is implemented. The situation where patterns may be missed occurs when there is a repeated or nested repeating patterns in the input stream or the pattern to be detected. A RP containing the sequence that is being searched for is loaded into storage where each element of the sequence has a unique address. An address register is loaded with the address of the first element of the RP that is to be compared with the first element of the input pattern (IP). This address register is called a “pointer.” In the general case, a pointer may be loaded with an address that may be either incremented (increased) or decremented (decreased). The value of the element pointed to by the pointer is retrieved and compared with input elements (IEs) that are clocked or loaded into a comparator.
[0007] In pattern recognition, it is often desired to compare elements of an IP to many RPs. For example, it may be desired to compare an IP resulting from digitizing a finger print to a library of RPs (all finger prints on file). To do the job quickly, elements of each RP may be compared in parallel with elements in the IP. Each RP may have repeating substrings (short patterns) which are smaller patterns embedded within the RP. Since a library of RPs may be quite large, the processing required may be considerable. It would be desirable to have a way of reducing the amount of storage necessary to hold the RPs. If the amount of data used to represent the RPs could be reduced, it may also reduce the time necessary to load and unload the RPs. Parallel processing may also be used where each one of the RPs and the IP are loaded into separate processing units to determine matches.
[0008] Other pattern recognition processing in biological systems may require the comparison of an IP to a large number of stored RPs that have substrings that are repeated. Processing in small parallel processing units may be limited by the storage size required for the RPs. Portable, inexpensive processing systems for chemical analysis, biological analysis, etc. may also be limited by the amount of storage needed to quickly process large numbers of RPs with repeating substrings.
[0009] There is, therefore, a need for a method and an apparatus to reduce the amount of information necessary to store RPs with repeated substrings by compressing and encoding the data representing the RPs. There is also a need for a method and apparatus to read and decode the RPs so that elements of the RPs may be compared to elements in an IP to determine occurrences of the RP contained in the IP.
SUMMARY OF THE INVENTION
[0010] RPs with repeating substrings are encoded and compressed so that they take less space in storage. Each reference element (RE) in a repeating substring is stored along with an operation code (OPC) and a flag. The first element in the repeating substring has an operation code that directs the storage of the first RE in a separate storage register. The OPC also indicates where the next element in the repeating pattern is stored. A repeat number is stored after the first element indicating how many times the repeating substrings is repeated after the first pass. The last element in the repeating substrings has a flag indicating it is the last element. The flag is used in determining whether to load the repeating number into a counter. If the last element matches an IE of an IP, then the repeating number is loaded into the counter while the next IE is compared to the stored first element without using an extra cycle. The remaining elements of the substring are compared to the IP and the counter decremented. If all of the elements in the repeated substring compare to elements in the IP, then the counter will be decremented to zero. When the counter reaches zero the next element after the repeated substring is compared to the IP. The amount of storage and processing required to compare RPs with repeated substrings to an IP is reduced and processing speed increased.
[0011] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0013] [0013]FIG. 1A illustrates a reference pattern (RP) with repeating substrings;
[0014] [0014]FIG. 1B illustrates a compressed and encoded RP with repeating substrings according to embodiments of the present invention;
[0015] [0015]FIG. 2 is a block diagram of system components used to read compressed and encoded RPs with repeating substrings according to embodiments of the present invention;
[0016] [0016]FIG. 3A illustrates a RP, an input pattern (IP), and a compressed and encoded form of the RP;
[0017] [0017]FIG. 3B is a table of steps and actions taken when reading and comparing elements from the compressed and encoded RP to elements in the IP according to embodiments of the present invention;
[0018] [0018]FIG. 4 is a flow diagram of method steps used in embodiments of the present invention; and
[0019] [0019]FIG. 5 is a block diagram of a data processing system that may run software routines that implement method steps in embodiments of the present invention for comparing RPs with repeating substrings to IPs.
DETAILED DESCRIPTION
[0020] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits may be shown in block diagram form in order not to obscure the present invention in unnecessary detail. For the most part, details concerning timing considerations and the like have been omitted in as much as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art.
[0021] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0022] [0022]FIG. 1A is a block diagram illustrating a RP 150 with nine reference elements (REs) (ABABABCDE). RP 150 is comprised of three repeating substrings (RSs) 151 and single REs 152 - 154 .
[0023] [0023]FIG. 1B is a block diagram of a RP 150 after it has been encoded as a compressed RP (CRP) 100 according to embodiments of the present invention. CRP 100 has RE 101 , and REs 103 - 106 . Element 102 is shown in the RE field, however it is not part of RP 150 itself, rather RE 102 is generated as part of the compression protocol used in embodiments of the present invention. RE 101 is the first element in CRP 100 . RE 103 is the second and last element in RS 151 . Since RE 103 is the last element in RS 151 , it has the flag 110 set in the last repeating (LR) field 114 . Each element in CRP 100 has an operation code (OPC) field 115 with stored OPC 107 - 109 and OPC 111 - 113 . These OPCs define how the REs in RE field 116 are to be processed when they are read using embodiments of the present invention.
[0024] In pattern recognition, it may be desired to determine if RP 150 in FIG. 1A occurs in a stream of IEs defining an IP (not shown in FIG. 1A or FIG. 1B). RE 150 is compressed when it is stored as CRP 100 in an addressable storage unit (not shown). The first RE 101 is an “A” and is stored in address 1 (shown in small numbers in field 116 in FIG. 1B). OPC 107 is stored at the same address and defines how RE 101 is to be processed when it is read. In this case OPC 107 , “Match and Jump 2 ,” indicates that RE 101 is the first element in RS 150 and is compared to an element in an IP to determine if they “Match.” OPC 107 indicates by “Jump 2 ” that the next element to be processed is to be read from address 3 (Jump 2 from address 1 ). Since RE 101 is the first element in RS 151 , OPC 107 also indicates that RE 101 is to be saved in a separate register for possible future use. RE 103 is at address 3 and is a “B.” OPC 109 (Match) indicates that RE 103 is simply compared to the next element in an IP when it is read. However, RE 103 also has flag LR 110 equal to a 1 indicating that it is the last repeating element in RS 151 . The fact that RE 103 has LR 110 equal to a 1 modifies the processing of RE 103 when it is read. If RE 103 matches the element of the IP to which it is compared, then circuitry (not shown) that generates addresses for reading CRP 100 indicates that the RE at the address immediately following the saved first element (RE 101 ) is to be loaded into a counter as the “repeat number” indicating how many times after the first pass through the RS 150 that it is to be repeated. In this case “2” would be loaded into the repeat counter. If RE 101 and 103 successfully compare to sequential elements in a RP two additional times, then circuitry in the address generator generates an address for reading the next RE (RE 104 ) which is a “C.” RE 104 has OPC 111 which is a simple “Match” indicating that it is to be compared to an IE and if it matches then the address for reading the next RE is incremented by accessing RE 105 . If the entire RP 150 is contained in the IP, then RE 106 will eventually be read and compared to an element in the IP. RE 106 has OPC 113 which indicates that it is the last element in CRP 100 (and thus RP 150 ). At this time the process of comparing other elements in the IP may be continued to see if RP 150 again occurs in the IP or the process may be terminated.
[0025] In one embodiment of the present invention, RPs for pattern recognition are compressed by encoding according to following compression protocol:
[0026] (1) The first element in an RS in a CPR has an OPC (e.g., OPC 107 ) that directs storing the first element in a separate storage location (e.g. register). It also directs the address generator to increment the address used to read elements of the CPR by two once the first element compares to an IE in the IP.
[0027] (2) The repeat number for the RS is stored as the second element in the encoded RS in the CPR indicating how many times to repeat the RS after the first time it compares to elements in the IP.
[0028] (3) All other REs in the RS are sequentially compared to sequential IEs in the IP until the last element in the RS is reached. A repeat counter is decremented if the last element in the RS matches an IE in the IP. If this is the first pass through the RS, then the counter will already be at zero from initialization or a previous cycle through an RS. At this point the repeat count is loaded into a counter and an IE is compared to the stored first element.
[0029] (4) After the last element in the RS compares, the address generator restarts at the address of the first element. This process repeats until the counter is decremented to zero and the last element has matched an IE. At this time the next element in the RP after the RS is compared to a next element in the IP.
[0030] The preceding was a short explanation of embodiments of the present invention which will be explained in more detail in the following.
[0031] [0031]FIG. 4 is a flow chart of method steps in embodiments of the present invention detailing embodiments of the present invention finding a RP with embedded RS in an IP. In step 400 indexes used in the remaining steps are initialized. In RE(I), the index “I” is used to identify which RE is being referred. To simplify the explanation, when a number is substituted for an index, the parenthesis are dropped. For example if 1=1, then RE(I) becomes RE1 and refers to the first RE in a reference pattern (RP).
[0032] In step 401 , the RE(I) and IE(N) determined by their particular indexes “I” and “N” are read. These indexes represent the storage addresses for the RP and the IP. In the following, these indexes may initially start at one but in general any initial address values could be used Addresses may be incremented by one or any other desired number within circuitry used to generate the addresses.
[0033] In step 402 , a test is done to determine if the OPC associated with RE(I) indicates that it is the first of an RS. The short hand description for the OPC indicating which is the first RE in an RS is; “Match and Jump 2 ” or simply “M+J2.” If the result of the test in step 402 is NO, then the OPC is a simple “Match” and in step 403 , RE(I) is compared to IE(N). In step 404 , a test is done to determine if RE(I) did in fact match the IE(N). A match is indicated by the variable CMP. If CMP is equal to one, then the compared RE(I) and the IE(N) do match. If the result of the test in step 404 is NO, then in step 405 an index in “Im”, used to keep track of the number of sequential compares, is set to zero indicating that RE(I) did not match IE(N). In step 406 , index N is incremented by one and the next IE(N) is read. Since the RE(1) did not match the IE(N) in the first pass, index I is not incremented and the same RE(I) (index I not incremented) is used in step 401 .
[0034] If RE(I) did compare to IE(N) in step 404 , then in step 407 , a match would be recorded. In this flow chart, a match is shown by recording (in index Im) the address (N) in the IP that first matches the first RE (RE1) and an index “MT” which keeps track of the number of sequential matches that occur following the first match (e.g., Im=N, MT). This means that the present index Im saves the index (N) of the IE that matched in step 404 along with a count (MT) indicating how many of the REs have sequentially matched sequential elements in the IP. Other methods of recording the occurrence of a match between all the REs in a RP and an equal number of sequential IEs in an IP may be used and still be within the scope of the present invention.
[0035] After step 407 records that an RE(I) matches an IE(N), then in step 408 , a test is done to determine if all R elements of the RP have matched an equal number of sequential IEs in the IP. If the result of the test in step 408 is NO, then in step 409 the index I is incremented by one and in step 406 index N is incremented by one. If the result of the test in step 408 is YES, then the complete RP has been found in the IP and the data defining the match is outputted in step 433 .
[0036] If the OPC in step 402 is equal to “M+J2”, then a repeating substring (RS) is being processed in the CPR (e.g., CPR 100 in FIG. 1B). If the result of the test in step 402 is YES, then in step 410 the first element of the RS (RE with the present index I) is saved in a separate storage register. In step 411 , RE(I) and IE(N) are compared. In step 411 , a test is done to determine if they matched (CMP=1 indicates a match). If the result of the test in step 412 is YES, then in step 413 the match is recorded as described in step 407 above. Since the OPC was “M+J2” (in step 402 ), which indicates that the RE is the first element in an RS, it means that the REs that follow the first RE are encoded and compressed according to the protocol described relative to FIG. 1B. Instead of incrementing index I by one, an OPC of “M+J2” directs that index I is incremented by two so that the repeat number (e.g., RE 102 in FIG. 1B) is skipped and instead the next RE in the RS is read. Therefore, in step 414 , index I is incremented by two and index N is incremented by one. The next sequential RE in the RS and the next IE in the IP are then read. In step 415 , RE(I) and IE(N) are compared. In step 416 a test is done to determine if they match (CMP=1 indicates a match). If the result of the test in step 416 is NO, then only the first RE in the RS matched an element in the IP. Therefore, in step 417 , the index IM that tracks matches is again set back to zero. In step 418 , index I is set to “IR” which is the index value of I when the first RE in the RS was read. Index N is incremented by one to access the next IE in the IP to continue the compare process. In step 425 , a branch is taken back to step 401 .
[0037] If the result of the test in step 416 is YES, then the second RE in the RS matches the next IE(N). In step 419 , the match is recorded by updating Im as described in step 407 . In step 420 , a test is done to determine the flag (LR), indicating that RE being processed is the last RE in the RS, is equal to one. If the result of the test in step 420 is YES, then an index CLR is tested in step 421 . Index CLR is equal to one if the RS has already been successfully matched once. During the first pass through the RS, CLR is equal to zero and the result of the test in step 421 is NO. In step 426 , a counter (CNT) is set equal to the value of RE(IR) in the CPR (e.g., it would be 2 in CPR 100 ). In step 427 , index CLR is set equal to one since the first pass through the RS has been completed. In step 428 , index I is set to the value IR (first RE in the RS) and index N is incremented by one to access the next IE in the IP. A branch is then taken back to step 411 where RE(I) and IE(N) are again compared.
[0038] After the first successful compare pass through the RS (all REs in the RS match IEs), CLR will be equal to one since it was set to one in step 427 . Therefore, in step 421 (the second successful compare pass), the result of the test is YES (CLR is equal to one) and in step 422 the CNT is decremented (keeps track of the number of time the RS is repeated). A test is then done in step 423 to determine if CNT has been decremented to zero. If it has not been decremented to zero, then more successful compare passes through the RS are required to determine if the entire RP with the RS matches to the IP.
[0039] Since CNT is not equal to zero, a branch is taken to step 428 where index I is reset to IR and N is incremented by on then a branch is taken back to step 411 where the steps continue as previously described. If the result of the test in step 423 is YES, then the RS has be successfully compared to sequential IEs in the IP for the number of times indicated by the value of RE(IR) plus one (the initial pass). In step 424 , index I is incremented by one. Since at this point the last value of I corresponds to the last RE in the RS (tested in step 420 ), then indexing I by one would move to the next RE after the RS of the RP. In step 424 , N is also incremented by one to to access the next IE to determine if the remaining elements of the RP, outside of the RS, match IEs of the IP. Then in step 425 a branch is taken back to step 401 to process additional IEs.
[0040] [0040]FIG. 3A illustrates an RP 310 containing a number of R reference elements. Values in index R 311 represents the addresses of the REs in RE(R) 312 . CRP 308 illustrates how RP 310 is compressed and encoded according to embodiments of the present invention. Values in index 1301 represents the storage addresses of the REs in RE(I) 302 . Each RE(I) 302 has a corresponding OPC 303 and a flag LR 304 . IP 307 has index N 305 which represents the address or sequence number corresponding to each of the elements IE(N) 306 .
[0041] In FIG. 3B, the table 350 illustrates the steps that are taken through flow diagram 450 in FIG. 4, when comparing CRP 308 to IP 307 . Arrow 357 indicates that step sequences 351 - 353 are read from the top to the bottom of table 350 . Actions 354 - 356 are shown next to the step numbers from flow diagram 450 .
[0042] Starting with step sequence 351 . In step 400 , the indexes I, N, Im, and CLR are set. In step 401 RE1 and IE1 are loaded into a comparator (not shown). In step 402 , the OPC (of RE1) is decoded as “Match” (M) and indicates that RE1 and IE1 are to be compared. In step 403 , RE1 which is an “A” and IE1 which is a “C” are compared. In step 404 , it is determined that they do not match (indicated by CMP not equal to one). In step 405 , the index Im is reset indicating a match was not recorded. In step 406 , only index N is incremented by one to a value of two. In step 401 , RE1 and IE2 are loaded into the comparator. Again the OPC for RE1 is decoded as M and in step 403 , RE1=A is compared to IE2=D. Step 404 determines that they do not compare (CMP is not equal to one). Again, in step 405 , Im is reset. In step 406 , index N is incremented by one so N=3. In step 401 , RE 1 and IE3 are loaded into the comparator. Again the OPC for RE1 is decoded as M, and in step 403 RE1=A is compared to IE3=A. Step 404 determines that they do compare (CMP is equal to one). In step 407 , index value Im is loaded with the index (address) value 3, which identifies which element of IP 307 matches the first element of RP 310 and corresponding CRP 308 .
[0043] Since a match has been determined, in step 408 the index I is tested to determine if all R elements of RP 310 have matched a sequence in IP 307 . Since it is the first compare, index I is not equal to index R. Therefore, in step 409 , index I is incremented by one (1=2) and in step 406 index N is incremented by one (N=4). A branch back to step 401 loads RE2 and IE4 into the comparator. Step 402 decodes the OPC of RE2 as M indicating a simple compare operation. In step 403 , RE2=C is compared to IE4=C and again they compare as indicated by CMP equal to one. In step 407 , index Im is updated recording a second sequential match, IE4 matches RE2. Since a match was recorded, index I is again tested to determine if all of the REs in CRP 100 have been processed. In step 407 , index Im is not equal to R and in step 409 index I is incremented (1=3) and in step 406 index N is incremented by one (N=5). In step 401 , RE3 and IE5 are loaded into the comparator. The OPC of RE3 is decoded as M indicating a simple compare. In step 403 , RE3=D is compared to IE5=D and again they match. In step 404 , CMP is equal to one indicating a successful compare.
[0044] Continuing with step sequence 352 : In step 407 , index Im is updated indicating a third sequential match of RE3 and IE5. Since a match was recorded, index Im is tested to see if all of the R REs have been processed. In step 408 , the current value of the index in Im (simply Im) is not equal to R, therefore, in step 409 index I is incremented by one (I=4) and index N is incremented by one (N=6) in step 406 . In step 401 , RE4 and IE6 are loaded into the comparator. The OPC of RE4 is decoded in step 402 as M+J2 which indicates the RE4 is the first element of a repeating substring (RS). In step 410 , RE(IR) is saved where IR is the value of index I corresponding to the first RE in the RS. In this case, IR is equal to four. In step 411 , RE4=A is compared to IE6=A. They match as indicated by CMP is equal to one in step 412 . In step 413 , index Im is updated to indicate that four sequential matches have occured. Because the OPC of RE4 was decoded as M+J2, index I is incremented by two (I=6) to “Jump” over the repeat count stored in RE5. Index N is incremented by one (N=7). In step 415 , RE6=B is compared to IE7=B. They compare indicated by CMP equal to one in step 416 . In step 419 , index Im is updated to indicating five consecutive matches between elements in CRP 308 and IP 307 . Since RE6 matched IE7, flag LR is tested in step 420 to determine if RE6 is the last element in the RS. In this case LR is equal to one indicating it is the last repeating element. Since LR=1, in step 421 index CLR is tested to determine if this is the second pass through the RS. CLR is equal to zero, so in step 426 a counter CNT is set to the count value stored in RE(IR). IR equals to four, the index of the first element in the RS. Therefore the repeat count value is loaded from RE5 (repeat count=2). A repeat count value of two indicates that the RS is repeated three times (two times after the first time). In step 427 , CLR is set to one so that step 426 will not be repeated the next time through the RS. In step 428 , index I is set to IR (4) and N is incremented by one (N=8). In step 411 , RE4=A is compared to IE8=A. They match as indicated by CMP equal to one in step 412 . In step 413 , Im is updated to indicate six consecutive matches of an element of CRP 308 to an element of IP 307 . Since the OPC of RE4 was decoded as a M+J2, index I is incremented by two (I=6) and index N is incremented by one (N=9). In step 415 , RE6=B is compared to IE9=B. They compare as indicated by CMP equal to one in step 416 . In step 419 , Im is updated indicating seven consecutive matches of an element of CRP 308 to an element of IP 307 . In step 420 , LR is equal to one. This time through the RS, L R is equal to one (set to one in step 427 ), therefore, in step 422 , CNT is decremented by one (CNT=1). In step 423 , CNT is tested to see if its count value is equal to zero. If CNT is equal to zero, then the RS has been processed the number of times determined by the repeat count loaded from RE(IR) plus one. In step 423 , CNT is not equal to zero (CNT=1) and a branch is taken to step 428 where index I is set to IR (I=4) and index N is incremented by one (N=10).
[0045] The sequence of steps starting with step 411 are again executed. In step 411 , RE4=A is compared to IE10=A and they compare as indicated by CMP equal to one in step 412 . In step 413 , Im is updated indicating eight consecutive matches of an element of CRP 308 to an element of IP 307 . In step 414 , index I is again incremented by two (I=6) to jump over the repeat number stored in RE5 and index N is increment by one (N=11). In step 415 , RE6=B is compared to IE11=B. They compare as indicated by CMP equal to one in step 416 . In step 419 , a match is recorded by updating the index in Im to nine. Again, in step 420 , LR is equal to one, therefore, step 421 is executed where CLR is equal to one. In step 422 , CNT is again decremented, this time to zero. In step 423 , CNT is then equal to zero indicating that the RS has been repeated the desired number of time determined by repeat number in RE(IR) plus one (three times). In step 424 , index I is incremented by one (I=7) and N is incremented by one (N=12). In step 425 , a branch is taken back to step 401 . In step 401 , RE7 and IE12 are loaded into the comparator. The OPC of RE7 is again decoded as an M. In step 403 , RE7=C is compared to IE12=C. They match as indicated by CMP equal to one in step 404 . In step 407 , a match is recorded by updating the index in Im to ten. In step 408 , the index of Im is compared to R to see if all of the R elements of RP 310 have been processed. Im=10 is not equal to R=12 and in step 409 index I is incremented by one (I=8) and in step 406 index N is incremented by one (N=13). A branch is taken back to step 401 where RE8 and IE13 are loaded into the comparator. The OPC of RE8 is decoded as an M indicating a simple match. In step 403 , RE8=D is compared to IE13=D and they compare as indicated by CMP equal to one in step 404 . In step 407 , index in Im is updated by one to eleven. Im=11 is not equal to R=12 in step 408 , therefore, in step 409 index I is incremented by one (I=9) and index N is incremented by one (N=14) in step 406 . In step 401 , RE9 and IE14 are loaded into the comparator. Again RE9 has an OPC decode of M. In step 403 , RE9=E is compared to IE14=E and they compare as indicated by CMP equal to one in step 404 . In step 407 , Im is updated by one to twelve. In step 408 , Im=12 is equal to R=12 indicating the RE9 is the last element in RP 310 and thus corresponding CRP 308 . Therefore, in step 433 , the data determining the location of the occurrence of RP 310 in IP 307 is outputted.
[0046] The preceding has shown how a simple RP 310 with an RS is compressed and encoded to CRP 308 and how CRP 308 is read and decoded to allow comparison of elements of the RP 310 to the elements of an IP 307 . More complicated RPs would be handled in a similar manner using embodiments of the present invention.
[0047] [0047]FIG. 2 is a block diagram of a system 200 for decoding and comparing a CRP (e.g., CRP 308 ) to an IP (e.g., IP 307 ). Addressable storage 201 is used to store a CRP compressed and encoded using a protocol according to embodiments of the present invention. Each entry of the CRP comprises an RE 208 , corresponding OPC 209 , and last element flag LR 210 . Unit 223 comprises address logic and an address generator for generating addresses for addressable storage 201 . Each time a new address is presented on address lines 225 , storage 201 presents an RE 208 and a corresponding OPC 209 and flag LR 210 . OPC 209 is decoded in decoder/controller 203 which generates a signal 226 to gate register 204 which provides separate storage for the first RE in an RS. Decoder 203 also sends a signal 224 to multiplexer (MUX) 227 and counter and compare logic 215 . If a decode of a OPC 209 indicates that a repeat number (e.g., RE 102 ) is to be loaded into a repeat counter (not shown) in Counter and Compare logic 215 , then the saved RE in register 204 is loaded into Compare logic 214 where it is compared to an IE in IP 202 while the repeat number is read from CRP 201 and loaded into the repeat counter. Decode signals 224 and LR 210 are also used to direct incrementing, decrementing, and loading the repeat counter (not shown) in Counter and Compare logic 215 . The results of the compare in Compare logic 214 are used to index the Input Address logic and Generator 213 which sends address 212 to IP storage buffer unit 202 . Input Address logic and Generator 213 also receives a signal 220 from Counters and Compare logic 215 to synchronize outputting a next address 212 to access an IE. Reference Address logic and Generator 223 receives a signal 218 from Compare logic 214 indicating the compare results and status. Reference Address logic and Generator 223 also receives a signal 219 indicating the status of the repeat counter and the amount to increment or decrement the Reference Address counter.
[0048] System 200 in FIG. 2 may be realized by a software routine programmed into a computer with sufficient speed to process the IP in real time or the IP may be stored in a memory subsystem and then read out and processed at system speed. RPs may be compressed and encoded using a set of instructions and the resulting compressed and encoded CRPs may be stored in RAM for later processing. Counters, registers, multiplexers, and comparators may be implemented as software routines and still be within the scope of the present invention.
[0049] A representative hardware environment 500 for practicing the present invention is depicted in FIG. 5, having CPU 534 , for executing instructions implementing method steps according to the present inventive principles, and a number of other units interconnected via system bus 512 . System 500 includes random access memory (RAM) 514 , read only memory (ROM) 516 , and input/output (I/O) adapter 518 for connecting peripheral devices such as disk units 520 to bus 512 , user interface adapter 522 for connecting keyboard 524 , mouse 526 , and/or other user interface devices such as a touch screen device (not shown) to bus 512 , communication adapter 534 for connecting the system to a data processing network, and display adapter 536 for connecting bus 512 to display device 538 .
[0050] RPs may be stored on disk units 520 . RPs may then be read into CPU 534 which contains instructions for compressing and encoding the RPs into CRPs according to embodiments of the present invention. The CPRs may be stored in RAM 514 . IPs may have been stored on a disk units 520 or they may be received from an I/O unit 540 or from a remote device over communication network 541 . A user may input search requests from a device via user interface 522 to search the IP to determine if various RPs occur in the IP. Results of the compare may be outputted to display 538 or stored in disk units 520 . To facilitate fast processing, the IP and the RPs may be stored in RAM 514 and accessed by CPU 534 . Software routines may be executed by CPU 534 to read the CRPs from RAM 514 by generating addresses according to embodiments of the present invention. Instructions may decode the CRPs and compare the REs in the CRP to IEs in the IP to determine if they match. Results of the comparisons may be stored for later use in RAM 514 or disk units 520 .
[0051] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A method and apparatus for compressing a reference pattern (RP) with repeated substrings by encoding produce compressed reference patterns (CRPs) with reduce storage requirements. Operation codes and a flag are stored with the CRPs. During comparison of reference elements of the CRP to input elements (IEs) of an input pattern (IP), the operation codes are read and the reference pattern is decoded allowing all reference elements including those of the repeated substrings to be compared to IEs in the IP to determine if the RP appears within the IP.
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RELATED APPLICATIONS
[0001] There is no related application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] None.
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] The present invention is generally directed toward the surgical treatment of articular chondral defects and is more specifically directed toward a surgical workstation for producing an allograft cartilage implant plug having a cartilage face and bone body.
[0006] 2. Description of the Prior Art
[0007] Articular cartilage injury and degeneration present medical problems to the general population which are constantly addressed by orthopedic surgeons. Every year in the United States, over 500,000 arthroplastic or joint repair procedures are performed. These include approximately 125,000 total hip and 150,000 total knee arthroplastics and over 41,000 open arthroscopic procedures to repair cartilaginous defects of the knee.
[0008] In the knee joint, the articular cartilage tissue forms a lining which faces the joint cavity on one side and is linked to the subchondral bone plate by a narrow layer of calcified cartilage tissue on the other. Articular cartilage (hyaline cartilage) consists primarily of extracellular matrix with a sparse population of chondrocytes distributed throughout the tissue. Articular cartilage is composed of chondrocytes, type II collagen fibril meshwork, proteoglycans and water. Active chondrocytes are unique in that they have a relatively low turnover rate and are sparsely distributed within the surrounding matrix. The collagens give the tissue its form and tensile strength and the interaction of proteoglycans with water give the tissue its stiffness to compression, resilience and durability. The hyaline cartilage provides a low friction bearing surface over the bony parts of the joint. If the cartilage lining becomes worn or damaged resulting in lesions, joint movement may be painful or severely restricted. Whereas damaged bone typically can regenerate successfully, hyaline cartilage regeneration is quite limited because of it's limited regenerative and reparative abilities.
[0009] Articular cartilage lesions generally do not heal, or heal only partially under certain biological conditions due to the lack of vascularity. The limited reparative capabilities of hyaline cartilage usually results in the generation of repair tissue that lacks the structure and biomechanical properties of normal cartilage. Generally, the healing of the defect results in a fibrocartilaginous repair tissue that lacks the structure and biomedical properties of hyaline cartilage and degrades over the course of time. Articular cartilage lesions are frequently associated with disability and with symptoms such as joint pain, locking phenomena and reduced or disturbed function. These lesions are difficult to treat because of the distinctive structure and function of hyaline cartilage. Such lesions are believed to progress to severe forms of osteoarthritis. Osteoarthritis is the leading cause of disability and impairment in middle-aged and older individuals, entailing significant economic, social and psychological costs. Each year, osteoarthritis accounts for as many as 39 million physician visits and more than 500,000 hospitalizations. By the year 2020, arthritis is expected to affect almost 60 million persons in the United States and to limit the activity of 11.6 million persons.
[0010] There are many current therapeutic methods being used. None of these therapies has resulted in the successful regeneration of hyaline-like tissue that withstands normal joint loading and activity over prolonged periods. Currently, the techniques most widely utilized clinically for cartilage defects and degeneration are not articular cartilage substitution procedures, but rather lavage, arthroscopic debridement, and repair stimulation. The direct transplantation of cells or tissue into a defect and the replacement of the defect with biologic or synthetic substitutions presently accounts for only a small percentage of surgical interventions. The optimum surgical goal is to replace the defects with cartilage-like substitutes so as to provide pain relief, reduce effusions and inflammation, restore function, reduce disability and postpone or alleviate the need for prosthetic replacement.
[0011] Lavage and arthroscopic debridement involve irrigation of the joint with solutions of sodium chloride, Ringer or Ringer and lactate. The temporary pain relief is believed to result from removing degenerative cartilage debris, proteolytic enzymes and inflammatory mediators. These techniques provide temporary pain relief, but have little or no potential for further healing.
[0012] Repair stimulation is conducted by means of drilling, abrasion arthroplasty or microfracture. Penetration into the subchondral bone induces bleeding and fibrin clot formation which promotes initial repair, however, the tissue formed is fibrous in nature and not durable. Pain relief is temporary as the tissue exhibits degeneration, loss of resilience, stiffness and wear characteristics over time.
[0013] The periosteum and perichondrium have been shown to contain mesenchymal progenitor cells capable of differentiation and proliferation. They have been used as grafts in both animal and human models to repair articular defects. Few patients over 40 years of age obtained good clinical results, which most likely reflects the decreasing population of osteochondral progenitor cells with increasing age. There have also been problems with adhesion and stability of the grafts, which result in their displacement or loss from the repair site.
[0014] Transplantation of cells grown in culture provides another method of introducing a new cell population into chondral and osteochondral defects. Carticel® is a commercial process to culture a patient's own cartilage cells for use in the repair of cartilage defects in the femoral condyle marketed by Genzyme Biosurgery in the United States and Europe. The procedure uses arthroscopy to take a biopsy from a healthy, less loaded area of articular cartilage. Enzymatic digestion of the harvested tissue releases the cells that are sent to a laboratory where they are grown for a period ranging from 2-5 weeks. Once cultivated, the cells are injected during a more open and extensive knee procedure into areas of defective cartilage where it is hoped that they will facilitate the repair of damaged tissue. An autologous periosteal flap with cambium layer is sutured around the defect to seal the transplanted cells in place and act as a mechanical barrier. Fibrin glue is used to seal the edges of the flap. This technique preserves the subchondral bone plate and has reported a high success rate. Proponents of this procedure report that it produces satisfactory results, including the ability to return to demanding physical activities, in more than 90% of patients and that biopsy specimens of the tissue in the graft sites show hyaline-like cartilage repair. More work is needed to assess the function and durability of the new tissue and determine whether it improves joint function and delays or prevents joint degeneration. As with the perichondrial graft, patient/donor age may compromise the success of this procedure as chondrocyte population decreases with increasing age. Disadvantages to this procedure include the need for two separate surgical procedures, potential damage to surrounding cartilage when the periosteal patch is sutured in place, the requirement of demanding microsurgical techniques, and the expensive cost of the procedure which is currently not covered by insurance.
[0015] Osteochondral transplantation or mosaicplasty involves excising all injured or unstable tissue from the articular defect and creating cylindrical holes in the base of the defect and underlying bone. These holes are filled with autologous cylindrical plugs of healthy cartilage and bone in a mosaic fashion. The osteochondral plugs are harvested from a lower weight-bearing area of lesser importance in the same joint. Reports of results of osteochondral plug autografts in a small numbers of patients indicate that they decrease pain and improve joint function, however, long-term results have not been reported. Factors that can compromise the results include donor site morbidity, effects of joint incongruity on the opposing surface of the donor site, damage to the chondrocytes at the articular margins of the donor and recipient sites during preparation and implantation, and collapse or settling of the graft over time. The limited availability of sites for harvest of osteochondral autografts restricts the use of this approach to treatment of relatively small articular defects and the healing of the chondral portion of the autograft to the adjacent articular cartilage remains a concern.
[0016] Transplantation of large allografts of bone and overlying articular cartilage is another treatment option that involves a greater area than is suitable for autologous cylindrical plugs, as well as for a non-contained defect. The advantages of osteochondral allografts are the potential to restore the anatomic contour of the joint, lack of morbidity related to graft harvesting, greater availability than autografts and the ability to prepare allografts in any size to reconstruct large defects. Clinical experience with fresh and frozen osteochondral allografts shows that these grafts can decrease joint pain, and that the osseous portion of an allograft can heal to the host bone and the chondral portion can function as an articular surface. Drawbacks associated with this methodology in the clinical situation include the scarcity of fresh donor material and problems connected with the handling and storage of frozen tissue. Fresh allografts carry the risk of immune response or disease transmission. Musculoskeletal Transplant Foundation (MTF) has preserved fresh allografts in a media that maintains a cell viability of around 50% at 35 days for use as implants. In the current technology frozen allografts lack cell viability and have shown a decreased amount of proteoglycan content, however, they are commonly used for large defects.
[0017] A number of United States patents have been specifically directed towards the manufacture of plugs or cores which are implanted into a cartilage defect. U.S. Pat. No. 6,591,591 issued Jul. 15, 2003 describes a precut bone plug for use in allograft core transplantation surgery which has a tissue bank harvest the graft using a coring trephine with teeth having an inner diameter between 0.5 mm to 0.1 to create a bone core with a hyaline cartilage layer in approximately 7.9 mm, 9.9 mm, 11.9 mm diameters. Alternatively a donor harvester having a cutter tube with a straight cutting edge windows and depth markings with a torque handle on the proximal end may be used to obtain an allograft core as is shown in U.S. Pat. No. 5,919,196 issued Jul. 6, 1999. U.S. Pat. No. 6,592,588 issued Jul. 15, 2003 discloses instruments for cutting a bone core by cutting or punching having collared pins disposed within the harvester for removal of the harvester cores.
[0018] U.S. Pat. No. 4,565,192 issued Jan. 21, 1986 shows a multi-plate device with fixed pins and movable pins for cutting a portion of a patella during knee surgery. U.S. Pat. No. 5,092,572 discloses an allograft vise with a “V” shaped vise face and moveable vise plates. The vise is affixed to a table and can be provided with spherical vise plates having a sharp tripod support for a femur.
[0019] U.S. Pat. Nos. 6,488,033 and 6,852,114 (a divisional application of the '033 patent) issued respectively Dec. 3, 2002 and Feb. 8, 2005 are directed toward an osteochondral transplant workstation for cutting a core out of an allograft bone held in an adjustable vise with a lubricated rotary cutting bit. The core is removed from the bit, held in a specially designed set of pliers, and cut to size by a saw blade to fit into a blind bore which has been oriented and drilled into the patient's arthritic defect area. This workstation while an improvement over existing procedure is cumbersome to use and requires experience and training use.
[0020] The present invention was designed to overcome prior art procedures and provide a simple to use core preparation devise which accurately fits into the patient's bore area to form a uniform cartilage surface for the patient.
SUMMARY OF THE INVENTION
[0021] A workstation for the preparation of osteochondral allograft cartilage implants having a portable plastic base with a fixed jaw member and a moveable jaw member to hold the allograft full or hemi condyle being cut to provide replacement cores. An articulated guide assembly for a variable size positioner and cutter is mounted on the fixed jaw body and a miter for a surgical saw is formed on one side of the fixed jaw and moveable jaw.
[0022] It is an object of the invention to provide a surgical workstation for forming osteochondral allograft plugs with a cartilage layer which are of the correct size for insertion into a blind bore in a patients knee to repair a cartilage defect.
[0023] It is also an object of the invention to provide a surgical workstation allowing the creation of a cartilage repair implant which has a cartilage layer contoured to the defect site and is easily placed in a defect area by the surgeon to form a continuous cartilage surface in the defect area.
[0024] It is still another object of the invention to provide a surgical workstation for creating a cartilage implant core during surgery which has load bearing capabilities.
[0025] It is further an object of the invention to provide a surgical workstation which can be easily used by the surgeon to create correctly dimensional and contoured cartilage implants.
[0026] It is yet another object of the invention to provide a surgical workstation which can be easily cleaned and sterilized.
[0027] It is still another object of the invention to provide a workstation with a miter so that accurate core lengths for the implant can be obtained.
[0028] It is a further object of the invention to provide a surgical workstation which holds the full or hemi condyle in a fixed stable position allowing a uniform core to be cut from the hemi condyle.
[0029] These and other objects, advantages, and novel features of the present invention will become apparent when considered with the teachings contained in the detailed disclosure along with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of the osteochondral allograft cartilage implant forming workstation with an exploded cutter positioning and guide assembly;
[0031] FIG. 2 is a perspective exploded view of the workstation of FIG. 1 including a bushing for the guide sleeve;
[0032] FIG. 2A is a perspective exploded view of another embodiment of the workstation of FIG. 2 showing drill guide holes for optional additional fixation of the hemi condyle including a bushing for the guide sleeve;
[0033] FIG. 3 is a side perspective view of the workstation shown in FIG. 1 with the cutter guide assembly in place holding the core cutter and a hemi condyle mounted in the vise jaws;
[0034] FIG. 4 is an opposite side perspective view of the workstation from that shown in FIG. 3 ;
[0035] FIG. 5 is a perspective view of the allograft cartilage implant workstation using a positioner to establish donor plug position and axis;
[0036] FIG. 6 is a perspective view of the osteochondral allograft cartilage implant workstation with bushing, cutter and slotted wrench tool shown in exploded position;
[0037] FIG. 7 is a side elevational view of the workstation shown in FIG. 6 with the cutter, cutter holder and hemi condyle shown in cross section and the cutter shown cutting the allograft cartilage implant core;
[0038] FIG. 7A is an alternate embodiment of a side elevational view of the workstation shown in FIG. 7 showing the jaws of the vise with chamfered bores used to receive wire fixation or drill bit for fixation;
[0039] FIG. 8 is a side elevational view of the workstation shown in FIG. 7 with the cutter removed and a saw blade isolating the donor plug by cutting same to desired length;
[0040] FIG. 9 is a partial enlarged perspective view of the plug length trim with the handle of the saw shown in phantom; and
[0041] FIG. 10 is a reversed view cross section taken through the center of FIG. 4 with cutter, bushing and hemi condyle removed.
DESCRIPTION OF THE INVENTION
[0042] The term “tissue” is used in the general sense herein to mean any transplantable or implantable tissue such as bone.
[0043] The terms “transplant” and “implant” are used interchangably to refer to tissue (xenogeneic or allogeneic) which may be introduced into the body of a patient to replace or supplement the structure or function of the endogenous tissue.
[0044] The terms “autologous” and “autograft” refer to tissue or cells which originate with or are derived from the recipient, whereas the terms “allogeneic” and “allograft” refer to tissue which originate with or are derived from a donor of the same species as the recipient. The terms “xenogeneic” and “xenograft” refer to tissue which originates with or are derived from a species other than that of the recipient.
[0045] The present invention is directed towards a cartilage repair implant forming workstation. The preferred embodiment and best mode of the invention is shown in FIGS. 1 , 2 , 3 - 7 , and 8 - 10 . In the inventive workstation 20 , a workpiece in the form of an allograft hemi condyle 210 from which an allograft plug or core 200 with a cartilage cap 202 and a subchondral bone portion 204 is prepared for implantation into a patient.
[0046] The portable workstation 20 is constructed with a plastic or metal base 22 having integral upwardly angled handles 24 . The angled handles 24 define grasping cutouts 26 and the base 22 defines a centrally located slot 28 which is stepped as shown in FIGS. 1 , 2 , 6 and 10 to receive a shoulder screw 66 which retains the traveling jaw 60 of vise 29 in the slot 28 . Located on each side of slot 28 are tracks 30 which receive the rails 64 of the traveling jaw 60 . The bottom surface of the base is provided with small ½ inch legs (not shown) at each corner of the base 22 which together with the grasping handles provide stability to the workstation during the cutting operations. Mounted on the top surface of base 22 is a solid fixed jaw 40 of the vise 29 having a planar top surface 42 , a planar side surface 43 , a rear grasping surface 44 and a front angled surface 45 . The top surface 42 is planar and the associated transverse work piece grasping surface 44 (or allograft work piece engaging surface) is formed with a angular cutout 46 which receives the notch of the allograft hemi condyle 210 which has been precut prior to surgery for easy insertion into the vise 29 . The top portion 48 of the grasping wall defines a plurality of vertically positioned parallel teeth 50 as best seen in FIG. 2 . If desired, a plurality of parallel throughgoing drill or wire guide bores 51 as seen in FIG. 2A with chamfered hole lead ins 55 are drilled through the top portion 48 for additional fixation of the hemi condyle 210 . This fixation is accomplished by wires 170 as shown in FIG. 7A or by the drill bit itself inserted through both jaws and the base of the hemi condyle 210 .
[0047] As shown in FIG. 10 , a central throughgoing bore 52 is cut through the middle of the fixed jaw 40 parallel to the top surface of the base 22 to receive the shaft 81 which drives the moving jaw 60 . A shaft retainer lug 54 is mounted in a groove 53 cut in the fixed jaw body adjacent the throughgoing bore 52 and extends into an arcuate groove 85 cut in the end of the shaft to keep shaft 81 in a fixed position within the fixed jaw 40 . A vertical bore 49 is cut into the top surface 42 of the fixed jaw body and extends down into the fixed jaw body to receive the post 92 of the articulated arm assembly 90 . A side bore 47 is cut into the side 43 of the fixed jaw body and communicates with the vertical bore 49 allowing contact of the end of shaft 59 of attachment knob 58 with the post 92 of the articulated arm assembly 90 to secure the post 92 of the articulated arm assembly at a fixed height within the fixed jaw 40 . The bottom of the fixed jaw 40 is secured to the base 22 by means of recessed securement bolts 31 screwed into the bottom of the base through the recessed bores 27 in the base which are aligned with threaded blind bores 59 cut into the bottom of the fixed jaw as best seen in FIG. 10 .
[0048] The moveable or traveling jaw 60 has a bottom surface 62 defining two parallel rails 64 which slide in the tracks 30 formed in the base 22 . A blind bore 66 is cut into the bottom surface of the slot 28 and is axially aligned with blind stepped bore 67 cut into the bottom of the traveling jaw body. The stepped bore 67 is threaded to receive the threaded end 69 of shoulder screw 68 which retains the traveling jaw 60 in the slot 28 .
[0049] The surface of the top wall 70 of the moveable jaw 60 is planar and the associated transverse grasping wall 72 is formed with a angular cutout 74 which receives the notch of the allograft bone workpiece 210 . The hemi condyle 210 can be mounted into the vise 29 on either axis. A planar side surface 77 forms one side of the moveable jaw 60 and a miter assembly 79 forms the opposite side of the moveable jaw. The top portion 75 of the grasping wall 72 defines a plurality of vertically positioned parallel teeth 76 as seen in FIG. 9 . A plurality of parallel throughgoing drill or wire guide bores 51 ( a ) as seen in FIG. 2A with chamfered hole lead ins are drilled through the top portion 75 and are axially aligned with bore holes 51 in the fixed jaw body for additional fixation of the hemi condyle 210 . This fixation is accomplished by wires 170 as shown in FIG. 7A or by the drill bit itself inserted through both jaws and the base of the hemi condyle 210 .
[0050] A throughgoing bore 78 is cut through the moveable jaw body and is axially aligned with the throughgoing bore 52 of the fixed jaw body to receive threaded shaft portion 82 . The thread on the shaft is an acme or convention type thread. Shaft assembly 80 comprises shaft 81 formed into threaded shaft portion 82 and a smooth surfaced shaft portion 84 with the distal smooth portion 84 of the shaft defining an arcuate groove 85 which holds shaft retainer lug 54 holding the shaft 81 fixed in place in the fixed jaw 40 . The proximal portion of shaft 81 has a knob 86 mounted thereto which is held in place by a securement cross pin 88 which is best shown in FIG. 10 . The proximal end of the knob 86 defines a wrench lug 87 which is adapted to receive a slotted wrench tool for tightening the vise 29 .
[0051] An articulated arm assembly 90 as best seen in FIG. 10 is mounted to the fixed jaw body as previously noted. The articulated arm assembly 90 comprises a post 92 which is indexed for ease of height adjustment as shown in FIGS. 1 and 2 , the distal end of the post 92 ending in an upper ball joint 93 upon which an articular arm 94 is mounted. The articular arm is positioned and locked to a designated axis as established with a sizer/positioner tool 300 as shown in FIG. 5 . The articulare arm 94 is “T” shaped with tapered threaded ends 95 and 95 ( a ), each of which defines a central recess 96 holding an acetal bearing pad 98 which respectively bears against ball joints 93 and 124 . The arm 94 has an integral finger tab 97 . Mounted over the lower threaded end 95 is a lower bearing lock body 100 which defines a conical threaded bore 102 sized to be threaded over the lower threaded end 95 and has an integral opposing finger tab 104 for locking end 95 in place against ball joint 93 . Mounted over the upper threaded end 95 a is an upper bearing lock body 110 which defines a conical threaded bore 112 , the lock body 110 having an integral opposing finger tab 114 for locking end 95 ( a ) in place against ball joint 124 . The upper bearing lock 110 holds a positional collar 120 which has an extending arm 122 with a ball joint 124 secured to the distal end which is held in a fixed position by the upper bearing lock body 110 . The collar 120 defines a central throughgoing bore 126 which can hold interchangeable bushings 130 as shown in FIG. 6-8 ranging in size from 15, 18, 20, 22, 25, 30 and 35 mm in diameter. The bushings in turn are adapted to hold core cutter blades 144 ranging from 15, 18, 20, 22, 25, 30 and 35 mm in diameter.
[0052] A plug or core cutting assembly 140 comprising an arbor 142 , chuck 144 and cylindrical cutting blade 146 are shown in FIGS. 7 , 7 A. The core trimmer is formed in the fixed jaw 40 and the moveable jaw 60 as best seen in FIG. 9 . Each jaw side portion 47 , 79 defines an aligned miter slot 142 , 144 which establishes a perpendicular cut to match the bottom of the recipient counterbore with the exterior side 145 of miter side portions 47 , 79 defining finger clearance reliefs 146 . The miter slot is of sufficient width to receive a standard type surgical saw blade 160 . The top surface 148 of each of the miter sections has a flat planar section 150 and a downward angled flat surface 152 with the ends being provided with a scale 154 set to the allograft plug length.
[0053] In operation, the lesion or defect is removed by cutting a counterbore in the patient of a predetermined diameter and depth in the defect area with a cannulated boring bit. An allograft hemi condyle is placed between the jaws of the vise to hold the condyle in the desired position. A donor cutting guide is placed over the allograft condyle in the same position and orientation as the original cartilage removed from the defect area and then a coring bit and arbor is used to obtain an allograft plug of the same diameter as the diameter of the core cut into the defect area of the patient as seen in FIG. 1 . The core is then removed from the allograft condyle by sawing the condyle transversely with a surgical saw as seen in FIG. 8 to make the allograft plug an independent entity. The plug is then trimmed to length by the surgical saw in the miter cutting area as shown in FIG. 9 or when held by forceps.
[0054] The plug 200 which has been cut to the desired length is placed in the bore which has been cut in the lesion area of the bone of the patient with the upper surface of the cartilage cap 202 being slightly proud or substantially flush with the surface of the original cartilage 202 remaining in the area. The length of the osteochondral plug 200 can be the same as the depth of the bore or less than the depth of the bore If the plug 200 is the same length, the base of the plug implant is supported and the articular cartilage cap 202 is level with the articular cartilage of the patients bone surface. If the plug is of a lesser length, the base of the plug implant is not supported but support is provided by the wall of the bore or respective cut out area as the plug is interference fit within the bore or cut out area with the cap being slightly proud or flush with the articular cartilage depending on the surgeon's preference. With such load bearing support the graft surface is not damaged by weight or bearing loads which can cause micromotion interfering with the graft interface producing fibrous tissue interfaces and subchondral cysts.
[0055] The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention should not be construed as limited to the particular embodiments which have been described above. Instead, the embodiments described here should be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the scope of the present invention as defined by the following claims:
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The invention is directed toward a portable surgical workstation and kit of accessory devises for cartilage implant formation comprising a base, a vise assembly mounted to the base, the vise assembly comprising a fixed jaw member and a moveable jaw member, each jaw member defining grasping surfaces for holding a bone workpiece. A shaft drive is threadably connected to the moveable jaw member and rotatably mounted in the fixed jaw member for transporting the moveable jaw toward and away from the fixed jaw. An articulated guide assembly is mounted to the fixed jaw member, the articulated guide means including a sleeve member and a plurality of moveable interconnected members selectively rotatable on a ball joint. A miter assembly defining a slot of a width to receive a surgical saw is mounted to at least one of the jaw members. The kit of accessory devices comprises a plurality of different diameter bushings which fit in the sleeve member and a plurality of different diameter cylindrical core cutter assemblies sized to fit in each respective sized bushing and a donor cutter guide adapted to fit in said sleeve.
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TECHNICAL FIELD
[0001] The present invention belongs to the field of energy conversion equipment, and relates to a fuel cell, which directly transforms chemical energy that fuel gas contains into electricity. In particular, the subject of the present invention is to increase the power generation efficiency of molten carbonate fuel cells (MCFC), while providing improvement to the system, to make recovery of CO 2 easier, and further contributing to the effective use of energy resources and improvement of earth environment.
BACKGROUND ART
[0002] FIG. 1 is a flow chart of a conventional internal reforming MCFC power generation system.
[0003] Externally-supplied new fuel gas F, such as urban gas, is first sent to a desulfurizer 1 , and after removal of its sulfur content, the new fuel gas is sent to a fuel humidifier 2 . The fuel humidifier 2 is a heat exchanger, which sprays and evaporates treated water into fuel gas, while at the same time, heats new fuel gas F using cathode exhaust of the molten carbonate fuel cell. Water supply W is pretreated by a water treatment equipment 3 , and is supplied to the fuel humidifier 2 by a pump 5 via a treated water tank 4 .
[0004] The mixed gas of hot fuel gas and vapor exiting the fuel humidifier 2 is then led to a pre-converter 6 . The pre-converter 6 is a container containing a reforming catalyst 7 , and hydrocarbon gas in the fuel gas is partly reformed. The pre-converter outlet gas is supplied to a fuel cell 9 , following heat exchange with cathode exhaust in a fuel gas heater 8 .
[0005] Since an internal reforming fuel cell 9 incorporates an internal reformer 10 , reforming of the fuel gas supplied to the fuel cell 9 is carried out by the internal reformer 10 , and transformed into gas consisting mainly of H 2 and CO; however, since the reforming catalyst is also arranged along the anode gas passage, reforming reaction and power generation reaction occur concurrently at the anode. Although about 70% of the total amount of H 2 and CO generated by the fuel cell 9 is utilized in the power generation reaction, the remainder is discharged from the fuel cell 9 as an anode exhaust.
[0006] The anode exhaust containing combustible components is mixed with air supplied by an air blower 11 a , and is then led to a catalyst oxidizer 12 , whereby the inflammable components in the anode exhaust is oxidized. Air is preheated by this oxidation reaction, while at the same time, carbon dioxide contained in the anode exhaust is added to air, and then led to the cathode. At the cathode, carbon dioxide and oxygen are partly consumed by the power generation reaction, and exit the cathode. The working temperature of the fuel cell 9 is around 600° C. After providing heat to the fuel gas in the fuel gas heater 8 , cathode exhaust that exits the fuel cell 9 is partly recycled to the cathode by a recycling blower 11 b , and the remainder is emitted to the atmosphere after providing heat to the fuel side in the fuel humidifier 2 .
[0007] In addition, for example, patent documents 1-3 are disclosed as a related art relevant to the present invention.
[0008] Patent documents 1 and 2 are related to combined power generation by molten carbonate type fuel cell and gas turbine, while patent document 3 relates to a production method of the synthesized gas using oxygen permeation film.
RELATED ART DOCUMENTS
Patent Documents
[0000]
Patent document 1: JP-A-H11-176455, “FUEL CELL COMPOSITE POWER GENERATING DEVICE”
Patent document 2: JP-A-2004-071279, “FUSED CARBONATE FUEL CELL POWER GENERATION SYSTEM, AND POWER GENERATION METHOD IN SYSTEM”
Patent document 3: JP-A-2003-183004, “METHOD FOR MANUFACTURING SYNTHETIC GAS, AND SYSTEM FOR MANUFACTURING LIQUID FUEL AND SYSTEM FOR GENERATING FUEL CELL-ELECTRIC POWER UTILIZING THIS”
[0012] In the above-described conventional internal reforming MCFC power generation system, the fuel gas, which contains hydrogen as its main component, in the anode exhaust is combusted in order to preheat air. Hence, there was a problem that power generation efficiency was low.
[0013] Moreover, although part of the carbon dioxide contained in the anode exhaust is used in the power generation reaction, most are emitted into the atmosphere with the cathode exhaust.
[0014] Therefore, the conventional internal reforming MCFC power generation system had low power generation efficiency, and was problematic in that carbon dioxide was unrecoverable.
SUMMARY OF THE INVENTION
Technical Problem to be Solved by the Invention
[0015] The present invention was invented in order to solve the above-described conventional problems. That is, the subject of the present invention is to provide a hydrogen-recycling MCFC power-generating system, which can make effective use of the fuel gas, whose main component is hydrogen, contained in the anode exhaust, and raise power generation efficiency, while enabling separation and collection of carbon dioxide, thereby reducing the amount of carbon dioxide discharge.
Means to Solve the Problem
[0016] According to the present invention, a hydrogen-recycling MCFC power-generating system, comprising:
[0017] a molten carbonate fuel cell;
[0018] a carbon dioxide separation system that divides anode exhaust of the fuel cell into carbon dioxide to be collected, recycle carbon dioxide that is to be recycled, and remaining recycled fuel gas;
[0019] a fuel gas heater, which diverges part of a mixed fuel gas obtained by mixing new fuel gas to the recycled fuel gas, preheats the mixed fuel gas to a certain temperature, and adds reforming steam;
[0020] a fuel gas heater, which diverges part of the mixed fuel gas, preheats the mixed fuel gas to a certain temperature, and adds reforming steam;
[0021] a multistage pre-converter, in which reforming reaction and methanation reaction of the mixed fuel gas occur simultaneously; and
[0022] a portion to supply the mixed fuel gas exiting the multistage pre-converter to the anode of the fuel cell
[0000] is provided.
[0023] According to a desirable embodiment of the present invention, the multistage pre-converter comprises two or more stages of reforming catalyst layers, wherein
[0024] reforming reaction and methanation reaction occur simultaneously in each reforming catalyst layer, consecutively, and after cooling by mixing part of the mixed fuel gas and reforming steam to outlet gas of each reforming catalyst layer, the gas is led to the reforming catalyst layer of the following stage;
[0025] hence, reforming reaction and methanation reaction are continued in two or more stages of the reforming catalyst layers, without external heating or cooling.
[0026] Moreover, in the multistage pre-converter, the mixed fuel gas, which contains the reforming steam preheated by the fuel gas heater, is led to a first stage reforming catalyst layer, wherein reforming reaction of hydrocarbon gas contained in the externally-supplied fuel gas, and methanation reaction of hydrogen and carbon dioxide gas contained in the recycled fuel gas, occur simultaneously at a temperature range of 250-450° C., and the reactions continue without external heating or cooling.
[0027] Furthermore, according to a desirable embodiment of the present invention, the system further comprises an exhaust heat recovery boiler that comprises a low-temperature shift catalyst layer and generates steam from the anode exhaust of the fuel cell, which collects reaction heat while increasing carbon dioxide by the shift reaction (CO+H 2 O—>CO 2 +H 2 ) in the low-temperature shift catalyst layer.
[0028] Furthermore, according to a desirable embodiment of the present invention, the system further comprises a cathode gas supplying system for supplying cathode gas to the fuel cell, wherein
[0029] the cathode gas supplying system comprises a closed loop, which comprises a recycling blower and circulates cathode gas of the fuel cell, an oxygen supplying equipment that supplies oxygen consumed by the power generation reaction to the closed loop, and a carbon dioxide supplying line that supplies the recycled carbon dioxide to the closed loop.
[0030] The oxygen supplying equipment consists of an air compressor that supplies air and an air separation equipment that separates oxygen from the air supplied and supplies oxygen to the closed loop.
[0031] Moreover, according to another embodiment, the oxygen supplying equipment consists of an air compressor that supplies air, and a low-temperature regenerated heat exchanger and a high-temperature regenerated heat exchanger for preheating air, and
[0032] air supplied from the air compressor is first preheated by the low-temperature regenerated heat exchanger, then mixed with the carbon dioxide supplied from the carbon dioxide supplying equipment, and then heated by the high-temperature regenerated heat exchanger, then further mixed with recycled gas from the recycling blower, before being supplied to the cathode entrance.
[0033] Said carbon dioxide supplying line further comprises a recycling carbon dioxide heater, wherein the recycled carbon dioxide is preheated by the anode exhaust.
[0034] Moreover, the carbon dioxide supplying line further comprises an oxidation catalyst layer, wherein the combustible gas contained in the recycled carbon dioxide is oxidized, after air is added to the recycled carbon dioxide.
Effect of the Invention
[0035] According to the above-described composition of the present invention, the anode exhaust can be separated into carbon dioxide to be collected, recycled carbon dioxide that is recycled, and remaining recycled fuel gas, by the carbon dioxide separation system; therefore, carbon dioxide can be separated and collected, and the amount of carbon dioxide discharge can be reduced.
[0036] Moreover, since new fuel gas is mixed with recycled fuel gas and reused as a mixed fuel gas, without combusting the remaining fuel in the anode exhaust, the fuel gas, of which its main component is hydrogen, is used effectively, and power generation efficiency can be raised.
BRIEF DESCRIPTION OF DRAWINGS
[0037] [ FIG. 1 ] is a flow diagram of a conventional internal reforming MCFC power generation system.
[0038] [ FIG. 2 ] is a configuration diagram of a first embodiment of the fuel cell power generation system of the present invention.
[0039] [ FIG. 3 ] is a configuration diagram of a second embodiment of the fuel cell power generation system of the present invention.
[0040] [ FIG. 4 ] is a flow diagram of the periphery of the multistage pre-converter 14 of FIG. 2 .
DESCRIPTION OF EMBODIMENTS
[0041] Hereinafter, favorable examples of embodiments of the present invention are described with reference to the accompanying drawings. The same or corresponding portions are denoted by the same reference numerals, and overlapping descriptions are omitted.
[0042] FIG. 2 is a configuration diagram of a first embodiment of the fuel cell power generation system of the present invention. An internal reforming molten carbonate fuel cell 9 is used in the fuel cell power generation system of the present invention. Hereafter, the internal reforming molten carbonate fuel cell 9 is referred to simply as the “fuel cell.”
[0043] In this figure, the sulfur content in fuel gas F, such as urban gas, supplied externally (hereafter referred to simply as “new fuel gas F”) is firstly removed by a desulfurizer 1 ; then, new fuel gas F is mixed with recycled fuel gas RF. Recycled fuel gas RF is the remaining gas obtained by cooling anode exhaust AE and partly separating carbon dioxide by a carbon dioxide separation system 20 .
[0044] In this example, said mixed fuel gas MF is equally divided into four parts, and ¼ of the mixed fuel gas MF is led to a fuel gas heater 13 and heated by the anode exhaust AE; meanwhile, reforming steam STM is supplied into the mixed fuel gas ME. Here, dividing the mixed fuel gas MF into four parts is merely one embodiment exemplifying the present invention, and in the spirit of the present invention, the mixed fuel gas may be divided into any number of equal parts; however, for the purpose of simplification, division into four equal parts will be applied hereinafter.
[0045] When mixed fuel gas MF is divided into four equal parts, reforming steam STM must also be divided into four equal parts and supplied to each stream, in order to balance the quantity of the mixed fuel gas MF. This steam is generated in an exhaust heat recovery boiler 17 from treated water obtained by pre-treating water supply W in a water treatment equipment 3 , and sent via a treated water tank 4 and a pump 5 .
[0046] In the fuel gas heater 13 , ¼ of mixed fuel gas MF and ¼ of reforming steam STM are heated by the anode exhaust AE, and led to a first stage catalyst layer R 1 of the multistage pre-converter 14 . In the first stage catalyst layer R 1 , contents with mass larger than ethane in new fuel gas F are reformed, while simultaneously, H 2 and part of the carbon dioxide in the recycled fuel gas RF are methanated.
[0047] Although reforming reaction is an endothermic reaction and a methanation reaction is exothermic, in total, heat generation is larger, and the temperature of gas exiting the first stage catalyst layer R 1 is considerably higher than that at the entrance.
[0048] Temperature is lowered by supplying and mixing ¼ of the mixed fuel gas MF of low temperature, and reforming steam STM in an amount corresponding to that of mixed fuel gas MF, before being led to the 2nd stage catalyst layer R 2 that follows.
[0049] Said process is repeated, and all of the mixed fuel gas MF and reforming steam STM pass through catalyst layers R 1 -R 4 of the multistage pre-converter 14 , whereby methane-rich fuel gas is obtained.
[0050] Details of the process of said multistage pre-converter 14 are the most important points of the present invention; here, the overall system will be described first, followed by a description of its details.
[0051] The fuel gas exiting the multistage pre-converter 14 is heated to a temperature somewhat lower than the working temperature of fuel cell 9 , by the anode exhaust AE in a fuel gas heater 15 , and is then supplied to the fuel cell 9 . A reformer 10 in the shape of a thin plate is installed inside the fuel cell 9 , every six to 8 cells, and fuel gas is supplied to the reformer 10 .
[0052] Since the heat source for the reforming reaction in the reformer 10 is the heat generated in the power generation reaction of the fuel cell 9 , its temperature is as low as around 600° C.; therefore, its rate of reforming is also low. Here, the fuel gas, in which half of its methane content has been reformed, is supplied to the anode A. The reforming catalyst is also arranged along the gas passage of the anode A, and the following reforming reaction and power generation reaction progress in parallel at the anode A.
[reforming reaction: CH 4 +H 2 O—>CO+3H 2 ,
CO+H 2 O—>CO 2 +H 2 ]
[power generation reaction: H 2 +CO 3 2− —>H 2 O+CO 2 +2e − ]
[0056] While H 2 O is consumed and H 2 is generated in the reforming reaction, H 2 is consumed and H 2 O is generated in the power generation reaction. Therefore, because completely opposite reactions proceed simultaneously in parallel, equilibrium of the reforming reaction is affected, and even though the temperature is low, the rate of reformation is close to about 100%.
[0057] The ratio between the amounts of hydrogen obtained when all of the fuel gas supplied to the fuel cell is converted into hydrogen, and hydrogen used in the power generation reaction, is called the “fuel utilization ratio.” Since the fuel utilization ratio of the internal reforming molten carbonate fuel cell 9 (fuel cell) is about 70%, the remaining 30% leaves the fuel cell 9 contained in the anode exhaust AE.
[0058] Since the temperature of the anode exhaust AE is almost the same as the working temperature of the fuel cell 9 , it works as a heat source for the fuel gas heater 15 , which first heats fuel gas exiting the multistage pre-converter 14 to a temperature somewhat lower than the working temperature of fuel cell 9 .
[0059] On the other hand, part of the carbon dioxide separated by the carbon dioxide separation system 20 is collected, while the remainder is recycled to the cathode. This carbon dioxide that is recycled is especially called “recycled carbon dioxide RC.”
[0060] Anode exhaust AE exiting the fuel gas heater 15 is then led to a recycling carbon dioxide heater 16 , and heats the recycling carbon dioxide RC to a certain temperature.
[0061] Next, anode exhaust AE is led to the fuel gas heater 13 , and heats ¼ of the mixed fuel gas MF, and ¼ of the reforming steam STM to a certain temperature. Subsequently, anode exhaust AE is led to an exhaust heat recovery boiler 17 , wherein steam is generated.
[0062] In part of the exhaust heat recovery boiler 17 , a low-temperature shift catalyst layer is installed, whereby carbon monoxide (CO) in the anode exhaust is reacted with steam to be converted to carbon dioxide (CO 2 ) and hydrogen (H 2 ). Since the reaction is an exothermic reaction, the exhaust heat recovery boiler 17 collects this reaction heat effectively, while converting carbon monoxide into carbon dioxide so that carbon dioxide recovery proceeds more effectively at the carbon dioxide separation system 20 .
[0063] Anode exhaust AE exiting the exhaust heat recovery boiler 17 is led to a cooler 18 , where it is cooled; then, part of the moisture is separated and collected in a knock out drum 19 . Anode exhaust AE exiting the knock out drum 19 is led to the carbon dioxide separation system 20 , where part of the carbon dioxide is separated and collected.
[0064] Although adsorption method using molecular sieves, absorption method using absorbing liquid, and liquefaction separation, etc. are known for the carbon dioxide separation system 20 , here, method for carbon dioxide separation is not specified.
[0065] Part of the carbon dioxide separated by the carbon dioxide separation system 20 is collected, and the remainder is recycled as recycled carbon dioxide RC to the cathode. Moreover, as mentioned above, the rest of gas, from which carbon dioxide was separated, is mixed with new fuel gas F, as recycled fuel RF, and is used effectively as fuel for the fuel cell 9 .
[0066] In FIG. 2 , the line that supplies carbon dioxide from the carbon dioxide separation system 20 to the cathode of fuel cell 9 , via a catalyst oxidizer 22 and a recycling carbon dioxide heater 16 , is referred to as a “carbon dioxide supply line.”
[0067] The fuel cell power generation system of the present invention is further equipped with a cathode gas supplying system, which supplies cathode gas to the fuel cell 9 .
[0068] In FIG. 2 , the cathode gas supplying system comprises: a closed loop, which comprises a recycling blower 26 , and circulates cathode gas of the fuel cell 9 ; an oxygen supplying equipment, which supplies oxygen consumed by the power generation reaction to said closed loop; and a carbon dioxide supplying equipment, which supplies carbon dioxide consumed by the power generation reaction to said closed loop.
[0069] At the cathode of the fuel cell 9 , oxygen consumed by the power generation reaction (CO 2 +½O 2 +2e − ->CO 3 2− ) is replenished with oxygen O 2 generated by the oxygen supplying equipment (namely, air compressor 27 and air separation plant 28 ). Furthermore, carbon dioxide consumed by the power generation reaction is replenished with recycled carbon dioxide RC, which is separated by the carbon dioxide separation system 20 and recycled to the cathode.
[0070] The temperature of the cathode gas is higher at the exit than the entrance, due to the power generation reaction; however, by supplying and mixing oxygen, which is about normal temperature, and recycled carbon dioxide RC, which is preheated to a certain temperature, the temperature of said cathode gas is set back to the entrance temperature; thus, the composition is made simple.
Effect of Invention
[0071] (1) According to the fuel cell power generation system comprising the above-described composition, 30% of the fuel gas that exists in the anode exhaust AE can be used effectively as recycled fuel gas RF; therefore, new fuel gas F supplied externally can be reduced to 70%, and power generation efficiency can be raised significantly.
(2) Moreover, since carbon dioxide can be separated and collected in this system, and carbon dioxide is hardly emitted into the atmosphere, the system can be highly effective for the improvement of earth environment.
(3) However, this system requires the carbon dioxide separation system 20 and the air separation equipment 28 . Therefore, the effective power generation is the value obtained by subtracting the power consumed by such equipments from the power generated by the power generation equipment. If such power is less than or equal to 30% of the power generated by the power generation equipment, there should be a large merit in the fact that carbon dioxide is recoverable without dropping the power generation efficiency of the power generation equipment.
[0072] Hereinafter, technical points of the present invention, which have been devised in order to realize this system, are described.
Technical Points of the Present Invention
[0073] In a conventional system as shown in FIG. 1 , heat obtained by combusting fuel, remaining in about 30% of the anode exhaust, is utilized to realize the system. On the other hand, in the present invention, power generation efficiency is increased by using the remaining fuel effectively as fuel, without combustion. In order for this to be realized, the following two conditions are necessary.
(1) Heat Balance of the System
[0074] In order to realize heat balance of the system without combustion of the remaining fuel in the anode exhaust, energy that was wasted in the conventional system has to be used effectively, and energy must be used efficiently in the present invention, to cover for the remaining fuel in the anode exhaust.
[0075] In the conventional system, in the end, only the cathode exhaust take away heat from the fuel cell, and heat is given to the fuel side at the fuel gas heater 8 and the fuel humidifier 2 ; however, cathode exhaust E that is emitted to the atmosphere still contains energy, and it is necessary to use this energy effectively.
[0076] Therefore, in the present invention, the cathode is a closed loop, and anode exhaust AE is the only side that takes away energy from the fuel cell; energy contained in the anode exhaust AE is collected as much as possible by various heat exchangers.
[0077] In addition, hydrogen H 2 and carbon dioxide CO 2 , which are the main components of the recycled fuel gas RF, are methanated, and its reaction heat is used effectively. Since methanation reaction is an exothermic reaction, it may be utilized as a heat source.
(2) Heat Balance of the Fuel Cell
[0078] Although the following power generation reactions proceed in the fuel cell 9 , heat is generated at the same time that electricity is generated. Therefore, the fuel cell must be cooled for the heat generated.
[0079] Power generation reaction:
[0080] Cathode reaction CO 2 +½O 2 +2e − ->CO 3 2−
[0081] Anode reaction H 2 +CO 3 2− —>H 2 O+CO 2 +2e −
[0082] Total reaction: H 2 +½O 2 —>H 2 O
[0083] Exotherm Q at the fuel cell is represented as Q=ΔH−ΔG(V/V0), where combustion reaction heat is ΔH, free energy is ΔG, theoretical voltage is V0, and operation voltage is V. If the operating conditions of the fuel cell are the same for the conventional system and the system of the present invention, the amount of heat generation is the same, as well.
[0084] On the other hand, reforming reaction, sensible heat of gas flowing through anode and cathode, and heat loss are what cools the fuel cell. Their total must balance out with the heat generated by the fuel cell. Among these values, heat loss is inherent to the fuel cell itself, and is not affected by the system. Moreover, although the cathode of the present invention is a closed loop, if the flow rate, the composition, and the temperature at the entrance and exit of the fuel cell are the same as those of a conventional system, the cooling effect would also be the same.
[0085] The temperature of the cathode gas rises from the entrance towards the exit, and carbon dioxide and oxygen are consumed by the power generation reaction. In the present invention, oxygen O 2 consumed is supplied by the air separation equipment 28 , and carbon dioxide is supplied by the recycled carbon dioxide RC. In such a case, by supplying and mixing oxygen at normal temperature and recycled carbon dioxide RC preheated to about 400° C., the temperature at the cathode exit is set back to the temperature at the entrance.
[0086] Therefore, the cooling effect of the cathode is the same as in the conventional system. As for the rest, if the sensible heats of the reformation cooling and the anode gas are the same, the cooling effect of the fuel cell would be the same, too. If the S/C ratio (steam/carbon ratio) is the same and the flow rate of methane supplied to the fuel cell is the same, the cooling effect of the fuel cell would be the same, too. However, since 30% of the fuel gas is the recycled fuel gas RF, of which its main components are H 2 and carbon dioxide, there is only 70% of new fuel gas F, such as urban gas containing methane, supplied externally; thus cooling effect of the fuel cell cannot be attained.
[0087] Therefore, methanation of the recycled fuel gas RF is necessary. Since methanation is exothermic, by using this heat, the heat balance of the system and the heat balance of the fuel cell can both be obtained. The point of the present invention lies in the multistage pre-converter 14 , which achieves this. Hereafter, detailed descriptions are given.
(3) Multistage Pre-Converter 14 :
[0088] a. Power Generation Reaction and Fuel Gas
[0089] In the fuel cell 9 , the following power generation reactions proceeds, and the total reaction is the combustion of hydrogen.
[0090] Cathode reaction: CO 2 +½O 2 +2e − ->CO 3 2−
[0091] Anode reaction: H 2 +CO 3 2− —>H 2 O+CO 2 +2e −
[0092] Total reaction: H 2 +½O 2 —>H 2 O
[0093] Although about 60% of the reaction heat of hydrogen is directly converted into electricity, the remainder becomes heat. Therefore, it is necessary to cool the fuel cell.
[0094] On the other hand, in the internal reforming fuel cell 9 , a reformer 10 is built into the fuel cell. Since the reforming reaction (CH 4 +H 2 O—>CO+3H 2 ) is an endothermic reaction, it is necessary to provide heat; however, in the internal reforming fuel cell 9 , reforming is performed using the heat generated by the power generation reaction of the fuel cell. Thus, conversely said, the fuel cell is cooled by the reforming reaction. Therefore, the methane concentration of the fuel gas supplied determines the cooling capacity of the fuel cell; it is thus preferable that the fuel gas for the internal reforming fuel cell 9 has a high concentration of methane.
[0000] b. The Reaction and Heat Balance in the Pre-Converter
[0095] New fuel gas F, such as urban gas, contains methane as its main component and further contains ethane, propane, butane, etc. Moreover, the main components of the recycled fuel gas RF are hydrogen (H 2 ) and carbon dioxide (CO 2 ), and steam (H 2 O) is contained depending on the carbon dioxide separation system 20 .
[0096] If each of these is independently applied to a conventional pre-converter 6 , the following problems may occur.
[0097] Since around 300° C. is desirable as the working temperature of the pre-converter 6 , with new fuel gas F, methane is hardly reformed while components heavier than ethane are almost 100% reformed, due to chemical equilibrium.
[0098] In order to initiate reformation with only the sensible heat that gas contains, the fuel gas must be preheated to about 400° C. and supplied to the pre-converter 6 , in which case, many heat sources would be needed for preheating.
[0099] On the other hand, although for recycled fuel gas methanation reaction is exothermic, in order to initiate the reaction, it must be preheated to about 250° C., and requires a heating source. However, when the reaction is initiated, the temperature rises by heat generation, and as the temperature rises, methane concentration decreases, due to chemical equilibrium; also, if the catalyst temperature increases too much, the catalyst may be damaged.
[0100] Furthermore, unlike the conventional system shown in FIG. 1 , the system of the present invention shown in FIG. 2 requires preheating of the recycled carbon dioxide RC; if each fuel gas is heated independently, many heat sources would be needed, and the anode exhaust alone will become insufficient, making the system inconceivable.
(Multistage Pre-Converter 14 of the Present Invention)
[0101] In order to solve the aforementioned subjects, a system, wherein new fuel gas F supplied externally and recycled fuel gas RF are pre-mixed, reforming steam in an amount compatible to that of the mixed fuel gas is added, and then led to the multistage pre-converter 14 , has been invented. By such a system, the endotherm of the reforming reaction and part of the exotherm of the methanation reaction can be canceled out.
[0102] However, in order to preheat these gases to about 250° C., the initiation temperature of the reaction, many heat sources are still required; also, a problem remains in that the final achieving temperature of the reaction becomes too high and inhibits the increase of methane concentration. In order to keep the reaction temperature low in this method, external cooling is needed, making the pre-converter expensive and difficult to operate.
[0103] Thus, in the present invention, only ¼ of the mixed fuel gas MF and reforming steam STM are heated to about 250° C., which is the initiation temperature for the reaction, and fed to the first stage catalyst layer R 1 . Here, reaction proceeds towards the chemical equilibrium between the reformation product of methane and components heavier than ethane (H 2 , CO, CO 2 , H 2 O), and the main components of the recycled fuel gas, H 2 , CO 2 , and H 2 O. That is, the following reaction proceeds in either direction.
CH 4 +H 2 O—>CO+3H 2
[0104] The ratio of the amount of hydrogen obtained when all of the fuel gas supplied to the fuel cell is converted into hydrogen, and the amount of hydrogen utilized in the power generation reaction is called the “fuel utilization ratio.” In an internal reforming fuel cell 9 , this is about 70%. That is, 30% of hydrogen will be recycled, making the fuel gas 70%; hence, it may be said that about 30% of the mixed fuel gas MF supplied to the multistage pre-converter 14 is reformed. Since this is a state of over-reforming, the reaction in the multistage pre-converter 14 proceeds towards methanation. That is, as a total, the temperature rises by heat generation.
[0105] However, since the reforming reaction of components heavier than ethane in the fuel gas occurring simultaneously, as well as the mixing of gases, cause the sensible heat of the gas to increase, the degree of temperature rise is mitigated. Temperature is lowered by supplying and mixing ¼ each of mixed fuel gas MF of almost-normal temperature and reforming steam STM of mitigated temperature, to the gas with increase temperature exiting the first stage catalyst layer R 1 ; then the gas is led to the 2nd stage catalyst layer R 2 . By repeating such a process and passing through four stages of catalyst layers R 1 -R 4 , the requirement for heat source is diminished, reforming reaction and methanation reaction continue without external heating or cooling, and the final achieving temperature of the reaction can be lowered, thereby increasing methane concentration.
(4) Heat Balance
[0106] As has been described above, the size of the heat source of the fuel gas heater 13 is considerably decreased, and the quantity of reforming steam STM necessary to be generated by the exhaust heat recovery boiler 17 is reduced to 70%, because the amount of new fuel gas F that needs to be supplied externally is reduced to 70% by recycling the fuel gas in the anode exhaust; therefore, even though a recycled carbon dioxide heater 16 was added, the anode exhaust AE alone is now sufficient as the heat source, and the system of the present invention is attained.
[0000] (5) The system of the present invention remarkably increases power generation efficiency, with very little carbon dioxide emission to the atmosphere, and can greatly contribute to the effective use of resources and the improvement of earth environment.
[0107] Furthermore, in FIG. 1 , there were two heat exchangers between cathode exhaust, i.e. gas containing oxygen, and fuel gas, fuel gas heater 8 and fuel gas humidifier 2 ; however, the present invention does not contain such heat exchangers, and is hence, improved from a safety standpoint, as well.
[0000] (6) Moreover, the cathode gas only circulates through a closed loop with a cathode recycling blower 26 , and is of a very simple composition. Since cathode gas is also effective in cooling the fuel cell, the outlet temperature is higher than the entrance temperature; however, by supplying and mixing oxygen of nearly normal temperature, and carbon dioxide preheated to about 400° C. to the outlet gas, the temperature is reduced to that of the entrance. Such temperature control is made possible by controlling the preheating temperature of carbon dioxide.
[0108] On the other hand, when impure gas is contained in oxygen and carbon dioxide, certain amounts of purging becomes necessary; however, since the amount of purging is very small compared to the amount supplied, it can hardly be considered a problem from the viewpoint of carbon dioxide discharge.
[0000] (7) Moreover, although a small amount of combustible gas may be present in the recycled carbon dioxide RC depending on the carbon dioxide separation system 20 , in such as case, by adding air in an amount equivalent to about 2 times that of the oxygen required to oxidize the combustible gas, and passing it through the oxidation catalyst layer, the combustible gas can be processed. Moreover, the quantity of nitrogen that is incorporated at this time is also slight, and hardly affects the composition of the cathode gas.
(8) Furthermore, since water is recoverable at the final stage of anode exhaust cooling in this system, external water supply is not necessary for the reforming steam except at start up; therefore, there is less restriction for location.
[0109] FIG. 3 is a total configuration diagram of the 2nd embodiment of the fuel cell power generation system of the present invention.
[0110] This embodiment is a system, which supplies oxygen supply to cathode by air. Since the fuel pretreatment system is exactly the same as that of FIG. 2 , description is omitted.
[0111] The difference from the first embodiment is that among the carbon dioxide separated by the carbon dioxide separation system 20 , the quantity of the carbon dioxide collected is half, at most, of the case in FIG. 1 .
[0112] The carbon dioxide separated by the carbon dioxide separation system 20 is the sum of carbon dioxide that migrates from the cathode to the anode in the power generation reaction, and carbon dioxide that is generated from carbon in the fuel gas; however, if the carbon dioxide produced from the new fuel gas F supplied externally is completely collected, the amount of carbon dioxide in the cathode exit will become zero, and the power generation reaction will not proceed; therefore, only half of the carbon dioxide generated from fuel gas is recoverable.
[0113] However, since this system does not require the air separation equipment 28 of FIG. 2 , the power needed within the system is reduced by the difference between its power and the power for the air blower, and is thus advantageous in that power generation efficiency improves; further, the amount of carbon dioxide emitted into the atmosphere is reduced to about ⅓ that of the system of FIG. 1 .
[0114] On the other hand, the cathode gas system is completely different from that of FIG. 1 , and is therefore described in detailed below.
[0115] Air AIR is supplied by the air blower 23 . This air is heated by cathode exhaust in the low-temperature regenerated heat exchanger 24 , and then mixed with the preheated recycled carbon dioxide RC. The air with recycled carbon dioxide RC mixed is again heated by the cathode exhaust in the high-temperature regenerated heat exchanger 25 , after which it is mixed with cathode recycling gas and supplied to the cathode entrance.
[0116] At the cathode, carbon dioxide and oxygen are consumed by the power generation reaction, and becomes cathode exhaust. Part of the cathode exhaust is recycled to the cathode entrance by the cathode recycling blower 26 , and the remainder is emitted to the atmosphere via the high-temperature regenerated heat exchanger 25 and the low-temperature regenerated heat exchanger 24 . The fuel cell cooling effect by cathode gas does not change in this system, either. Moreover, in this cathode gas system, a heat exchanger with fuel gas does not exist, and is therefore a highly safe system.
Example 1
[0117] FIG. 4 is a flow diagram of the periphery of the multistage pre-converter 14 of FIG. 2 . Moreover, an example of the heat balance and mass balance of FIG. 4 is shown in Table 1.
[0118] Table 1 shows the calculated result for an example, where a multistage pre-converter 14 with four stages of catalyst layers R 1 -R 4 is used, with mixed fuel gas MF and reforming steam STM each divided into four parts, and the reaction onset temperature at the first stage in the fuel gas heater 13 is set at 250° C.
[0119] In addition, in FIG. 4 , the numbers indicated in the <diamond> are stream numbers in this flow diagram and the state of each gas and their composition at major positions are shown in Table 1.
[0000]
TABLE 1
Stream Number
1
2
4
6
7
11
15
19
position
NF
RF
13 entrance
13 exit
R1 exit
R2 exit
R3 exit
R4 exit
Temperature (° C.)
15
15
15
250
416
375
358
350
Pressure (ata)
1.66
1.25
1.25
1.24
1.23
1.22
1.21
1.2
Flow rate (kgmol/H)
20
60.12
15.53
26.59
24.92
48.34
72.63
95.53
(Nm 3 /H)
448
1348
415
596
556
1093
1628
2164
Composition (mol %)
CH 4
16
0.05
3.17
3.16
4.87
10.29
15.59
21.05
C 2 H5 (etc.)
1.4
0.36
0.36
H 2
26.25
0.56
0.56
2.55
3.13
3.65
4.56
CO
0.21
0.05
0.05
0.2
0.15
0.15
0.15
CO 2
33.61
5.4
5.4
7.42
14.55
21.65
28.75
H 2 O
8.05
9.87
20.58
31.25
41.97
N 2
O 2
[0120] Table 1 indicates that although the exit temperature of the first stage catalyst R 1 is 416° C. under these conditions, the exit temperatures of the catalyst layer in the second to fourth stages are all 400° C. or less, and significant rise in temperature by the methanation reaction is not present. Moreover, the exit temperature of the final catalyst layer R 4 is 350° C., and the concentration of methane is high enough.
[0121] Furthermore, the value converted into the rate of methane reformation under this condition is about 5%, and the cooling effect of the fuel cell is satisfactory, too. The variation range of the working temperature is 250-416° C., showing that extremely stable operation is possible.
INDUSTRIAL APPLICABILITY
[0122] The above-described fuel cell power generation system of the present invention has high power generation efficiency, and is suitable as a power supply that can significantly reduce the atmospheric discharge of carbon dioxide; thus, it could become popular as a new power-generation equipment from the viewpoint of effective use of resources, and improvement of earth environment. Hitherto, improvement of power generation efficiency and reduction of atmospheric discharge of carbon dioxide were considered for electric power company-oriented large-size power generation equipments; however, in reality, there is also an abundance of distributed power supplies, for which carbon dioxide reduction has progressed sluggishly. However, carbon dioxide reduction of distributed power supplies is now made achievable by the present invention.
[0123] The present invention is not limited to the above-described embodiments and various changes can be made without departing the scope of the present invention.
LIST OF REFERENCE SIGNS
[0000]
A anode, AE anode exhaust, AIR air,
C cathode, CE cathode exhaust,
DR condensed water, E exhaust,
F new fuel gas, MF mixed fuel gas,
PG purge gas,
R 1 first stage catalyst layer, R 2 second stage catalyst layer,
R 3 third stage catalyst layer, R 4 fourth stage catalyst layer,
RC recycled carbon dioxide,
RF recycled fuel gas,
STM vapor, W water supply,
1 desulfurizer, 2 fuel humidifier, 3 water treatment equipment,
4 treated water tank,
5 pump, 6 pre-converter, 7 reforming catalyst, 8 fuel gas heater,
9 fuel cell, 10 internal reformer,
11 a air blower, 11 b recycling blower,
12 catalyst oxidizer, 13 fuel gas heater,
14 multistage pre-converter, 15 fuel gas heater,
16 recycling carbon dioxide heater,
17 exhaust heat recovery boiler, 17 a low-temperature shift catalyst layer,
18 cooler and 19 knockout drum,
20 carbon dioxide separation system, 21 air blower,
22 catalyst oxidizer, 23 air blower,
24 low-temperature regenerated heat exchanger,
25 high-temperature regenerated heat exchanger,
26 cathode recycling blower, 27 air compressor,
28 air separation plant
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Provided is a hydrogen-recycling MCFC power-generating system that can improve power generation efficiency by effectively utilizing fuel gas having the hydrogen included in anode exhaust as the main component, and that can reduce the amount of carbon dioxide discharged by separating and recovering the carbon dioxide. The system is provided with a molten carbonate fuel cell ( 9 ), a carbon dioxide separating system ( 20 ) that separates and recovers a portion of the carbon dioxide from the anode exhaust (AE) from the fuel cell, a gas mixer that mixes recycled fuel gas (RF) after a portion of the carbon dioxide has been separated from the anode exhaust with new fuel gas (F) that is supplied from outside to make a mixed fuel gas (MF), a fuel gas heater ( 13 ) that diverts a portion of the mixed fuel gas, preheats it to a constant temperature and adds reforming steam (STM), and a multistage pre-converter ( 14 ) that performs a reforming reaction and a methanation reaction of the mixed fuel gas simultaneously. The mixed fuel gas exiting the multistage pre-converter is supplied to the anode (A) of the fuel cell.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a U.S. national stage of application No. PCT/JP2011/074190, filed on Oct. 20, 2011. Priority under 35 U.S.C.§119(a) and 35 U.S.C.§365(b) is claimed from Japanese Patent Application No. 2010-237800, filed on Oct. 22, 2010, the disclosure of which are also incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a vehicle, a control method, and a computer program.
BACKGROUND ART
[0003] A so-called hybrid vehicle that is driven by an internal combustion engine and an electric motor receives attention. When the hybrid vehicle decelerates, the electric motor functions as an electric generator in order to perform an electric power regeneration (hereinafter, also simply referred to as a regeneration) and store the electric power. The stored electric power is used for generating driving force, for example, when the vehicle accelerates or runs.
[0004] Some hybrid vehicles have a gear box configured to automatically shift gears. Hereinafter, the gear box is also referred to as a transmission.
[0005] In such cases, a clutch that connects the power or cuts the connection of the power can be provided between the internal combustion engine and the electric motor.
[0006] Some conventional vehicles include an internal combustion engine, an electric machine capable of operating as an electric motor and as an electric generator, a clutch, a gear box of which transfer ratio is variable, a power electronics, and an electric energy storage device. The clutch is provided between the internal combustion engine and the gear box. The driving torque can be led through the clutch from the internal combustion engine to the gear box and from the electric machine to the internal combustion engine. The electric machine is provided between the only clutch placed between the internal combustion engine and the gear box, and the gear box so that the electric machine can directly transfer positive torque or negative torque to the gear box input shaft of the gear box (for example, see patent literature PTL1).
CITATION LIST
Patent Literature
[0007] PTL1: JP 2007-118943 A
SUMMARY OF INVENTION
Technical Problem
[0008] However, when the hybrid vehicle starts moving only by the electric motor and then the electric motor stops although generating torque, for example, when the vehicle surmounts a steep upgrade or an obstacle, the vehicle sometimes cannot start moving because the current is concentrated in the element of an inverter that drives the electric motor and heat is generated.
[0009] In order to solve the problem, enhancing the heat-resistance or cooling performance of the element can be considered. However, it is concerned that this increases the cost.
[0010] In light of the foregoing, an objective of the present invention is to solve the problem or, in other words, to provide a vehicle, a control method, and a computer program that enable the vehicle to certainly start moving without changing the hardware.
Solution to Problem
[0011] To solve the above-mentioned problem, an aspect of the present invention is directed to a vehicle driven by an internal combustion engine and an electric motor that are connected to shafts configured to transfer power through a clutch configured to connect the power or disconnect the connection of the power, the vehicle includes an apparatus comprising: determination means for determining, while the clutch is disengaged, whether a condition, where an absolute value of a rotational speed of the electric motor is equal to or less than a predetermined first threshold and where torque of the electric motor is equal to or more than a predetermined second threshold, lasts for a predetermined third threshold or more; and control means for controlling the electric motor to limit the torque of the electric motor and controlling the clutch to be engaged when it is determined, while the clutch is disengaged, that the condition where the absolute value of the rotational speed of the electric motor is equal to or less than the first threshold and where the torque of the electric motor is equal to or more than the second threshold lasts for the third threshold or more.
[0012] In addition, in the vehicle according to the aspect of the present invention, the control means may control the electric motor to cause the torque of the electric motor to be equal to or less than a predetermined fourth threshold within a predetermined period.
[0013] In addition, in the vehicle according to the aspect of the present invention, the control means may control the electric motor to cancel the limitation of the torque of the electric motor after a predetermined period elapses after the torque of the electric motor is limited.
[0014] According to another aspect of the present invention, a control method for controlling a vehicle driven by an internal combustion engine and an electric motor that are connected to shafts configured to transfer power through a clutch configured to connect the power or disconnect the connection of the power includes the steps of: determining, while the clutch is disengaged, whether a condition, where an absolute value of a rotational speed of the electric motor is equal to or less than a predetermined first threshold and where torque of the electric motor is equal to or more than a predetermined second threshold, lasts for a predetermined third threshold or more; and controlling the electric motor to limit the torque of the electric motor and controlling the clutch to be engaged when it is determined, while the clutch is disengaged, the condition where the absolute value of the rotational speed of the electric motor is equal to or less than the first threshold and where the torque of the electric motor is equal to or more than the second threshold lasts for the third threshold or more.
[0015] According to still another aspect of the present invention, a computer program causes a computer for controlling a vehicle driven by an internal combustion engine and an electric motor that are connected to shafts configured to transfer power through a clutch configured to connect the power or disconnect the connection of the power to perform a process including the steps of: determining, while the clutch is disengaged, whether a condition, where an absolute value of a rotational speed of the electric motor is equal to or less than a predetermined first threshold and where torque of the electric motor is equal to or more than a predetermined second threshold, lasts for a predetermined third threshold or more; and controlling the electric motor to limit the torque of the electric motor and controlling the clutch to be engaged when it is determined, while the clutch is disengaged, that the condition where the absolute value of the rotational speed of the electric motor is equal to or less than the first threshold and the time when the torque of the electric motor is equal to or more than the second threshold lasts for the third threshold or more.
Advantageous Effects of Invention
[0016] According to an aspect of the present invention, a vehicle, a control method, and a computer program that enable the vehicle to certainly start moving without changing the hardware can be provided.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a block diagram for illustrating an exemplary structure of a hybrid vehicle 1 .
[0018] FIG. 2 is a block diagram for illustrating an exemplary configuration of a function implemented in an HV-ECU 21 .
[0019] FIGS. 3A to 3C are time charts for describing a process for limiting the torque of an electric motor 14 .
[0020] FIG. 4 is a flowchart for describing a process for limiting the torque of the electric motor 14 .
DESCRIPTION OF EMBODIMENTS
[0021] Hereinafter, a hybrid vehicle according to an embodiment of the present invention will be described with reference to FIGS. 1 to 4 .
[0022] FIG. 1 is a block diagram for illustrating an exemplary structure of a hybrid vehicle 1 . The hybrid vehicle 1 is an example of a vehicle. The hybrid vehicle 1 is driven by an internal combustion engine and/or an electric motor through a gear box configured to automatically shift gears. For example, when the vehicle decelerates, the electric power can be regenerated by the electric motor. The gear box configured to automatically shift gears is, for example, referred to as an automated mechanical/manual transmission. The transmission can automatically shift the gears while having the same structure as a manual transmission.
[0023] The hybrid vehicle 1 includes an internal combustion engine 11 , a clutch 12 , a hybrid device 13 , an electric motor 14 , an inverter 15 , a Hybrid Vehicle (HV) battery 16 , a gear box 17 , an output shaft 18 , a differential gear 19 , a wheel 20 , and an HV-Electronic Control Unit (ECU) 21 . Note that the hybrid device 13 includes the electric motor 14 , the inverter 15 , the HV battery 16 , and the HV-ECU 21 . Note that the gear box 17 includes the above-mentioned automated mechanical/manual transmission and is operated by a shift unit (not shown in the drawings) including a drive range (hereinafter, referred to as a D (Drive) range).
[0024] The internal combustion engine 11 internally combusts gasoline, light oil, Compressed Natural Gas (CNG), Liquefied Petroleum Gas (LPG), alternative fuel, or the like in order to generate power for rotating a shaft and transfer the generated power to the clutch 12 .
[0025] The clutch 12 transfers the shaft output from the internal combustion engine 11 to the wheel 20 through the electric motor 14 , the gear box 17 , the output shaft 18 , and the differential gear 19 . In other words, the clutch 12 mechanically connects (hereinafter, simply referred to as connects) the rotating shaft of the internal combustion engine 11 to the rotating shaft of the electric motor 14 by the control of the HV-ECU 21 in order to transfer the shaft output of the internal combustion engine 11 to the electric motor 14 . On the other hand, the clutch 12 cuts (hereinafter, simply referred to as cuts or disconnects) the mechanical connection between the rotating shaft of the internal combustion engine 11 and the rotating shaft of the electric motor 14 so that the rotating shaft of the internal combustion engine 11 and the rotating shaft of the electric motor 14 can rotate at different rotational speeds from each other.
[0026] For example, the clutch 12 mechanically connects the rotating shaft of the internal combustion engine 11 to the rotating shaft of the electric motor 14 , for example, when the hybrid vehicle 1 runs by the power of the internal combustion engine 11 and this causes the electric motor 14 to generate electric power, when the driving force of the electric motor 14 assists the internal combustion engine 11 , and when the electric motor 14 starts the internal combustion engine 11 .
[0027] Alternatively, for example, the clutch 12 cuts the mechanical connection between the rotating shaft of the internal combustion engine 11 and the rotating shaft of the electric motor 14 when the internal combustion engine 11 stops or is in an idling state and the hybrid vehicle 1 runs by the driving force of the electric motor 14 , and when the hybrid vehicle 1 decelerates or runs on the down grade and the electric motor 14 generates electric power (regenerates electric power) while the internal combustion engine 11 stops or is in an idling state.
[0028] Note that the clutch 12 differs from the clutch operated by the driver's operation of a clutch pedal, and is operated by the control of the HV-ECU 21 .
[0029] The electric motor 14 is a so-called motor generator that supplies a shaft output to the gear box 17 by generating the power for rotating the shaft using the electric power supplied from the inverter 15 , or that supplies electric power to the inverter 15 by generating the electric power using the power for rotating the shaft supplied from the gear box 17 . For example, when the hybrid vehicle 1 accelerates or runs at a constant speed, the electric motor 14 generates the power for rotating the shaft to supply the shaft output to the gear box 17 in order to cause the hybrid vehicle 1 to run in cooperation with the internal combustion engine 11 . Further, the electric motor 14 works as an electric generator, for example, when the electric motor 14 is driven by the internal combustion engine 11 , or when the hybrid vehicle 1 runs without power, for example, the hybrid vehicle 1 decelerates or runs on the down grade. In that case, electric power is generated by the power for rotating the shaft supplied from the gear box 17 and is supplied to the inverter 15 in order to charge the HV battery 16 .
[0030] The inverter 15 is controlled by the HV-ECU 21 , and converts the direct voltage from the HV battery 16 into an alternating voltage or converts the alternating voltage from the electric motor 14 into a direct voltage. When the electric motor 14 generates power, the inverter 15 converts the direct voltage of the HV battery 16 into an alternating voltage and supplies the electric power to the electric motor 14 . When the electric motor 14 generates electric power, the inverter 15 converts the alternating voltage from the electric motor 14 into a direct voltage. In other words, in that case, the inverter 15 works as a rectifier and a voltage regulator for supplying a direct voltage to the HV battery 16 .
[0031] Further, the inverter 15 determines, for example, whether a condition, where the absolute value of the rotational speed of the electric motor 14 is equal to or less than a predetermined rotational speed A and where the torque of the electric motor 14 is equal to or more than a predetermined torque B, lasts for a predetermined period C or more. When it is determined that the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more, the inverter 15 transmits a current concentration determination flag to the HV-ECU 21 .
[0032] The HV battery 16 is a secondary cell capable of being charged and discharged. The HV battery 16 supplies electric power to the electric motor 14 through the inverter 15 when the electric motor 14 generates power. Alternatively, the HV battery 16 is charged with the electric power generated by the electric motor 14 when the electric motor 14 generates electric power.
[0033] The gear box 17 includes an automated mechanical/manual transmission (not shown in the drawings) that selects one of a plurality of gear ratios (change gear ratios) according to the instruction signal to shift gears from the HV-ECU 21 in order to shift the change gear ratios and transfer the gear-shifted power of the internal combustion engine 11 and/or of the electric motor 14 to the wheel 20 through the output shaft 18 and the differential gear 19 . Alternatively, the gear box 17 transfers the power from the wheel 20 through the output shaft 18 and the differential gear 19 to the electric motor 14 , for example, when the vehicle decelerates or runs on the down grade. Note that the automated mechanical/manual transmission can also shift the gear position to a given gear number by the driver's hand operation of the shift unit.
[0034] The output shaft 18 is a so-called propeller shaft or drive shaft. The output shaft 18 transfers the power output from the gear box 17 to the differential gear 19 . The differential gear 19 transfers the power to the right and left wheels 20 and absorbs the difference between the rotations of the right and left wheels 20 .
[0035] The HV-ECU 21 is an example of a computer, and controls the electric motor 14 by controlling the inverter 15 . When receiving the current concentration determination flag transmitted from the inverter 15 , the HV-ECU 21 determines that the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more.
[0036] For example, the HV-ECU 21 includes a Central Processing Unit (CPU), an Application Specific Integrated Circuit (ASIC), a microprocessor (micro-computer), a Digital Signal Processor (DSP), and the like, and internally has an operation unit, a memory, an Input/Output (I/O) port, and the like.
[0037] Note that a computer program to be executed by the HV-ECU 21 can be installed on the HV-ECU 21 that is a computer in advance by being stored in a non-volatile memory inside the HV-ECU 21 in advance.
[0038] The wheel 20 is a drive wheel for transferring the driving force to the road surface. Note that, although only a wheel 20 is illustrated in FIG. 1 , the hybrid vehicle 1 actually includes a plurality of the wheels 20 .
[0039] FIG. 2 is a block diagram for illustrating an exemplary configuration of a function implemented in the HV-ECU 21 executing a predetermined computer program. In other words, when the HV-ECU 21 executes the computer program, a determination unit 51 , a torque control unit 52 , and a clutch control unit 53 are implemented.
[0040] The determination unit 51 determines whether a condition, where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and where the torque of the electric motor 14 is equal to or more than the predetermined torque B, lasts for the predetermined period C or more, and determines whether a predetermined period F has elapsed after the torque of the electric motor 14 has been limited. The determination unit 51 includes a current concentration determination unit 61 , a period elapse determination unit 62 , and a threshold storage unit 63 .
[0041] According to whether the current concentration determination unit 61 has received a current concentration determination flag transmitted from the inverter 15 , the current concentration determination unit 61 determines whether the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more. Note that, in order to determine whether the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more, the current concentration determination unit 61 can also obtain, in real time, the data indicating the rotational speed and the torque of the electric motor 14 from the inverter 15 , and read a threshold A indicating the rotational speed A, a threshold B indicating the torque B, and a threshold C indicating the period C from the threshold storage unit 63 that stores the thresholds in advance. In that case, the current concentration determination unit 61 can internally maintain the thresholds A, B, and C, for example, as constant numbers.
[0042] The period elapse determination unit 62 reads a threshold F indicating the period F from the threshold storage unit 63 that stores the threshold in advance, and compares the elapsed time shown by a real time clock housed in the HV-ECU 21 with the threshold F in order to determine whether the predetermined period F has elapsed after the torque of the electric motor 14 has been limited.
[0043] The threshold storage unit 63 stores the predetermined thresholds A, B, C, and F.
[0044] Note that the period elapse determination unit 62 can internally maintain the threshold F, for example, as a constant number.
[0045] The torque control unit 52 controls the electric motor 14 to increase and decrease the torque generated by the electric motor 14 by controlling the inverter 15 .
[0046] The clutch control unit 53 controls the clutch 12 to be engaged, be in a so-called half-engaged clutch state, or be disengaged by transmitting a control signal.
[0047] FIGS. 3A to 3C are time charts for describing a process for limiting the torque of the electric motor 14 . The horizontal axes in FIGS. 3A to 3C show a time. FIG. 3A is a time chart in which the rotational speed of the electric motor 14 corresponding to the time shown as the horizontal axis is shown as the vertical axis. FIG. 3B is a time chart in which the torque of the electric motor 14 corresponding to the time shown as the horizontal axis is shown as the vertical axis. FIG. 3C is a time chart in which the torque of the internal combustion engine 11 corresponding to the time shown as the horizontal axis is shown as the vertical axis.
[0048] As illustrated in FIGS. 3A and 3B , when the condition, where the absolute value of the rotational speed (r.p.m.) of the electric motor 14 is equal to or less than the predetermined rotational speed A and where the torque (Nm) of the electric motor 14 is equal to or more than the predetermined torque B, lasts for the predetermined period C (sec) or more before a time t 1 , it is determined that the current is concentrated in the inverter 15 and the inverter 15 transmits, to the HV-ECU 21 , the current concentration determination flag indicating that the current is concentrated.
[0049] Note that the internal combustion engine 11 stops or is in the idling state, the hybrid vehicle 1 runs by the driving force of the electric motor 14 , and the clutch 12 is disengaged at the period C.
[0050] When the current concentration determination flag has been transmitted to the HV-ECU 21 , the torque control unit 52 controls the inverter 15 by transmitting a command to the inverter 15 in order to limit the torque of the electric motor 14 and then linearly narrow the torque of the electric motor 14 to a predetermined torque E during a period D (sec) from the time t 1 to a time t 3 . In other words, the torque of the electric motor 14 is limited to the torque E. In that case, at the timing when a predetermined time has elapsed from the time t 1 , the clutch 12 gets in the so-called half-engaged clutch state in which the torque of the internal combustion engine 11 is partially transmitted to the electric motor 14 , and the clutch 12 is engaged at the timing when the rotational speed of the electric motor 14 and the rotational speed of the internal combustion engine 11 synchronize with each other.
[0051] Accordingly, as illustrated in FIG. 3A , the rotational speed of the electric motor 14 increases from a time t 2 . Further, as illustrated in FIG. 3C , the torque of the internal combustion engine 11 rises during the period D (sec) from the time t 1 to the time t 3 .
[0052] The torque of the electric motor 14 that has been limited to the torque E is added to the torque of the internal combustion engine 11 after the time t 3 . This causes the vehicle to start moving with assistance. When the vehicle starts moving with assistance, the electric motor 14 assists the internal combustion engine 11 .
[0053] The limitation of the torque of the electric motor 14 is cancelled at the time t 4 when the period F (sec) has elapsed from the time t 3 when the torque of the electric motor 14 has been limited to the torque E. At the time t 4 , the electric motor 14 can generate torque exceeding the torque E.
[0054] Next, the process for limiting the torque of the electric motor 14 will be described with reference to the flowchart in FIG. 4 . In step S 11 , the inverter 15 determines whether the condition, where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and where the torque of the electric motor 14 is equal to or more than the predetermined torque B, lasts for the predetermined period C or more.
[0055] When it is determined in step S 11 that the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more, the process goes to step S 12 and the inverter 15 transmits the current concentration determination flag to the HV-ECU 21 .
[0056] In step S 13 , when receiving the current concentration determination flag, the current concentration determination unit 61 in the determination unit 51 determines that the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the time when the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more. Then, the torque control unit 52 controls the inverter 15 by transmitting a command to the inverter 15 in order to limit the torque of the electric motor 14 and then narrow the torque of the electric motor 14 to the predetermined torque E during the period D after the current concentration determination flag has been received.
[0057] In step S 14 , the clutch control unit 53 engages the clutch 12 by transmitting a control signal in order to switch the start of the vehicle to the start with assistance using the power of the internal combustion engine 11 and the power of the electric motor 14 . In more detail, during the period D after the current concentration determination flag has been received, the clutch control unit 53 controls the clutch 12 to get in the so-called half-engaged clutch state in order to partially transmit the torque of the internal combustion engine 11 to the electric motor 14 . After the period D has elapsed, the clutch control unit 53 controls the clutch 12 to get in a so-called engaged state in order to transmit all of the torque of the internal combustion engine 11 to the electric motor 14 .
[0058] In step S 15 , the period elapse determination unit 62 in the determination unit 51 reads the threshold F indicating the period F from the threshold storage unit 63 that stores the threshold in advance, and compares the elapsed time with the threshold F in order to determine whether the predetermined period F has elapsed after the torque of the electric motor 14 has been limited (after the torque of the electric motor 14 has become the torque E). When it is determined that the period F has not elapsed, the process goes back to step S 15 and the process of the determination is repeated until the period F has elapsed.
[0059] When it is determined in step S 15 that the period F has elapsed, the process goes to step S 16 . Then, the torque control unit 52 cancels the limitation of the torque of the electric motor 14 and the process for limiting the torque of the electric motor is completed.
[0060] When it is determined in step S 11 that the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the time when the torque of the electric motor 14 is equal to or more than the predetermined torque B does not last for the predetermined period C or more, the process for limiting the torque of the electric motor is completed without limiting the torque of the electric motor 14 because it is not necessary to limit the torque of the electric motor 14 .
[0061] Note that, in step S 11 , the current concentration determination unit 61 can also obtain, in real time, the data indicating the rotational speed and the torque of the electric motor 14 from the inverter 15 , and read the threshold A indicating the rotational speed A, the threshold B indicating the torque B, and the threshold C indicating the period C from the threshold storage unit 63 in order to determine whether the condition where the absolute value of the rotational speed of the electric motor 14 is equal to or less than the predetermined rotational speed A and the time when the torque of the electric motor 14 is equal to or more than the predetermined torque B lasts for the predetermined period C or more.
[0062] As described above, when the current is concentrated in the inverter 15 , the torque of the electric motor 14 is limited and the start of the vehicle is switched to the start with assistance. Thus, the inverter 15 is prevented from excessively generating heat. Accordingly, even when the hybrid vehicle 1 stops, for example, when the vehicle 1 surmounts a steep upgrade or an obstacle, constant torque can continuously be generated so that the vehicle 1 can certainly start moving.
[0063] Further, it is not necessary to enhance the heat-resistance or cooling performance of the element and it is not necessary to change the hardware.
[0064] As described above, the vehicle can certainly start moving without changing the hardware.
[0065] Further, while the computer program executed by the HV-ECU 21 is installed on the HV-ECU 21 in advance in the description above, the computer program can be installed on the HV-ECU 21 as a computer by attaching removable media recording the computer program (storing the computer program), for example, to a drive (not shown in the drawings) and storing the computer program read from the removable media in a non-volatile memory inside the HV-ECU 21 , or receiving, by a communication unit (not shown in the drawings), a computer program transmitted through a wired or wireless transmission medium and storing the computer program in a non-volatile memory inside the HV-ECU 21 .
[0066] Note that the computer program executed by the computer can be for performing the process in chronological order according to the order described herein or can be for performing the process in parallel or at the necessary timing, for example, when the computer program is invoked.
[0067] Further, the embodiments of the present invention are not limited to the above-mentioned embodiment, and can be variously modified without departing from the gist of the invention.
[0068] Although the threshold F is fixedly set in the above-mentioned embodiment, the threshold F can variably be set. For example, the A is set as the threshold of the rotational speed of the electric motor. However, a threshold A 1 lower than the A is provided. When the rotational speed of the electric motor is equal to or less than the threshold A 1 and the process reaches step S 14 , the period F can be controlled to be extended. The B is set as the threshold of the torque of the electric motor. However, a threshold B 1 higher than the B is provided. When the torque of the electric motor is equal to or more than the threshold B 1 and the process reaches step S 14 , the period F can be controlled to be extended. In such cases, one of the thresholds A 1 and B 1 can be adopted, or both of the thresholds A 1 and B 1 can be adopted. In other words, for example, (1) when the rotational speed of the electric motor is equal to or less than the threshold A 1 , the period F is extended. (2) when the torque of the electric motor is equal to or more than the threshold B 1 , the period F is extended. (3) when the rotational speed of the electric motor is equal to or less than the threshold A 1 and the torque the electric motor is equal to or more than the threshold B 1 , the period F is extended. Alternatively, the period F can be extended even longer in the case (3) than in the cases (1) and (2).
[0069] As another method to variably set the threshold F, the inclination of the road surface on which the hybrid vehicle 1 runs can be taken into consideration. For example, even though the limitation of the torque of the electric motor 13 has been cancelled, the torque is possibly limited again soon when the hybrid vehicle 1 runs on a steep upgrade. In light of the foregoing, a threshold is provided for the angle of the upgrade surface during the period F so that the period F is controlled to be extended when the angle of the upgrade exceeds the threshold. In that case, the period F is preferably extended until the angle of the upgrade is equal to or less than the threshold.
[0070] Further, when the weight of the load on the hybrid vehicle 1 is large even though the angle of the upgrade is equal to or less than the threshold, the torque of the electric motor 13 is possibly limited again soon even once the limitation of the torque has been released. In light of the foregoing, the threshold of the angle of the upgrade surface during the period F can be changed according to the weight of the load on the hybrid vehicle 1 . For example, when the load is relatively heavy, the threshold of the angle of the upgrade is changed to a smaller threshold. On the other hand, when the load is relatively light, the threshold of the angle of the upgrade is changed to a larger threshold.
[0071] Note that the quantity of the load on the hybrid vehicle 1 can be found by measuring the load of the carrier, for example, using an axle load sensor provided on the axle. Alternatively, the gross weight of the hybrid vehicle 1 can also be estimated by checking the behavior of the running hybrid vehicle 1 (for example, see JP 2004-025956 A). Further, the inclination of the road surface on which the hybrid vehicle 1 runs can be found, for example, using an inclination sensor or the like.
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Provided are a vehicle, control method, and computer program with which reliable starting is possible without modifying hardware. When a clutch is disconnected, an inverter determines whether the time period in which the absolute value of the rotational speed of a motor becomes a predetermined first threshold or less and the torque of the motor becomes a predetermined second threshold or greater has continuously equaled or exceeded a predetermined third threshold. When the clutch is disconnected and it is determined that the time period in which the absolute value of the rotational speed of the motor becomes the predetermined first threshold or less and the torque of the motor becomes the predetermined second threshold or greater has continuously equaled or exceeded the predetermined third threshold, an HV-ECU controls the motor to restrict the torque of the motor and also controls the clutch to connect the clutch.
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CROSS-REFERENCE TO PROVISIONAL APPLICATION
[0001] This Patent Application claims the benefit of Provisional Application No. 60/623,287 filed Oct. 29, 2004.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to the field of microwave and RF electronics, and more particularly to broadband hybrid structures.
[0004] 2. Related Art
[0005] A 180° hybrid is a component that provides a phase-shifted output of unbalanced RF signals. The 180° hybrid is an essential component for a multi-port vector network analyzer (VNA) that offers true differential measurement capability. Differential measurements are becoming more important due to greater use of differential components and circuits in the modern communications industry.
[0006] In order to provide a phase-shifted output, an unbalanced signal must be converted into two balanced signals that are later converted into two unbalanced output signals with equal amplitude and 180° phase shift. To create two balanced signals, a balun is typically employed. A balun is an electronic circuit component that converts an unbalanced Radio Frequency (RF) signal at an input port into a balanced RF signal at an output port. In essence a balun is an unbalanced to balanced transformer.
[0007] A balun-transformer can be implemented using a number of prior art 180° hybrid structures. A low frequency implementation can be achieved with the use of lumped components with constant reactance. The frequency range of application for this type of balun was recently extended into low-gigahertz frequencies.
[0008] Coaxial-line balun transformers have good power handling, but limited bandwidth. These devices are relatively large. As the frequency of application increases, it becomes more difficult to connect the quarter-wave sections in the coaxial-line balun circuit without introducing significant discontinuities that degrade the balun performance. The bandwidth of the best coaxial-line baluns was extended into much lower frequencies by introducing ferrite cores mounted along the outer conductor of a coaxial line. The ferrite cores present a high impedance for the common mode currents along the outer conductors of the balun sections, which corresponds to a good input to output isolation at much lower frequencies.
[0009] Due to the growing demand for ultra-broadband balanced circuits and systems in the optical communications and test and measurement industries, there is a growing demand for very broadband 180° hybrid structures that would cover frequencies from well below 1 GHz up to 40 GHz. It would be desirable to provide a single 180° hybrid structure that could operate over this entire bandwidth.
SUMMARY
[0010] According to embodiments of the present invention a hybrid electronic component (planar hybrid transformer, or differential balun) is provided that converts an unbalanced radio frequency signal at the common port into two radio frequency signals with equal amplitude and 180° phase difference at two differential ports.
[0011] The hybrid includes a coplanar waveguide at the common port. A power divider connects the coplanar waveguide to two symmetrical slot lines. In one embodiment, the slotlines are tapered from a wider slot (larger impedance) to a more narrow slot (lower impedance) toward a slotline to microstrip transition to provide a desired impedance matching. The hybrid provides transitions from the two broadband slotlines to microstrip lines in such a matter that the output RF signals have a 180° phase shift with respect to each other. The microstrip lines are formed on the substrate opposite the metalization regions wherein the slotlines are provided.
[0012] Each slotline to microstrip transition includes a loop of the slotline around a ground via connecting the microstrip to the metalization region where the slotline is formed. The slotline to microstrip transitions are done in such a manner that one of the microstrip lines is terminated to the metallization region connected to a central conductor of the input coplanar waveguide and the other microstrip line is terminated to the metallization region connected the coplanar ground plane strips. The grounding in different regions causes the 180° phase difference at two differential ports. The slotlines are terminated after the microstrip to slotline transition in a geometric opening structure formed in the metalization on the substrate to provide an open circuit. In one embodiment, the geometric structure is covered with a magnetic material.
[0013] In one alternative, one of the differential slotlines provided from the power divider is terminated in a large geometric structure without transition to a microstrip line. The large geometric structure is filled in with a thin film resistive material to form a termination. The second slotline is then provided directly as an output to a balanced port of the hybrid device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Further details of the present invention are explained with the help of the attached drawings in which:
[0015] FIG. 1 is a block diagram illustrating a 180° hybrid component according to the present invention;
[0016] FIG. 2 shows a top view of an embodiment of the 180° hybrid component in accordance with the present invention;
[0017] FIG. 3 illustrates the instantaneous electric (E) field polarities of signals carried at terminals of the power divider shown in FIG. 2 ;
[0018] FIG. 4 illustrates details of the microstrip to slotline transition of FIG. 2 ;
[0019] FIG. 5 illustrates details of the open circuit termination region connected to the slotline in FIG. 2 ;
[0020] FIG. 6 illustrates an alternate substrate for the 180° hybrid component wherein magnetic material is applied over the slotline terminations;
[0021] FIG. 7 illustrates the substrate of FIG. 2 as provided in a support fixture with connectors;
[0022] FIG. 8 shows simulation results for S 12 and S 13 measurements through a 180° hybrid device having components as shown in FIG. 2 ;
[0023] FIG. 9 shows simulation results for S 11 , S 22 and S 33 measurements through a 180° hybrid device having components as shown in FIG. 2 ;
[0024] FIG. 10 shows simulation results for phase difference measurements between S 12 and S 13 measurements made through a 180° hybrid device having components as shown in FIG. 2 ; and
[0025] FIG. 11 shows an alternative embodiment for a 180° hybrid device according to the present invention.
DETAILED DESCRIPTION
[0026] FIG. 1 is a block diagram illustrating an embodiment of a 180° hybrid component according to the present invention. The hybrid includes a common port 1 and differential ports 2 and 3 . The common port 1 connects to coplanar waveguide 10 . The coplanar waveguide 10 leads to a power divider 12 . In one embodiment, the impedance of the coplanar waveguide 10 is set at 50 Ohms. The power divider 12 in one embodiment transitions the 50 Ohms from the coplanar waveguide 10 to an impedance of 100 Ohms. The outputs of the power divider 12 are connected to two slotlines 14 and 16 . In one embodiment, the slotlines 14 and 16 are tapered to transition the 100 Ohm impedance from the power divider 12 down to 50 Ohms. The slotlines 14 and 16 pass the signal to slotline to microstrip transitions 18 and 20 . The slotline to microstrip transition passes the signal to two microstrip lines 22 and 24 .
[0027] The two microstrip lines 22 and 24 feed into the differential ports 2 and 4 . The two microstrip lines 22 and 24 are each terminated (by a connection as illustrated in FIG. 4 ) into oppositely polarized metalized areas (metalization where the slotlines 14 and 16 are formed) by the slotline to microstrip transitions 18 and 20 , thus producing a phase difference of 180° . The microstrip line 22 which feeds port 2 is terminated in the metalized area that has the same polarity as the ground plane conductor of the input coplanar waveguide 10 . The microstrip line 24 which feeds port 3 is terminated into the metalized area that has the same polarity as the central conductor of the coplanar waveguide 10 .
[0028] FIG. 2 shows a top view of an embodiment of the 180° hybrid component in accordance with the present invention. Etching on both sides of a substrate 6 making up the 180° hybrid device is shown. The solid lines represent the microstrip transmission lines connected to the differential ports 2 and 3 formed on a first side of the substrate 6 . The dashed lines represent components formed on an opposing side of the substrate 6 including: coplanar waveguide 10 (made up of center conductor 10 A and outer conductor 10 B) connected to port 1 , power divider 12 , slotlines 14 and 16 extending from power divider 12 , two slotline open circuit terminations 28 and 29 and two slotline to microstrip transitions 18 and 20 .
[0029] FIG. 3 illustrates the instantaneous electric (E) field polarities of signals carried at the coplanar waveguide and at the terminals of the power divider 12 . The slotline 16 that feeds port 3 is terminated by the open circuit 28 in a metalized area of substrate 6 . The microstrip line 24 is terminated into the metal strip connected to the center conductor 10 A. The ground plane for microstrip line 24 is electrically isolated from the metalized area connected to conductor 10 A with a large size open termination 28 which establishes the phase component for the RF signal at Port 3 The microstrip line that feeds port 2 is terminated in the metalized area that has the same polarity as the ground plane conductor of the coplanar line 10 ( 10 B). The ground plane for microstrip line 22 is electrically isolated from the metalized area connected to the conductor 10 B of coplanar waveguide 10 by a large size slotline open termination 29 which establishes the phase component for the RF signal at port 2 . This way the phase shift between the signals at port 2 and port 3 is maintained at 180° over an extremely wide frequency range.
[0030] FIG. 4 illustrates details of the microstrip to slotline transition 20 . The physical connection from the microstrip 24 to the metallization area at one side of slot 16 is made using a via 26 through the hybrid substrate 6 . The energy carried in each of slotlines 14 and 16 is coupled to the metalized pad in the microstrip lines 22 and 24 through the substrate 6 by the vias, such as 26 . To improve the transition, in one embodiment, the slotlines 14 and 16 make a 270° turn, or “spiral” under the microstrip pad around the corresponding via holes and then is abruptly terminated with an open circuit regions 28 and 29 .
[0031] FIG. 5 shows details of the slotline 16 as connected to an open circuit region 28 . The frequency bandwidth of the 180° hybrid structure is greatly expanded at frequencies below 3 GHz by optimizing the shape, size and position of the slotline open circuits 28 and 29 . In some embodiments, the optimization of the slotline-to-microstrip transitions 18 and 20 , including the slotline open circuits 28 and 29 and the remainder of the 180° hybrid structure can be performed through the use of commercially available high accuracy 3-D high frequency structure simulator software. In one embodiment a 180° hybrid can be fabricated on a 0.01 inch thick substrate.
[0032] For the substrate of FIG. 2 , the metalization layer in which the slotlines 14 and 16 are formed can be gold, copper, silver or a other desired conductive material. The metallization is etched away to form the coplanar waveguide structure 10 , power divider 12 , slotline structures 14 and 16 and slotline open terminations 28 and 29 .
[0033] In some embodiments, impedance transformation is used in one or both of the coplanar waveguide 10 and the slotlines 14 and 16 . The characteristic impedance of the balanced slotlines 14 and 16 are gradually transformed from 100 Ohms at the power divider 12 to 50 Ohms at slotline to microstrip transitions 18 and 20 by gradually reducing the width of both slots along the length of the slotlines 14 and 16 . The coplanar waveguide 10 is likewise shown gradually transitioned from the unbalanced port 1 gradually toward the power divider 12 . The impedance transformation in the power divider 12 with an unbalanced-to-balanced transformer can be accomplished by using a gradual taper in the width of metal conductors and in the width of the slots. In some embodiments a 50 Ohm coplanar structure is transformed into two 100 Ohm slotline structures. In other embodiments, the characteristic impedance of the balanced slotline structures is gradually transformed from 100 Ohms to 50 Ohms.
[0034] FIG. 6 illustrates an alternate substrate for the 180° hybrid component wherein magnetic material 30 and 32 is applied over the slotline terminations 28 and 29 . The particular type of magnetic material used to form regions 30 and 32 depends on the application requirements. Polyiron mix or a variety of ferrite materials may be applied according to the bandwidth requirements. The shape of the regions 30 and 32 and the extent of coverage over the termination regions 28 and 29 can be selected according to design requirements.
[0035] FIG. 7 illustrates the substrate 6 for the 180° hybrid component of FIG. 2 as provided in a support fixture 36 with connectors 41 - 43 . The displayed hybrid component 6 of FIG. 2 is presented only for illustrative purposes. It should be clear to those of ordinary skill in the art that any number of physical designs could be used. Components carried over from FIG. 2 are similarly labeled in FIG. 7 , as are components carried over in other figures.
[0036] FIGS. 8-10 illustrates simulation results for measurements from a 180° hybrid component in accordance with one embodiment of the present invention using components as illustrated in FIG. 2 . In FIGS. 8-9 , the magnitude vs. frequency plots are shown, while FIG. 10 provides a phase difference between port 2 and port 3 signals vs. frequency plot.
[0037] FIG. 8 provides S-parameters with transmission coefficient measurements S 12 ( 51 ) and S 13 ( 52 ) superimposed. The measurement for S 12 ( 51 ) is shown with a solid line, while S 13 ( 52 ) is shown with a dashed line. For the measurement S 12 , a signal is applied at port 1 and then measured at port 2 , while for S 13 the signal is applied at port 1 and results measured at port 3 . The magnitude is plotted in 1 dB per division from −3 dB to −10 dB, while frequency ranges from 0-40 GHz. As shown, both the plots S 12 and S 13 remain between −3.5 dB and −5.5 dB from 3 to 40 GHz. In some embodiments the frequency range of application was extended down to 900 MHz
[0038] FIG. 9 provides S-parameters with reflection coefficient measurements S 11 ( 61 ) and S 22 ( 62 ) and S 33 ( 63 ) superimposed. The reflection measurements are made by applying a signal to a port and measuring results from the same port. The measurement for S 11 ( 61 ) is shown with a solid line, while S 22 ( 62 ) is a dashed line with long dashes and S 33 ( 63 ) is a dashed line with short dashes. The magnitude is plotted in 5 dB per division from 0 dB to −25 dB, while frequency ranges from 0-40 GHz. As shown, reflection coefficients remain below −5 dB from 0-40 GHz for all of the reflection measurements S 11 , S 22 and S 33 .
[0039] The phase plot demonstrates the phase difference between port 2 and port 3 differential output signals.
[0040] FIG. 10 illustrates the simulation result plot 65 showing the phase difference for the signals S 21 and S 31 . For the frequency range of 0-25 GHz, the phase difference remains within two degrees of 180 degrees. From 0-40 GHz, the phase difference remains within four degrees of 180 degrees.
[0041] Referring to FIGS. 8-10 , it has been determined that as the frequency of the signal decreases there is a certain ratio of the diameter of open circuit circular termination 28 and 29 to the length of the slotline at which the slotline mode becomes the non-dominant mode for the propagation of electromagnetic energy along the structure. Thus, in the present embodiments, the frequency bandwidth of the 180° hybrid structure is greatly expanded at frequencies below 3 GHz by optimizing the shape, size and position of the slotline open circuits 28 and 29 in the slotline-to-microstrip transition.
[0042] FIG. 11 shows an alternate embodiment of a planar balun in accordance with the present invention. The illustrated embodiment is based on a unbalanced to balanced transformer utilized in a 180° hybrid similar to FIG. 2 with components similarly labeled. In FIG. 11 one of the slotlines 14 is terminated into tapered thin film resistive media. The resistive material is simply applied over the etched out metalization region. The resistive material value in ohms-per-square can be selected to meet design requirements. By doing so approximately 50% of the energy of input signal is absorbed by a resistor and another 50% of the input signal energy is coupled to balanced slotline 16 . The characteristic impedance of slotline 16 can be adjusted to meet any particular design requirements. The gradual tapered impedance transformer shown can be used to meet the desired bandwidth requirements. The gradual taper introduced to the resistive termination in the illustrated coplanar to slotline greatly improves the bandwidth of this structure.
[0043] Although the present invention has been described above with particularity, this was merely to teach one of ordinary skill in the art how to make and use the invention. Many additional modifications will fall within the scope of the invention, as that scope is defined by the following claims.
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A hybrid 180° microwave balun device is provided to convert an unbalanced RF signal at the common port into two radio frequency signals with equal amplitude and 180° phase difference at two differential ports. The hybrid device includes a coplanar waveguide connecting to the common port. A power divider separates the coplanar waveguide into two symmetrical slotline waveguides to carry balanced signals. Two broadband multioctave slotline to microstrip transitions constructed in a way that the microstrip lines carry 180° phase separated signals to the differential output ports.
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TECHNICAL FIELD
The present invention relates to railing systems. In particular, it relates to a railing system that can be easily attached to and removed from portable platforms, staging, risers or the like.
BACKGROUND OF INVENTION
Portable or movable railing systems are designed and used to prevent people or objects from falling off surfaces not provided with permanent barriers at the edge thereof. Such railing systems are particularly useful if they are easy and quick to set up and take down.
Portable railing systems are widely used in the construction industry, typically consisting of a plurality of vertical supports and horizontal rails. The vertical supports usually have a clamp-like base. The clamp-like base serves to secure the vertical supports at the edge of platforms, framing or flooring surfaces and usually is adjustable to fit platforms of varying thickness. The vertical supports typically carry one or more means for supporting the rope, elongated wooden members, metal tubes or the like used to form the rails.
U.S. Pat. No. 3,084,759 (to Squire) discloses a guard rail support including a stanchion, a clamping means for gripping a platform and guard rail structures. The clamping means includes a spoked nut carried by a threaded member and the clamping action is achieved by turning the spoked nut. The guard rail structures include rectangular bands for holding rails, the bands being supported by the stanchion. The rectangular bands are provided with screws having angularly offset handles. When tightened, the inner ends of the screws push the rails against the inner surface of the bands.
While the Squire patent represents an improvement in the art of securing a stanchion to floor structures or the like, and securing guard rails to a stanchion, it does not make securing and removing both stanchions and railings as quick and easy as possible. For example, a user, typically with a number of units to erect, must tighten and loosen each spoked nut and each screw, a time consuming and fatiguing process.
There are other problems associated with the Squire guard rail support. The handles of the screws used to secure the rails protrude from the rectangular bands and unintentional contact with these handles can cause personal injury, equipment damage or loosen the grip of the screw end against the rail. Another problem is that the screws will damage and split wooden rails, weakening the guard rail, reducing the number of times the rails can be reused and increasing costs. Further, the Squire device does not have a locking mechanism to insure the spoked nut does not loosen as the result of external forces such as vibrations or being hit by an object.
The clamping means disclosed in U.S. Pat. Nos. 4,669,577 (to Werner) and 3,756,568 (to Mocny et al.) are somewhat similar to the Squire clamp means in that they include a jack screw assembly, including a threaded rod and a winged nut operably coupled to the rod. Rotation of the winged nut causes the rod to travel up or down carrying clamping surfaces toward or away from a platform. Rails are inserted into square tubes (Werner patent) or brackets (Mocny et al. patent) carried by uprights and secured therein by nails, screws or the like. None of the Squire, Werner or Mocny et al. patents discloses structure for preventing the unwanted or accidental turning of the winged nut.
U.S. Pat. No. 3,747,898 (to Warren) discloses a guard rail post apparatus including a post, clamping system and rail brackets. The clamping system has a fixed jaw and a movable jaw pinned to a lever member pinned or fulcrummed to the post. The gap between the jaws can be adjusted by selectively repositioning the lever member relative to the post and tightening a threaded driving member carried by the lever member against the post. Rails laid in the rail brackets are secured therein by driving nails into the rails through holes in the brackets. U.S. Pat. No. 3,480,257 (to Bourn et al.) discloses a somewhat similar arrangement.
In the Warren and Bourn et al. designs, in order to adjust the gap between the jaws a pin must be removed, then the lever member is moved to an alternative position on the post and repinned. This is time consuming and if the pin is misplaced or dropped and not recovered the guard rail post is unworkable. Further, the Warren patent does not disclose a rail bracket to which rails can be secured and removed quickly and easily.
U.S. Pat. No. 3,938,619 (to Kurabayashi et al.) discloses a stanchion or supporting post for use with railing systems. The stanchion includes a clamp-type base, and is telescopically adjustable for setting the general distance between the upper and lower parts of the clamping means. To complete the tight mounting of the stanchion, a tool is required to turn a bolt.
U.S. Pat. No. 2,905,445 (to Blum) discloses a clamping means for mounting rails to wall brackets or posts wherein a rail is secured to the clamping means by drawing an outer cylindrical member towards an inner cylindrical member by tightening a screw that passes through the cylindrical members. Although the Blum patent represents an improvement in the art of securing rails to vertical supports, it does not adequately address the need to secure rails quickly and easily, and a tool is required to ensure the clamp is tightened adequately.
While the above-cited prior art discloses adaptations in portable railing systems that improve stability and make the components easier to set up and take down, one inadequately addressed problem is that it is time consuming to screw or nail each rail in or against a bracket or the like. It would be advantageous if rails could be secured in and removed easily and quickly from a bracket in one simple operation and without using tools. A related problem is that the rails are damaged by prior art railing systems, diminishing the safety of the railing system and increasing costs.
The prior art clamps for securing a vertical support to platform, framing or flooring surfaces are designed with tightening mechanisms, such as wing nuts, threaded screws or threaded bolts, that carry or force clamping surfaces toward each other. Such tightening mechanisms present at least two disadvantages. First, it is difficult to apply sufficient torque to obtain adequate clamping force without using a tool. Even if wings or extensions (e.g., on a nut) are provided, the length of such extensions is limited because the extensions must clear adjoining structures and, because the length is limited, an individual installing the device will be unable to exert sufficient torque to ensure a secure hold without using a tool.
Second, in railing systems that have clamps with tightening mechanisms with extensions to assist a user in tightening the clamp, clothing or equipment may be snagged on the extensions. Such contact could injure a person or damage equipment. Equally serious is the possibility that the tightness of the clamp and the integrity of the railing could be compromised. It would be advantageous to have a clamp tightening mechanism that produces sufficient clamping force with relatively little effort, yet has no exposed extensions when clamped in place. Ideally, such a tightening mechanism would be resistant to vibration and accidental blows.
Another problem in the prior art is that the clamp adjustment structures and methods used to vary the gross distance between two platform gripping surfaces involve removing and replacing a pin. In addition to the time required to perform this operation and the need to use tools to remove pins, cotter keys or the like, the pins themselves could be misplaced, making the unit inoperable. It would be advantageous to be able to adjust the distance between clamp components or gripping surfaces without disassembly and without using tools.
Clearly, there is a need for an efficient, portable railing system that can be erected quickly and easily, maximizes safety, and complements portable staging platforms and the like.
SUMMARY OF THE INVENTION
The present invention provides an adjustable, portable railing system for use with raised portable staging platforms or the like. The railing system broadly includes a plurality of generally horizontal rails and generally vertical rail uprights for supporting the rails. The rail uprights include a standard carrying at least one railing bracket, a platform clamp mechanism and a platform clamp operating means.
The elongated post-like standard has a generally central longitudinal axis, an upper crown end and a lower base end. The crown end supports the railing bracket and the base end is associated with the platform clamp mechanism. The uppermost portion of the standard angles slightly away from the axis of the standard whereby the crown end is offset relative to the base end.
The clamp mechanism adjacent the base end of the standard includes a top or upper fixed jaw and a lower movable jaw. The top jaw is fixedly attached adjacent the lower end of the standard, and the floating, movable jaw is operably connected to the operating means. When the clamp is closed, (i.e., when the jaws are relatively close together) the compressive force of the fixed and movable jaws on the staging platform holds the standard in a rigid, generally upright, vertical position. The jaws of the clamping mechanism can be modified to include tabs, serrations, projections, or the like, that will engage platform perimeter frames or cladding to further lock or secure the uprights in place.
The clamp operating means includes a generally U-shaped lever movable between closed and open positions and a tubular link member having two ends. One end of the lever is pivotally connected to the standard at a pivot joint and to the first end of the link member, which depends therefrom and is generally parallel to the standard. The other, free end of the lever is movable through a short arc into close proximity to and away from the standard. The movable jaw is connected to the link at the second link end. The link is slidably guided in an aperture in the fixed jaw so it remains closely adjacent and parallel to the standard. When the free end of the lever is close to or abutting the standard, the clamp is closed and locked. The lever is secured in the closed position by a releasable spring-loaded locking mechanism. An adjustment member for adjusting the distance between the fixed and movable jaws is carried at the extreme end of the link, under the movable jaw.
A railing bracket is attached to the uppermost end or crown of the standard, and extends generally perpendicularly therefrom. The bracket comprises a pair of spaced parallel flanges attached to opposite sides of the standard. The uppermost edge of each flange is identically relieved or scalloped in two places to receive and complement two rails. The ends of a C-shaped band, the band being as wide as the space between the flanges, are mounted between the flanges. The middle portion of the band is flat, generally above and parallel to the scalloped edges of the flanges. A bracket operator is mounted in apertures adjacent the ends of the band. The operator is a continuous rod having an elliptical portion with two flattened sides between the ends of the band, and has a handle portion at one end. The handle is outside one end of the band and at an obtuse angle to the elliptical portion.
The present invention also encompasses a modified form of the bracket wherein the bracket operator is replaced by a plurality of resilient, deformable wafers sandwiched between the flanges. The wafers have relieved areas or scallops that substantially conform to the rails, but are slightly smaller and have lip edges through which the rails must be forced.
In using the railing system of the present invention, a standard is positioned at an edge of a platform with the underside of the upper jaw resting on the upper platform surface. With the lever of the clamp operating means, and thus the clamp, in the open position, i.e., with the free end of the lever spaced from the standard, the adjustment means associated with the clamp, specifically, with the link member, is used to adjust the gripping space between the jaws approximately to the thickness of the platform. The clamp operating lever is then moved to its closed position abutting the standard, pulling the movable jaw upwardly into contact with the underside of the platform, and fixing the standard in place. Rails are slid into the railing bracket and the bracket operator is closed to lock them in the bracket.
It is an object of the present invention to provide a railing system for use with portable platforms, staging, risers, or the like.
It is another object of the present invention to provide a portable railing system including a substantially rigid, strong upright carrying a base clamp and clamp operating mechanism whereby the upright can be removably mounted on a platform.
Yet another object of the present invention is to provide a railing system including an upright or standard carrying a platform gripping base clamp and a clamp operating mechanism, wherein base clamp includes a fixed jaw and a movable jaw and wherein the gripping space between the jaws is adjustable.
Still another object of the present invention is to provide an upright baluster or standard for supporting at least one generally horizontal, elongated rail, wherein the standard is removably mounted at the edge of a platform or the like and carries a rail receiving bracket adjacent its uppermost end.
A further object of the present invention is to provide an effective rail barrier for portable staging or the like that maximizes safety and complements the staging, yet is easily installed, removed, transported, and stored.
One of the features of the present invention is that the lower, movable jaw of the platform clamp carried by the standard is operably linked to a relatively long clamp operating lever pivotally connected to the standard and generating significant mechanical advantage, whereby substantial gripping force can be applied to the platform with relatively little effort by the individual clamping the standard in place. An associated advantage of the present invention is that the clamp operating lever abuts, rather than extends away from, the standard when the platform clamp is closed.
Another feature of the present invention is that the rail bracket and the bracket operating means enable the user to insert rail members quickly and easily into the brackets, yet secure the rails in place simply by turning the bracket operator handle through a quarter turn. An advantage associated with the bracket operator is that when the rails are locked in the brackets, the operator handle is abutting or immediately adjacent to the standard.
Other features and advantages of the railing system of the present invention include that it is lightweight and can be adapted to many staging configurations, that one or more rail brackets can be attached to a single standard, that the platform clamp operating lever is held closed by a releasable safety latch means, and that installation and removal of, and all adjustments to, the system are accomplished without removing and replacing discrete pins or the like, and without using tools.
Other objects and advantages of the railing system of the present invention will be understood with reference to the following specification and appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention.
FIG. 2 is a fragmentary side elevation view of the present invention, depicting the base clamp mechanism and operating lever.
FIG. 3 is a fragmentary rear elevation view, depicting the bottom jaw and adjustment member.
FIG. 4 is a fragmentary sectional view taken along line 4--4 of FIG. 2, and depicts the latch pin mechanism of the present invention.
FIG. 5 is a sectional top plan view taken along line 5--5 of FIG. 2, and depicts the jaw link member, the standard and the lever member.
FIG. 6 is a perspective view of an alternative embodiment of the present invention with a second railing bracket mount in use.
FIG. 7 is a fragmentary perspective view of a rail corner assembly.
FIG. 7a is a cross section taken along line 7a--7a of FIG. 7, and depicts the locking mechanism used in association with the railing bracket.
FIG. 7b is a cross section taken along line 7b--7b of FIG. 7, and depicts the locking mechanism used in association with the railing bracket in an unlocked or open position.
FIG. 8 is a fragmentary side elevation view, depicting the second or middle railing bracket for use with a multiple railing embodiment of the present invention.
FIG. 8a is a cross section taken along line 8a--8a of FIG. 8.
FIG. 9 is a top plan view of a false flooring platform with the present invention erected along three sides of the platform.
FIG. 10 is a front elevational view of a false floor platform with the present invention erected along three sides of the platform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the rail system 12 of the present invention includes a standard 14, a rail bracket assembly 16, a base platform clamp assembly 18 and an operating linkage 20. The system broadly also may include rail members 150 formed of elongated materials such as metal tubes, wood timbers, rope or the like.
The standard 14 and the operating linkage 20 each have a generally central longitudinal axis depicted at lines A, A', respectively, and the rail system 12 is designed so that the axes A, A' are generally parallel and close together.
The standard 14 is a generally rectangular, rigid, unitary member having front, back and lateral sides, 22, 24, and 26, 27, respectively. The designation of front, back and lateral reflect the position of the sides 22, 24, 26, 27 of the standard 14 relative to a stage platform panel 30 when the standard 14 is attached thereto as depicted in FIG. 2. The back side 24 of the standard 14 is generally coplanar with the metal perimeter molding 32 of the platform panel 30 and the front 22 and lateral sides 26, 27 are supported over the platform 30. When secured to the stage platform panel 30, the standard 14 is generally vertical from its base end 28 to a point generally adjacent to or above midway between the base end 28 and crown end 29. In the preferred embodiment, at a point generally adjacent the crown end 29, the standard 14 is slightly angled whereby the crown end 29 of the standard 14 is offset from the base end 28 and over the stage platform panel 30.
The base clamp assembly 18 includes a top jaw 40 and a bottom jaw 50. The immovable top jaw 40 is a generally trapezoidally shaped plate rigidly attached to and extending outwardly from all sides of the standard 14. The top jaw 40 is generally adjacent to, but spaced from the base end 28 of the standard 14. The jaw 40 has a blunt apex 42 and a base 44. A generally rectangular aperture 46 is adjacent the back side 24 of the standard 14 in the blunt apex area 42 of the top jaw 40. As depicted in FIG. 2, in the preferred embodiment the forward or base edge 44 of the top jaw 40 bends back over itself forming a continuous brace flange 48 that extends toward and is rigidly attached to the front side 22 of the standard 14. The underside or inside surface 49 of the top jaw 40 is the upper, platform contacting or biting, gripping surface for the base clamp assembly 18. FIG. 1 depicts a modified form of the top jaw 40 without a flange 48.
The bottom jaw 50 consists of two L-shaped cheeks 52, 53 rigidly attached to a C-shaped housing 54. The cheeks 52, 53 are spaced and parallel, and each includes a tine 56, 57. The tines 56, 57 provide the platform contacting, lower gripping surface 58, 59 for contacting the underside of the platform or perimeter base 34. As depicted in FIGS. 1 and 3, the C-shaped housing 54 has generally rectangular upper and lower apertures 60, 61, respectively, for operably connecting the bottom jaw 50 to the operating linkage 20. Referring to FIGS. 1 and 3, the apertures 60, 61 are located substantially equidistantly from the outside edges 64, 65 of the housing 54. Referring to FIG. 1, an angled trap tab 66 protrudes from inside the upper end of the housing 54, at the edge thereof nearest the gripping surface of the top jaw 40.
The operating linkage 20 includes a jaw link member 70 having a lever end 72, a free end 74, and a generally central longitudinal axis A'. The linkage 20 also includes the generally rectangular, flat adjustment sole plate 76 and a bite adjustment member 78. Referring to FIG. 2, the jaw link 70 is a generally rectangular, rigid, unitary member having front, back and lateral sides, 80, 82, and 84, 85, respectively, being substantially similar to the standard 14 in cross-section, as seen in FIG. 5, but relatively shorter, approximately one-third the length of the standard 14, as seen in FIG. 1. The axes A', A of the jaw link 70 and the standard 14, respectively, are parallel and the front side 80 of the jaw link 70 abuts the back side 24 of the standard 14. The jaw link 70 is pivotally connected to the lever 17 at a jaw link joint 86 and extends immediately adjacent and along the standard 14 through the aperture 46 in the top jaw 40. The jaw link joint 86 is formed by a pin 87 received in apertures adjacent the lever end 72 of the jaw link and the lever 17, being secured in place with a press-on lockwasher 89. The link 70 extends through the apertures 60, 61 in the bottom jaw 50 and terminates at its free end 74 where the adjustment sole plate 76 is fixedly carried. The link 70 operably connects the lever 17 with the bottom jaw 50.
Referring to FIG. 3, the adjustment sole plate 76 has a threaded aperture 90 adjacent one corner for receiving the threaded bite adjustment member 78. One end of the bite adjustment member 78 contacts the bottom or underside of the bottom jaw 50. The other end of the member 78 has a hexagonal head 92 that provides a gripping surface for facilitating turning the bite adjustment member 78.
With reference to FIGS. 1, 2 and 5, the platform clamp operating lever 17 is slightly shorter than the jaw link 70 and is pivotally connected to the standard 14 at a fulcrum joint 100, generally horizontally coplanar with and adjacent to the jaw link joint 86. The fulcrum joint 100 is formed by a pin 101 received in apertures in the standard 14 and the lever 17, being secured in place with a press-on lockwasher 103. The lever 17 extends upwardly from the fulcrum joint 100 toward the crown end 29 of the standard 14. The lever 17 is a generally U-shaped unitary member having a spine 102 and a pair of parallel, triangularly-shaped side shoulder flanges, 104, 105.
The spine 102 has a relieved area or notch 106 adjacent its lower end 108. Referring to FIG. 2, the shoulders 104, 105 substantially envelop and abut the rear and lateral sides 24 and 26, 27, respectively, of the standard 14 when the lever 17 is in its closed position, the lower and upper ends 108, 109 of the spine 102 being substantially flush with the standard 70 and jaw link 14, respectively. The notch 106 allows the upper, free end 109 of the lever 17 to pivot away from the standard 14 to its open position, depicted in phantom.
With continued reference to FIG. 2, a pin latch hole 110 is located in one shoulder 104 at the upper end 109 of the lever 17. A flared, handgrip area 112 for receiving a user's fingers or thumb is at the upper end 109 of the lever 17 adjacent to the latch hole 110.
Referring to FIG. 4, the standard 14 carries a lock 120 for the lever 17. The lock 120 includes a latch pin 122 that protrudes through an aperture 124 in the standard 14 and the latch pin hole 110. Adjacent to and vertically in-line with the latch pin 122 is a latch operating button 126. The latch button 126 protrudes through a hole 128 in the standard 14 just beyond the end of the lever 17.
Both the latch pin 122 and latch button 126 are attached to a springsteel leafspring 129 mounted within the interior of the standard 14. The leafspring 129 is of sufficient strength to bias both the latch pin 122 and latch button 126 outwardly through their respective holes 124, 110, 128 but is sufficiently supple so as to allow the user to depress the latch button 126 with a finger, whereby the spring 129 carries or retracts the latch pin 122 out of the latch hole 110 releasing the lever 17 for movement.
Referring to FIG. 1, the rail bracket assembly 16 includes a pair of parallel side flanges 130, 131, an overstrap band 132 and rod-like clamp operator 134. Each flange 130, 131 is rigidly attached to and generally coplanar with one side 26, 27 of the standard 14 adjacent the crown end 29 of the standard 14, and each has two arcuate scalloped grooves or rail nests 136, 137, and 136a, 137a along its upper edge. The flanges 130, 131 extend generally perpendicularly outwardly relative to the front side 22 of the standard 14, the grooves 136, 137, and 136a, 137a forming a nesting surface to complement the shape of the rails 150.
Referring to FIG. 7, the overstrap band 132 is a solid, unitary, generally C-shaped band rigidly attached along its side edges adjacent its ends 133, 135 to the inside surfaces of the flanges 130, 131. The flanges 130, 131 and the overstrap 132 define an enclosed rail receiving area. The overstrap 132 has an aperture 138, 139 at each end generally midway between its side edges.
As depicted in FIGS. 1, 7, 7a and 7b, a clamp operator 134 comprising a trunnion rod 140 having a handle 142 and an elliptical cam area 144 is received in and supported by the two apertures 138, 139 in the overstrap 132, being secured in place with a press-on lockwasher 146. The handle 142 is angled so that the axis B of the handle 142 and the axis B' of the standard 14 at the crown end 29 are substantially parallel to each other when the trunnion rod 140 is rotated to the point where the distance between the inside surface of the overstrap 132 and the cam area 144 is most greatly reduced, as depicted in FIG. 7a. This is the locked position. As depicted in FIG. 7b, when the trunnion rod 140 is turned to the point where the distance between the inside surface of the overstrap 132 and the cam area 144 is the greatest, the axis B of the handle 142 is substantially perpendicular to the axis B' of the standard 14 at the crown end 29.
A modified dual rail form 212 of the present invention is depicted in FIGS. 6, 8 and 8a. A modified, second rail bracket assembly 216 includes two side plate flanges 230, 231 and eight resilient wedge wafers 240. The flanges 230, 231 are attached to the standard 14 and the wafers 240 are mounted between the flanges and secured by screws 232. The flanges have relieved upper edges 234, 235 and the grooves, scallops or arcuate recesses 242, 243 of the wafers 240 have lips 244. The recesses 242, 243 of the wafers 240 are sufficiently deep so that when a rail 150 is pressed past the lips 244 into a recess 242, the scalloped recess 242 extends around over one-half the circumference of a rail 150.
FIG. 6 depicts a modified corner rail 250 incorporating a box frame 252 adjacent the junction end 254 of the corner rail 250 used to construct corner junctions. The box frame 252 is a generally square member having two horizontal sides 256, 257, two vertical sides 258, 259, and two open ends 260, 261. The designation of horizontal and vertical reflect the position of the box frame sides 256, 257, 258, 259 relative to a horizontal stage platform 30 when the modified corner rail 250 is held in a rail bracket assembly 16 of a standard 14 attached thereto. The junction end 254 of the corner rail 250 includes a stub rail end 262 rigidly attached to one vertical side 259. The two open ends 260,261 define a rail receiving area slightly larger than the dimensions of a rail 150.
In use, before placing the rail system 12 on a staging platform panel 30, the adjustment member 78 located in the adjustment plate 76 is turned, backing the adjustment member 78 away from the bottom jaw 50 until the bottom jaw 50 comes to rest on the adjustment plate 76, providing maximum space between the jaws 40, 50. The adjustment member 78 will still be retained in the threaded aperture 90 in the adjustment plate 76.
Referring to FIG. 2 and 4, the platform clamp 18 is opened by depressing the latch button 126 in the direction of arrow N to free the latch pin 122 from the lever 17. The free end 109 of the lever 17 can then be pulled away from the standard 14 until fully opened (as depicted in phantom in FIG. 2).
Once the platform clamp 18 is open, the rail system 12, specifically, the gripping surface 49 of the top jaw 40, is placed on the surface of the stage platform panel 30 and the rail system 12 is pushed inwardly until the perimeter frame molding 32 and the metal perimeter base 34 contact the jaw link 70 and bottom jaw 50, respectively. The adjustment member 78 is turned to move the bottom jaw 50 toward the perimeter base 34 until the platform contacting surfaces 58, 59 of the tines 56, 57 are about one-half inch from the platform metal perimeter base 34.
Next, the lever 17 is moved toward the standard 14 (in the direction of arrow G in FIG. 2), drawing the bottom jaw 50 up toward the top jaw 40, the direction of movement of the bottom jaw 50 being depicted by arrow J, thereby pressing the stage panel 30 between the two jaws 40, 50. In addition to the compressive force exerted by the jaws 40, 50, the trap tab 66 engages the depending skirt 36 to assist in firmly securing the standard 14 to the stage platform panel 30.
The lever 17 is pushed or moved toward the standard 14 until the latch pin 122 engages the latch hole 110. The flared area 112 provides a leading edge that assists driving the latch pin 122 into the standard 14. When the lever 17 reaches its fully closed position, the spring 129 drives the latch pin 122 into the latch hole 110 (in the direction of arrow O in FIG. 4), thereby locking the lever 17 securely to the standard 14.
After the rail systems 12 have been secured to the panels 30 as outlined above, rails 150 can be inserted in the bracket assemblies 16. First, the clamp handle 142 is turned to rotate the cam area 144 of the trunnion rod 140 to the open position depicted in FIG. 7b. Referring to FIG. 1, a rail 150 is inserted and rests in one set of the scalloped rail nests 136, 136a. Another rail 150a, extending 180° away from the first rail 150, is placed in the second set of rail nests 137, 137a. The second ends of the two rails 150, 150a are similarly supported in adjacent brackets 16. Ideally, the rails 150 should be positioned with their ends extending equidistantly through the bracket assemblies 16.
After the rails 150 have been placed, the handle 142 is turned to rotate the trunnion rod 140 bringing the rounded portion of the elliptical cam area 144 into contact with the lower surface of the rail 150 (as depicted in FIG. 7a) and pressing the rails 150 against the overstrap 132, binding them firmly in place. An advantage of the present invention is that a user is able to secure the rails 150 within the brackets 16 by simply moving the handle 142 in a short arc with one relatively short continuous hand movement.
FIGS. 9 and 10 are pictorial views of a false floor or stage platform 300, constructed from panels 302, with the portable railing system 12 of the present invention erected along the sides of the platform 300. FIG. 9 is a top plan view of the staging platform 300 with steps 304, the portable railing system 12 being placed along three sides of the staging platform 300, and rails 150 and corner rails 250 interconnecting the standards 14 to provide a continuous edge barrier. FIG. 10 is a front elevational view of the platform 300 and portable railing system 12 shown in FIG. 9. It should be understood that FIG. 9 and 10 are presented for illustrative purposes, depicting one example of a platform or the like with which the present invention may be used.
In the preferred embodiment, the components of the present invention, including the standards 14, the railing brackets 16, the platform clamp assembly 18 and the operating means 20 may be formed from suitable gauge steel. The wafers 240 for the second bracket assembly 216 may be made of ABS plastic. Typical rails 150 have a 1.250 inch outside diameter and are formed from 14 gauge tubing steel. Other appropriate materials, such as aluminum or plastic, may be used for any of the components.
The length, diameter and shape of the rails 150 can vary, but a preferred length is from three to eight feet. The spacing between the standards 14 can be varied, but typically the rails 150 will overlap at each standard 14 to form a continuously extending barrier at a platform edge. One or more modified rail bracket assembly 216, or an equivalent thereof, may be located anywhere along the length of the standard 14 as long as the operation of the lever 17 is not impaired. At lower places on the standard 14, the second rail bracket 216 supports rails 150 acting as a lower chair stop.
Although a description of the preferred embodiment has been presented, it is contemplated that various changes, including those mentioned above, could be made without deviating from the spirit of the present invention. It is therefore desired that the present embodiment be considered in all respects as illustrative, not restrictive, and that reference be made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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The present invention provides an adjustable, portable railing system for use with raised platforms or the like. The railing system broadly includes a plurality of generally horizontal rails and generally vertical uprights for supporting the rails. The uprights include a standard carrying at least one railing bracket, a platform clamp mechanism and a platform clamp operator. The elongated post-like standard has an upper crown end, a lower base end and a generally central longitudinal axis. The crown end supports the railing bracket and the base end is associated with the platform clamp mechanism. The platform clamp operator has a generally central longitudinal axis that is closely adjacent and substantially parallel to the axis of the standard.
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This application claims the benefit of provisional application Ser. No. 60/197,346 filed Apr. 14, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to methods and apparatus for separating water borne residuals created during the high pressure waterjet cutting of material in nuclear reactors and more particularly to a rapid process for continuously and rapidly removing same when using particulate matter in the Waterjet cutting such as garnet.
2. Description of the Prior Art
The waterjet cutting process when used in nuclear reactors uses an approximately 50,000 psi water stream which includes a small amount of particulate shot material such as garnet pellets to assist in the waterjet cut through the stainless steel or any other metal encountered in the reactor. Garnet is a form of silicate with traces of iron, aluminum as well as other possible trace elements such as chrome, magnesium, calcium, manganese and titanium. The typical chemical formula for garnet is: A 3 B 2 (SiO 4 ) 3 , where A=iron, manganese, calcium or magnesium and B represents elements such as aluminum, iron, chromium or titanium. The waterjet garnet is substantially fractured by the high-pressure impact of the garnet on the cut stainless steel of the reactor. This results in a variety of particle sizes from less than 1 micron to about 300 microns.
Due to the high energy fracturing of the garnet during the waterjet cutting the creation of very small colloidal particles of garnet was seen. This is true for other particles used in Waterjet cutting such as stainless steel and others, although the amount of such created colloids may change. During this process Si(OH) 4 is created which, due to its chemistry (and the approximate neutral carrying water) the presence of charged hydroxyl complexes such as: (HO) 3 SiO are allowed. These bear a negative charge. This negative charge is a universal problem when particle removal from water is desired. Further, the creation of other typical very small colloidal particles of less than 10 microns that may have a variety of SiOx structures will also bear a negative net charge. Colloids are any particles, by definition, between about 0.005 and 10 microns in size, regardless of their chemical or biological composition.
A universal property of water borne colloidal silica, in neutral to near neutral pHs, is that they will bear a negative charge. This negative charge, combined with the small size creates a substantial particle removal problem.
Although colloidal particles are small, they have a very large surface area which permits the colloid to scatter light far beyond what might be suggested by its mass. The surface area value for the “typical particle” is in the range of 250-350 square meters per gram. This results in a very, very low quantity of colloidal silica causing significant turbidity (light scatter and failure to pass light) in any colloidally contaminated water. It has been found that the waterjet process water even when filtered through a 1 micro filter will still absorb over 98% of 400 nano-meter light at a distance of 5 feet in depth.
Another feature of the small mass of each colloid particle is that its electric charge (negative) to its mass is quite high. This high charge allows colloidal particles to repel other particles vigorously and, hence, hinders efficient removal or filtration or centrifuging (hydro cyclones, cyclone separators and centrifuges).
The negative charge is measured in a known manner using a Zeta potential meter. Typical waterjet cutting polluted reactor water was tested to have a value of between minus 20 and minus 40. An acceptable value for treated and filtered water is minus 5 to plus five as published by the Zeta meter manufacturer.
When “un-charge neutralized” colloidal particles are trapped in or on a filtering surface, the repulsion energy grows quickly. The net result is that the filtering surface is quickly “plugged” with a very low mass, but which mass also has a high repulsion energy to the acceptance of any more negatively charged mass in the water. Also, some colloidal particles, which remain uncharged or are neutralized, will not be filtered out at all, even with a 0.5 micro filter, and will pass into the filtrate causing turbidity.
When untreated colloidal particle filtration continues for a brief time, the bulk of the suspended mass in the water, which is non charged, cannot be efficiently filtered from the water due to premature filter plugging by the negatively charged colloidal particles. Experiments showed that process water that was even first passed through a cyclone separation continued to rapidly plug down field 3M filters of both 3 micron and 1 micron. This is due to the retained colloids and negative Zeta potential of the water.
The problem is further exasperated by the fact that the spent cutting water from the reactor also contains metal fines or what is referred to as swarf. None of these particles are colloidal. But, a very small amount is fractured by the waterjet process into a colloidal state. This occurs because about 0% of the suspended_stainless swarf, by weight, is fractured so vigorously into small particles that the chromium and nickel from the steel is forced into solution. Colloidal particles of metal are likely to be in a hydrated form similar to the hydrated/ionized silica and hence would contribute to the negative repulsion of the spent water stream.
This generation of fractured garnet and metal particles, during waterjet cutting in nuclear reactors that are less than 1 micron is size creates a huge problem in that prior art normal filtration is seriously hindered. In order to remove these very small particles, a very fine filter is required even though the overwhelming mass of the residuals are large enough to be trapped by a relatively high capacity corrugated depth filter such as a 2-10 micro fabric or a paper filter.
The very fine particles require fine filters, which by definition have a far lower capacity than a crasser filter. The use of fine filters leads to a very high generation of filter body waste, all of which will also be highly radioactive and thus extremely costly to dispose of.
The very fine, colloidal, particles further retard typical filtration because they are very negatively charged, repelling each other, leading to even a faster decline in filtering capacity and yet producing an even higher quantity of “dead” filters. This phenomena was confirmed through testing. During testing, fine filters were clogged in less than ten minutes with a fraction of the solids loading normally observed. Thus it was seen that the particle distribution for the whole body of total suspended waterjet particles in the process water, being from less than 1 micron to about 300 microns, is in a range that is totally unsuitable for mechanical separation with any level of efficiency.
It should be noted that during our testing, untreated process water was subjected to both a Krebs hydro cyclone and a Lykos liquid solids separator. Neither method could provide a removal efficiency, on average, of even 50%. This was due to the small negatively charged particles and the large negative Zeta potential of the water. Treatment of the waste water prior to mechanical separator treatment indicated some potential in substantially improving this mechanical method, but with treatment costs included, other methods of residual removal indicated much less expensive potential.
All the mentioned treatment systems were slow and inefficient and totally inappropriate to meet the needs for rapid removal of the pollutants within less than a minute and preferably within seconds.
In order to rapidly remove the waterjet residuals from the process water within the mentioned time factors, some form of traditional pre-filtration chemical treatment seemed to be required.
Properly treated nuclear reactor water needs a treatment and collection system, which will rapidly (within seconds) achieve the following required points:
a bulk solids in water separation efficiency of 98%+
the addition of any treatment solids requires minimization
high radioactivity due to the metal swarf needs a robust treatment system that will function under water
the process treatment system has to function at 1,000 gallons per minute.
the space available for treatment equipment is very restricted.
To achieve these goals mechanical separation techniques were evaluated but were found completely unsatisfactory.
The known mechanical technology used to remove turbidity and color from waters of all kinds has been established in the United States since early in the twentieth century. While there are a variety of approaches they all involve some variation of the following steps:
Coagulation
Flocculation
Sedimentation or Settling
Final Filtering.
These techniques are defined as follows:
Coagulation is the process of removing the negative, repulsive charge on the smallest particles that create the turbidity and filtering problems of premature filter clogging. Classically, this is done with either +3 charged aluminum or plus 3 charged iron salts. In more recent times, in circumstance the will allow for the extra cost, or where low turbidity exits, organic cationic polymers are used to reduce the negative charge (Zeta potential) of the water. Once the charge has been removed, the very small particles can begin to agglomerate into larger particles. This aids direct filtration as well as settling.
Flocculation aids the pace at which the very small charge neutralized particles will clump into bigger particles, large organic molecules called flocculants are used. There a great many of them and some work better than others on any particular water. These agents bridge between particles aiding in more rapidly getting them into filterable, settleable sizes.
Settling is defined as the time it takes to adequately coagulate and flocculate water in order for it to self-settle into clear treated decantable water is hours, days or even weeks. However, in cases where there is not sufficient room to store large quantities of treated water, awaiting settling to clarity, filtration is used after a period of reaction between the coagulants, flocculants and the waste water. Depending upon the level of turbidity, this period is widely considered to, be between ˜15 minutes and several hours.
Water that has been treated by the previous steps can be readily filtered. This is typically done using rotary vacuum filters with blade scrappers or plate and frame pressure filters. Very slightly turbid water may, in some instances, simply be treated using sand and granular activated carbon (GAC) back-washable filters. Highly turbid waters are seldom if ever final filtered in this way.
Because of the reasons presented above, simple, direct filtration of highly charged water, such as the waterjet water, does not work from a practical point of view. Experience at the Framatome Mill Ridge testing facility during 1999 proved this point. Even filtration using some fine filter precoating did not work. These results are anticipated by the nature of the waterjet process and the resultant water quality, which by American Water Works Association falls into the highest class of 3 classes of turbid water.
Certain U.S. Patents teach processes for treating reactor water. These patents are as follows:
U.S. Pat. No. 6,156,194 teaches a method of treating reactor water that is contaminated with both radioactive metal cutting fines that come from the reactor and non-radioactive waterjet cutting particles that come from the waterjet cutting process.
The separation method taught is to magnetically filter the magnetic metal cuttings from the non-magnetic garnet waterjet particles to thus separate the two and subject the two streams to filtration that can produce recyclable reactor water.
This patent does not address the problems posed by colloidal particles produced by the garnet particle waterjet process and there is no indication therein that this process can rapidly remove these particles within seconds.
U.S. Pat. No. 5,637,029 teaches a method of recovering desired size abrasive shot material from a slurry recovered from a liquid—abrasive blast cleaner apparatus. The slurry is filtered for different size shot to recover usable materials.
Again, this patent does not address the problems posed by colloidal particles produced by the garnet particle waterjet process and there is no indication therein that this process can rapidly remove these particles within seconds.
A careful review of both of the above patents shows that it is known to remove the metal cuttings and garnet from the water in a reactor in which a waterjet cutting operation using garnet was used. However, the known removal method uses magnetic filters to separate the metal cuttings from the garnet particles. A filtration of the water slurry for collecting desired size particles is also shown. However, none of these patents recognize the problem of rapidly treating, within seconds, colloidal, negatively charged particles of both particles such as garnet and metal cuttings, swarf, to provide clean turbidity free recyclable reactor water, Also, the processes described therein do not teach any systems that will optimally remove the negative charge on the colloidal suspensions nor any optimized chemicals and their composition to flocculate them into larger particles making a special mechanical filtration feasible.
Thus a rapid process for processing water from a nuclear reactor contaminated by waterjet particles such as garnet particles and metal cuttings formed as colloidal suspensions of metal cutting particles and swarf to an acceptably clean level within seconds was sorely needed.
SUMMARY OF THE INVENTION
The present invention solves the problems associated with prior art processes and others by providing a rapid method and apparatus for cleaning very small colloidal material from the abrasive material used in waterjet cutting (such as gamet) and metal particles from a cut reactor section. Both are found in the reactor water after a high-energy waterjet cutting of metal such as stainless steel using abrasive shot cutting particles such as garnet particles. All abrasive shot materials will yield some colloidal suspension. The high energy of the waterjet cutting process causes fracturing of the abrasive material as well as the cut metal fines producing a negatively charged colloidal suspension having a large area. This colloidal suspension causes water turbidity and makes normal filtration techniques impractical.
To clean the reactor water effectively and rapidly, a process was optimized to draw turbid water from a reactor, which had been subjected to garnet waterjet cutting. This water was first subjected to a Zeta treatment followed by the addition of coagulants and flocculants. The treated water was then sent to a filtering tank to which a precoat was added and which separates the solids from the clean liquid and sends the liquid to a secondary filtration station from which clean water which is Zeta adjusted and which has all colloidals removed may be recycled to the reactor.
In view of the foregoing it will be seen that one aspect of the present invention is to provide a method of very rapidly treating reactor water having waterjet cutting colloidal particles.
Another aspect is to provide a method of removing colloidal cutting particles such as garnet and metal cutting swarf from reactor water.
Yet another aspect is to provide an optimized reactor water treatment process using specific filtration and filter precoat techniques.
Still yet another aspect is to provide an optimized reactor water treatment process using specific negative charge removal and flocculants techniques.
Still yet another aspect of the present invention is to provide a method of treating reactor water having waterjet cutting colloidal particles within seconds.
These and other aspects of the present invention will be more fully understood upon a review of the following description of the preferred embodiment when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein:
FIG. 1 is a schematic of the optimized reactor water treatment process of the present invention; and
FIG. 2 is a graph depicting known classic pH treatment coagulation ranges.
DESCRIPTION OF THE PREFERRED EMBODIMENT
To optimize the very rapid reactor water treatment process of the invention, a series of experimental designs were applied to raw process water having waterjet-produced particles in an attempt to first find a suitable combination of coagulant and flocculant. The chemical test screens involved the application of plus 3 aluminum (aluminum sulfate), plus 3 iron (ferric chloride and ferric sulfate) and several anionic and cationic polymers. All these products are known chemical coagulants.
In association with the coagulants, a variety of anionic (minus charged) and cationic (plus charged) flocculants were tested. The impact of treatment and final treated water pH was also studied. There are recommended ranges for classic coagulant-flocculation chemistries and they are seen in FIG. 2 . The goal of the bench laboratory work was to optimize the chemical combinations and ranges for the waterjet type polluted reactor water.
The best performing coagulant and flocculant combination was determined to be an aluminum sulfate solution from BetzDearborn called CP-1301 and a Betz (anionic flocculant) product called AP-1100. The pH range for treatment was about 5 with a final pH of between 6.2 and 7.2, which was further optimized to between 6.8 and 7.2. The initial work involved both sodium hydroxide and/or sodium carbonate as ph modifiers this was not only to keep the ph in a convenient range but to optimize coagulation and flocculation. This need for optimization is best seen in the FIG. 2 classic treatment coagulation ranges.
In order to keep the overall pH's within the needed range, an alkalinity booster was used. Initially, sodium hydroxide was applied due to cost and ease of use. Later, due to the need to do everything possible to get a faster reaction, heavier flock, sodium carbonate was used. This change helped, but was not “the” solution to the lack of reaction time combined with the restriction on using typical plate and frame or vacuum filter presses.
The goal was to provide a rapid process reaction with settling times limited to well under a minute and more in the range of seconds. The initial impact on this quickly treated water was that the back-washable filters (all under evaluation) could not without help: (1) Remove the very small unreacted particles and (2) Defend themselves against the naturally sticky colloid-silica flocks. If the filter was fine enough to catch the remaining very small particles, the filter would not back wash. This impact was true for every known precoated filter, until the final combination of a specific filter, namely the Johnson filter, and a precoat was discovered.
It should be noted that with or without the use of flocculating agents, coagulation produces sticky flocks. Over a substantial time period, days and weeks, fully coagulated flocculated silica turbidity particles became less sticky as they age and oxidize and are easier to filter using back-washable filters.
Initial testing focused on “non-precoated” filters because of the concern about adding additional waste. A significant amount of testing was carried out with four different backwash filter designs. If the filter was able to reduce the total suspended solids (TSS) flowing to the polishing filters, it could not be back-washed repeatedly. And, if the filter was back-washable it would permit greater than 100 ppm of down-field solids on the polishing filters, which was completely unacceptable. Finally, pre-coating had to be evaluated.
Because of the un-precoated results noted and the inherent stickiness problem of the flocculated solids, as well as the need to capture unflocked, reaction time sensitive, very small particles, the concept of precoating the filter was initiated.
Precoating was attempted on several filters designs using five different precoats at a variety of precoat levels. Some immediate filtering-backwash improvement was noted. However, none of the combinations of filter and precoat proved adequate. A filter would produce water that contained so much TSS that the radioactivity of down-field filters would be seriously raised as well as resulting in too many waste filters; or, it produced satisfactory, if not excellent water, but still would not back-wash reliably.
Finally, it was discovered that using a stainless steel surface filter, based on Johnson Screen, at ˜20 to ˜25 microns, with a precoat of a particular range of thickness provided the desired results. The precoat used was an expanded volcanic ash called PERLITE which produced the needed and unexpected results. However, other precoats such as diatomaceous earths and crushed garnet could also be used. The key found was to use a stainless steel filter with a precoat.
A specific study was performed using several precoat types and level in combination with the Johnson Screen 20 micron filter. The Johnson Screen/PERLITE combination produced water that contained less than 1 ppm total suspended solids (non-detect) and light transmission that was nearly as good as 0.2 micron filtering. Further, the filter body back-washed successfully and repeatedly. The final filtered Zeta potential of the waster was ˜+5.
Due to the inherent rapid treatment requirements of under one minute, floc stickiness, plus the remaining fine, unreacted small particles, the time in between back-washes was 30 minutes minimum and the average cycle time is more than 5 times this value. The backwashing was done at a pressure differential of about 30 pounds. The average flux under these conditions was about 2 gallons per minute per square foot of precoated stainless steel filter surface.
The final process design provided minimum life cycle costs and maximum waste contained in each disposal package with an minimal chemical additions. It also simplified the chemical addition controls. It further provided absolute minimization of down-field filter capture of “total suspended solids” and of down-field filter radiation capture. Also provided were minimal cation and anions in the water which could impact the mixed bed resins while optimizing and minimizing filter pre-coat mass applied to the Johnson Screens and minimize the time between treatment and filtration.
Referring to FIG. 1, the optimized process, as a first stage, takes water from a nuclear reactor (not shown) containing suspended particles and colloidal contamination from the previously described garnet waterjet operation and feeds it to a tank ( 10 ) and through the process at 1,000 gpm. A flow of 1,000 gal/min flow rate from the tank ( 10 ) is maintained by a centrifugal pump ( 12 ) connected to the tank ( 10 ) by a line ( 14 ).
To simplify the process the +3 valent salt was replaced with a cationic (+) polymer. Based on the relatively stable pH band anticipated in the actual process, and due to the wide applicability of the cationic polymers studied, it was determined that there was no need for a pH control additive; nor did cationic polymer treatment require one. This is unlike the tri valent metal approach which initially drives down the water's ph and requires that it be returned to a satisfactory level before final treatment and filtration. The actual use of cationic polymer application combined with a precoat filter still did not meet the high standards of our defined -process when the TSS levels were very high (about >100 ppm). When levels of polymer were increased, there was a diminishing return due to the very quick reaction time required, the increased polymer resulted in to much “glue” on the filter which would not backwash after a cycle. This problem was solved by adding Bentonite. This seeded the water with some immediately available coagulation sites. However, Bentonite has a negative (bad) Zeta on the water and required the correct addition order of polymer and Bentonite.
As seen in FIG. 1, the process feed a dilute slurry of Wyoming sodium bentonite into the reactor water which was mixed in the tank ( 10 ) with polymer to have a polymer content of 1-1.5 ppm This provides the proper order of polymer and bentonite injection since it was found that a reversal of this order the down-field filters were plugged.
The level of bentonite injection is fixed at 20 parts per million of bentonite for high TSS levels. For TSS levels of ˜30 ppm the use of polymer may be reduced to 0.20 ppm and often to 0.05 ppm the use of bentonite may also be reduced or put on stand by. Under these low level TSS conditions (>100 ppm), the addition level of polymer and the use of bentonite are controlled by Zeta monitoring and light transmission of the process return water.
The bentonite is contained in an open tank, ( 16 ) and is feed into the exhaust line ( 18 ) of pump ( 12 ) by centrifugal pump ( 20 ) connected to the tank ( 16 ) by line ( 22 ) and to line ( 18 ) by line ( 24 ). Bentonite is from the smectite family of clays. Montmorillonite or sodium bentonite also called Wyoming bentonite are among smectite clays. These clays are crystalline, quartz which itself is a silica. This material is used in a great variety of ways including water treatment, cosmetics, food stuffs and solid stabilization, to name a few.
Bentonite is a safe, non-toxic, non-hazardous material having a large surface area per particle and is able to absorb water, cations, anions, organics (to some degree). It is made up of octahedral sheets which allows the adsorption property. It has a general approximate formula of: Na 0.3 Al 0.7 Mg 0.3 Si 1 O 10 (OH) 2 and supplies a small amount of alkalinity to the process water with a rise in pH into the 7-8 range with an addition of ˜10-20 ppm. It also provides mild coagulation capability by adsorption and absorption of charged particles and through the presence of electric charge distribution on the clay particles. The material used is called FRAMACHEM™20 (FC-20).
The above-described process of injecting the raw water with these coagulation/agglomeration clay sites causes many small colloids to be electrically and physically attached to the larger clay bentonite particles.
An alternate fine particle catcher that can be added to ad and absorb particles is fine powdered activated carbon. It is usually more efficient than bentonite for many chemical entities. However, it is much more expensive, more difficult to handle and feed and is usually much more difficult to filter from the process water.
In the next stage of the process a flocculation agent is added to a second tank ( 26 ) and is inputted into the system by a centrifugal pump ( 28 ) connected to the tank ( 26 ) by line ( 30 ) and to a system line ( 32 ) downstream of a filter ( 34 ) by exhaust line 36 .
Due to the extreme rapidity with which the raw water passes through the system before it reaches filtration, the coagulation process requires some help to remove the negative colloidal charge on the particles so that the smallest particles have a chance to agglomerate, thereby allowing back-washable filtration. This is accomplished through the use of a BetzDearborn product called CP-1601 and referred to as FRAMACHEM™310 (FC-310). This is a very large organic molecule (molecular weight >100,000) that contains nitrogen, carbon, hydrogen, and oxygen. It bears a positive charge at one end of each molecule.
This flocculating agent is added in a 0.2% by weight water solution and makes the product slightly acidic (about pH 4). The product helps bind colloid/clay particles together in large clumps. The negative Zeta potential of the water, after filtration without this agent shows that the chemical is tying up the smallest of the colloids, thus eliminating the Zeta potential associated with them.
The total amount of FC-310 added is 1 part per million with 1.5 ppm required when vacuuming and very high solids levels are present in the water.
In the third stage of the process PERLITE precoat is used to pre-oat the stainless steel Johnson-Screen filter ( 32 ). PERLITE precoat material, FRAMACHEM™10, was found to be extremely powerful for this application. This product has a bulk density of only about 7 pounds per cubic foot and therefore when wetted it occupies very little space.
When 100 mls of the dry PERLITE is mixed with 100 mls of water only about a 1% expansion in total volume is seen. PERLITE minimizes the addition of weight to the final disposal packages. Inorganic, volcanic ash, that has been heated in the presence of a trace of water yielding a very high surface area, low bulk density material. The supplier of the PERLITE used in Silbrico, Grade 17S.
Nearly no volume or mass expansion results due to the use of PERLITE. Perlite serves as a very efficient filtering medium due to very high surface area per gram. It protects the stainless steel filter surface from stickiness permitting good backwash ability and permits excellent de-waterability of the back-washed precoat-sludge mixture. The range of precoat coverage was found to be effective when used in the range of 75 mls/square foot-300 mls/square foot depending on the how dirty the reactor water had become.
The Johnson-Screen filter ( 32 ) is a sturdy stainless steel mesh tube. The finest mesh size currently available is about 700 mesh or ˜20-25 microns. From earlier work, this was a compromise filter pore size that allowed good filtration (with pre-coat) without plugging and slowly eliminating back-washability.
Johnson-Screen is manufactured for filter manufacturing companies or supplies tubes alone from US Filter, Inc. it comes as a stainless steel tube with shinny, hard surface, with ˜20 micron tapered “tunnels” cut in the surface. The mentioned mesh allows precoat entry in the filtering “tunnels”. Pre-coat also coats the entire surface of the filter to a depth of a few millimeters protecting the surface from the sticky floc. Water and air are used to backwash the materials off the surface from inside the tubes out in a manner well known in this area. A flux can be maintained at about 2 gls per square foot for about 45 minutes with a maximum pressure drop of about 75-100 psi (estimated). The Johnson-Screen filter tubes are rated at 150 psi. Any form of pleated filter tube design did not work well and would not allow continuing back-wash without significant plugging after few cycles.
After the treated water leaves the backwash filter, it passes through a 2-3 micron 3M pleated fabric filter ( 34 ) and then through a 0.5 micron final polishing filter ( 40 ). Even through pilot test results have shown that the treated water using the Johnson-Johnson Screen system passes literally no solids, there could be upsets where solids could pass. An example would be a “re-coating” of the Johnson Screen with PERLITE that was uneven. In this event some TSS might move down-field to the polishing filters. The 3M filters have shown themselves to be very robust and excellent filters of “charge neutralized” water.
An open tank ( 42 ) containing a controlled feed of PERLITE precoated is connected to the filter ( 38 ) by a centrifugal pump ( 44 ), which is connected to the precoat tube ( 42 ) by line ( 46 ) and the filter ( 38 ) by line ( 48 ).
The goals of the secondary treatment and solids removal system have been explained. The final step, after proper treatment, filtration and then removal of them from the filtering screens is to provide a surge of high pressure water with air inputted into the filter ( 38 ) along line ( 50 ) used to move the sludge collected at the bottom of the filter ( 38 ) along a line ( 52 ) to the collection vessels (not shown). The presence of the PERLITE mixed with the treatment sludge aids in the reduction of stickiness and experiments have indicated that the sludge will move smoothly and rapidly along line ( 52 ) into collection vessels. Further work with the sludge alone and then with PERLITE mixed in shows a very substantial enhancement in dewaterability. The final sludge after gravity dewatering will have a bulk density of between 64-68 pounds per cubic foot. Free, entrained water, will rise to the top of the collection vessel for decanting a second method of removing water from the sludge once it is in the waste package.
The previously discussed stages separated the bulk (>99%) of the solids from the water. The balance of the solids will be removed with cartridge filtration. A 2 micron cartridge filter in a pressure vessel (referred to as a Sludge Collection Filter (SCF) is provided downstream of the BWF effluent. The BWF with precoat will remove 2 micron particles. However, in case precoat material is applied unevenly or a breakthrough in the BWF occurs, the SCF provides “defense in depth”. The effluent from the SCF filters is pumped through the final polishing filter ( 40 ) containing ½ micron filters. The polishing filters are not expected to remove much solids. The treatment process and precoat BWF are expected to bind the submicron particles and remove said particles. However, it is believed to be advantageous to capture any submicron particles that escape the bulk separation process prior to release to the cavity.
It will be understood that certain details as well as alternate embodiments and apparatus have been deleted herein for the sake of conciseness and readability but are fully intended to fall within the scope of the following claims
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A method and apparatus is disclosed for very rapidly cleaning very small, colloidal particles from nuclear reactor water subjected to a high-energy waterjet cutting of metal using metal shot particles for cuffing such as garnet particles with the cutting causing fracturing of the metal shot as well as the cut metal fines into a negatively charged colloidal suspension having a large area. This colloidal suspension causes water turbidity and makes known filtration techniques impractical for rapid removal of such suspensions for recycling to the reactor.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a multisection laser diode system that can be operated over a range of frequencies and a method of operating such a system.
[0002] The original multisection diode laser is a three-section tunable distributed Bragg reflector (DBR) laser. Other types of multisection diode lasers are the sampled grating DBR (SG-DBR) and the superstructure sampled DBR (SSG-DBR) which both have four sections. A further multisection diode laser is the grating-assisted coupler with rear sampled or superstructure grating reflector (GCSR), which also has four sections. A review of such lasers is given in Chapter 2 of PhD by Geert Sarlet, University of Gent, Belgium (September 2000) “Tunable laser diodes for WDM communication—Methods for control and characterisation”
[0003] Multisection diode lasers are useful in wavelength division multiplexed (WDM) systems. Typically, WDM systems have channel spacings conforming to the International Telecommunications Union (ITU) standard G692, which has a fixed point at 193.1 THz and interchannel spacings at an integer multiple of 50 GHz or 100 GHz. An example dense WDM (DWDM) system could have a 50 GHz channel spacing and range from 191 THz to 196 THz (1525-1560 nm).
[0004] FIG. 1 is a basic schematic drawing of a SG-DBR laser 10 . The laser 10 comprises back and front reflector sections 2 and 8 with an intervening gain or active section 6 and phase section 4 . An antireflection coating 9 can be provided on the front and/or rear facet of the chip to avoid facet modes. The back and front reflector sections include reflectors which take the form of sampled Bragg gratings 3 and 5 .
[0005] The raison d'{circumflex over (r)}tre of multisection diode lasers is their wavelength tunability. Each section of the laser diode is supplied with a drive current, and the lasing wavelength is a function of the set of drive currents, this function generally being quite complex. Setting the output wavelength of such a laser is thus usually performed by a sophisticated microprocessor controlled control system. As well as the fact that there is a complex relation between output wavelength and the set of drive currents, there is the additional factor that wavelength switching of the laser destroys its thermal equilibrium, which results in transient wavelength instabilities until thermal equilibrium is reached at the new set of drive currents. The time needed for temperature stabilisation can be quite long.
[0006] FIG. 2 is a schematic representation of an output characteristic (or mode map) of a SG-DBR laser as a function of the currents applied to the front and back reflectors (I f and I b respectively). The mode map is made up of a number of operating cells, each occupying its own area in front and back current space. Each cell in the mode map corresponds to a coincidence in frequency space of reflectivity peaks for both the front and back reflectors with a cavity mode of the active section 6 . An aligned pair of reflectivity peaks for the front and back reflectors may be tuned (by altering I f and I b ) to coincide with one of a set of cavity modes. This set of cavity modes is collectively known as a supermode. The cells labelled ‘A’ to ‘L’ belong to one supermode, while the cells labelled ‘M’ through ‘W’ belong to another. Accordingly, each supermode occupies a branch of current space on the mode map. The most stable operating points for the laser in terms of values of I f and I b are those which lie at the centre of a cell, away from mode hop boundaries which define the cell edges. An example of a stable operating point of this kind is point 7 in cell H. While each cavity mode is generally associated with a cavity mode frequency of the active section, the phase current I ph may also be used to fine tune the laser within a cell. Each cell has a phase tuning range available to it, which is typically of the order of ±25 GHz. Beyond this tuning range the effective cavity length of the active region is sufficiently altered for the laser to be forced into the next highest (or lowest) cavity mode in that supermode.
[0007] The transient thermal properties of a SG-DBR laser result in two main effects.
[0008] A first effect is that, directly after the laser is switched, the thermal gradient across the device to the heatsink, upon which it is mounted, will be different to that measured at steady state operating conditions for the same currents, due to a different heating level generated in the laser as the currents are different. The steady state temperature gradient will reassert itself over a period measured in a timescale from a few hundred nanoseconds to tens of microseconds. Because the device is at a different temperature during this period some temperature tuning of the wavelength occurs. For a positive (negative) change in tuning current the change in temperature will be such that the device is initially colder (hotter) than at equilibrium for those currents and some time will pass before the extra current dissipates enough heat energy to change this. During that period the device will be colder (hotter) than expected so a blue (red) shift from the expected output wavelength will occur.
[0009] A second effect takes place over a much longer timescale. The laser is thermally connected to a heat sink of finite thermal mass which has a temperature controller maintaining its temperature. The temperature controller cannot react instantaneously to a change in temperature, which means that with an increase (decrease) in bias current, the heat sink will heat up (down). This temperature change results in the temperature of the device overshooting and going higher (lower) than would be normal for those currents. This effect will persist until the temperature controller returns the heat sink to its normal temperature, which may take 1-1.5 seconds.
[0010] A known technique of addressing the transient (and non-transient) thermal effects, and also any other effects that cause the wavelength to deviate from the intended wavelength for a predetermined set of drive currents, is to provide a wavelength measuring system which supplies measurements of the output wavelength to the control system. The laser drive current can then be adjusted in a feedback loop to provide locking of the output to the desired output wavelength.
[0011] FIG. 3 shows a typical application example where a SG-DBR laser 10 is used as a source for a WDM system, with a microprocessor control system being provided for wavelength locking. The SG-DBR 10 has a pigtailed output connection to an optical fibre 20 . An optical coupler 12 is arranged in the optical fibre output path 20 to couple off a small proportion of the output power, for example 5%. The coupler 12 may be a fused taper coupler, for example. The part of the output beam diverted off by the coupler 12 is supplied to an optical wavelength locker 14 , for example a JDS FPWL211501100 series wavelength locker. The optical wavelength locker 14 is a wavelength measuring device based on a Fabry-Perot etalon or other device.
[0012] FIG. 4 shows the frequency response of a power normalised etalon response in terms of its percentage throughput T as a function of frequency f. For WDM applications, the etalon is designed to have its cyclical frequency response (or Free Spectral Range (FSR)) matched to the ITU grid. In this example, an etalon with a FSR of 50 GHz has been chosen so as to match to the 50 GHz channel spacing of the ITU C-band. Consequently, each of the ITU frequencies lies on a point on the etalon response with the same values of both T and dT/df. An etalon with a sinusoidal frequency response has been assumed. The laser output can thus be tuned to any one of a number of discrete frequency channels separated by a fixed channel spacing matched to the etalon response period.
[0013] The frequency response of the etalon is such that an ITU channel frequency occurs on the maximum positive slope of the etalon peaks, i.e. maximum positive value of dT/df, as indicated in the figure. (Alternatively, the maximum negative slope points could be chosen.) The optical wavelength locker 14 includes first and second photodiodes PD 1 and PD 2 . Photodiode PD 1 is arranged to receive light transmitted by the etalon. Accordingly, if the output frequency of the laser is, for example, greater than the ITU frequency, the photodiode PD 1 will receive a higher incident power level P 1 than it would at the ITU channel frequency. Similarly, if the output frequency of the laser is below the ITU channel frequency, the power P 1 incident on the photodiode PD 1 will be lower than the value it would have if the laser output was at the ITU channel frequency. The photodiode PD 1 thus outputs a voltage V pd1 that can be used as a basis for generating an error signal relating to the frequency deviation of the laser output from the ITU channel frequency.
[0014] The second photodiode PD 2 of the optical wavelength locker is arranged to measure the optical power input to the locker 14 , thereby providing a measure of the total output power of the laser in the form of a measurement voltage V pd2 . The measurement voltages V pd1 and V pd2 are supplied by respective signal lines 16 and 18 to an analogue-to-digital converter (ADC) 22 . The ADC 22 may for example have 12 bit resolution. The ADC 22 supplies the digitised measurement voltages V pd1 and V pd2 to a microprocessor 24 which may be connected to ancillary computer equipment through an interface 26 .
[0015] When initially setting the laser 10 to a given ITU channel frequency, the microprocessor 24 refers to a predetermined set of drive voltages V f V b V g and V ph for the ITU channel frequency concerned. The sets of drive voltages may be conveniently held in a look-up table (LUT). The microprocessor 24 may thus include on-chip memory for this purpose, for example flash memory. To set the laser 10 to a particular ITU channel frequency, the microprocessor 24 asserts a set of voltages to a digital-to-analogue converter (DAC) 28 . The DAC 28 may have 14 bit resolution, for example. The DAC 28 then supplies these voltages to a driver circuit 30 which converts the voltages to corresponding drive currents I f I b I g and I ph which are then applied to the front reflector, back reflector, gain and phase sections 8 , 2 , 6 and 4 respectively of the SG-DBR 10 . A portion of the LUT may look as follows:
Channel No. Gain Phase Front Back 1 11823 1417 767 7064 2 12102 1539 812 7132 3 12674 1612 856 7132 4 12698 1655 952 7349
The numbers are bit values supplied to the DAC 28 in order to generate a suitable set of output voltages for each ITU channel.
[0016] Feedback from the optical wavelength locker 14 is provided in this control system by the microprocessor 24 continually re-adjusting the set of voltages sent to the DAC 28 on the basis of the measured voltages V pd1 and V pd2 . The feedback adjustment is implemented principally through varying I ph , the current applied to the phase section 4 of the SG-DBR 10 .
[0017] Standard prior art systems, such as described above, are designed to provide stable output at frequencies at ITU channel frequencies, typically 50 or 100 GHz apart. However, it is desirable for other applications to be able to provide stable output at an arbitrary frequency and to be able to sweep through a frequency range in a continuous, or at least quasi-continuous, manner, for example in steps of 2 GHz. A system with such capabilities would for instance be useful for the calibration of passive optical components over a broad range in frequencies, as described in “Wavelength analysis of photonic components using a fast electronically tunable laser”, T. Mullane, D. McDonald, T. Farrell, International Optical Communications, pages 22-24, Spring 2002.
[0018] The standard 50 GHz etalon is an inexpensive mass produced item, but is clearly not ideally suited to locking to non-ITU frequencies, especially to frequencies where dT/df is small, such as at the maxima of T. Moreover, the values of both T and dT/df are different at different frequency values within a cycle of the etalon response making any feedback more complex to implement. Standard WDM systems make no provision for tuning to arbitrary frequencies on the etalon response curve and are reliant upon locking to a single value of T and dT/df. Other schemes use transform functions to linearise the response which requires processing of the data or a non-linear element which normalises the slope of the wavelength locker to a constant value.
[0019] FIG. 5 shows an etalon response curve with three target frequencies (f 1 , f 2 , f 3 ) indicated. Frequency f 1 lies at the centre of the response curve at a point corresponding to one of the ITU channel frequencies shown in FIG. 4 . Also shown in FIG. 5 are the upper and lower bounds for effective locking to this frequency using a conventional locking circuit, namely f upper and f lower . The locking circuit operates by supplementing one or more of the operating currents with a feedback signal which is determined by the difference between the measured response of the etalon and the expected response of the etalon at the target frequency. It is important to note that a given transmission response from the etalon is degenerate in output frequency because of the periodicity in the etalon response such that each value of T (and respective value of dT/df) corresponds to more than one frequency. It is not possible to discriminate between the various ITU frequencies by simply observing the output response of the etalon. Consequently, the locking circuit can only provide an appropriate feedback signal for operating frequencies which lie within the same half period of the etalon response as the target frequency. That is, the locking range of the system is equal to one half period of the etalon response.
[0020] At frequency fi, it is seen that the locking range is symmetrical, with a full quarter period of the response curve being available in either direction in frequency from f 1 . In contrast, for target frequencies other than those which lie near to the centre of the etalon response, the locking range becomes distinctly asymmetric. Frequency f 3 for example has only a small locking range for frequencies higher than f 3 while for frequencies lower than f 3 the locking range is much larger. The opposite is true for target frequency f 2 . Furthermore, it can be seen that the slope of the response curve varies with frequency. Accordingly, the sensitivity of the feedback circuit is greatly reduced for frequencies approaching the extrema of the response curve (i.e. f upper and f lower ).
[0021] The asymmetry in the locking range and the variability in the sensitivity of the feedback circuit are therefore both functions of frequency and degrade the feedback efficiency when attempting to stabilise at frequencies away from ITU frequencies.
[0022] As well as considering the effects that thermal transients have on the feedback control implemented through an etalon, it is also necessary to consider the effects that thermal transients have when switching between different cells in the mode map, as is necessary when sweeping frequency over larger ranges. To provide a laser diode that can be tuned continuously through a significant range of frequencies, drive currents corresponding to operating points within a number of different operating cells will have to be employed. When switching between operating cells, the associated changes in the drive currents will give rise to thermal transients, which as well as causing an error in the output frequency will also distort the mode map of the laser. For example, while a cavity mode may occupy a first region in (front and back) current space in thermal equilibrium, the same cell may occupy a slightly different region in current space in the presence of thermal transients on switching. This effect can complicate the switching of currents between operating cells since the target operating cell position is time dependent during the period immediately after the mode jump.
[0023] If the operating cells are significantly shifted, it is even possible that the selected operating point on the distorted mode map may lie in an operating cell other than the target cell. In this event, the laser diode would begin to operate in an undesired operating cell at an arbitrary unenvisaged frequency. Furthermore, the locking circuit would be unable to compensate for this error since the output frequency would be likely to be outside the locking range for that target frequency and in any case the locking circuit (which predominantly employs phase tuning) can only provide effective tuning within a single cell (i.e. the target cell).
[0024] It is therefore desired to provide a laser diode which is robust against thermal transient effects and which can be operated over a fine frequency grid. In particular, it is desired to provide a laser diode that can be tuned rapidly in a quasi-continuous manner through a range of frequencies on a fine frequency grid.
SUMMARY OF THE INVENTION
[0025] According to the invention there is provided a system comprising: a multisection diode laser with a plurality of sections that are drivable by control inputs to select a desired output mode from among a plurality of available output modes; a wavelength locker for locking the selected output mode to a target frequency where the wavelength locker has a characteristic response period and there are at least 2 target frequencies in each response period of the wavelength locker; and a controller operable to sweep the diode laser in a pre-determined frequency direction through a series of frequency points by asserting a pre-calibrated series of sets of control input values to the sections of the diode laser and using the wavelength locker to lock to each of the frequency points, wherein the frequency points are obtained from cavity modes in a plurality of different supermodes, and the sets of control input values are pre-determined to take account of thermal transients that are known to arise from jumps in the output modes that occur when sweeping through the pre-calibrated series of sets of control input values in the pre-determined frequency direction.
[0026] By taking account of the previous output mode of the laser when defining the control input values to be set to obtain the next output mode, the wavelength locker and controller can lock onto each frequency point much more quickly than if the control input values were simply taken from the thermal equilibrium state for the next output mode.
[0027] The controller is preferably also operable to allow sweeping in the opposite frequency direction. Namely, the controller is preferably further operable to sweep the diode laser in the opposite frequency direction by asserting a further pre-calibrated series of sets of control input values to the sections of the diode laser, wherein the further pre-calibrated sets of control input values take account of thermal transients that are known to arise from jumps in the output modes that occur when sweeping through the further pre-calibrated series of sets of control input values in the opposite frequency direction.
[0028] Thermal transient effects that depend on the previous output mode can be taken account of by adopting a frequency skewing policy. This can be defined by setting the control input values as follows: at least one of the sets of control input values has control input values that deviate from their thermal equilibrium values by amounts dependent on the difference between the sum of its own control input values and those of the set of the preceding frequency point.
[0029] Thermal transient effects that depend on the previous output mode can also be taken account of by adopting a cell skewing policy. Namely, each set of control input values can be considered to define an operating point in drive current space. Drive current space is subdivided into cells defined by the output modes of the laser. According to the cell skewing policy, at least one of the sets of control input values is pre-calibrated so that it defines an operating point that is offset from the central region of its cell in a direction of a predicted transient thermal shift in the cell when arrived at by jumping from the preceding operating point.
[0030] Thermal transient effects that depend on the previous output mode can also be taken account of by adopting a policy of restricting supermode jumps to frequencies that lie in an optimum part of the wavelength locker response. Supermode jumps will in general result in the largest changes in thermal loading of the diode, e.g. the L to M transition of FIG. 2 . Consequently, supermode jumps impose the most stringent requirements on the feedback loop. The supermode jump policy adopted is therefore that, when a set of control input values defines an output mode in a different supermode from the output mode of the preceding set of control input values, the set of control input values is pre-determined so that the jump to that output mode is made to occur at a frequency midway between adjacent minima and maxima of the response of the wavelength locker (and not at any other frequency which is not midway between the adjacent minima and maxima of the response of the wavelength locker). The capture range of the wavelength locker is maximised at this point in its response, and is made to coincide with the transition which results in the maximum frequency transient, which results when moving between supermodes in a swept frequency fashion. It will be understood that midway means as close as possible to the half-way point between the adjacent maxima and minima. In practice, anywhere not too close to the extrema will be sufficient and beneficial. Adoption of this policy should avoid the output frequency of the laser having to pass over a maximum or minimum in the wavelength locker response when recovering from thermal effects after a supermode jump.
[0031] It is beneficial for practical reasons to use a standard wavelength locker designed for WDM applications, wherein the response period of the locker matches the ITU grid. The response period of such a locker will typically be 50 GHz or 100 GHz.
[0032] In embodiments of the invention, there are at least 4, 8 or 16 frequency points in each response period of the wavelength locker.
[0033] Moreover, the frequency points are conveniently spaced apart by a constant frequency increment, preferably 2, 4, 8.33, or other sub-multiples of the FSR of the locker used.
[0034] The system preferably further comprises a control circuit operable to output a correction signal for driving the diode laser that is dependent on the difference between a measured value output from the wavelength locker and a desired value output from the controller.
[0035] In one embodiment, the wavelength locker has a response with a frequency derivative which alternates in sign (e.g. sinusoidal or more typically the Airy function form), and the control circuit is configured so that the correction signal has a magnitude independent of the sign of the difference.
[0036] In another embodiment, the wavelength locker has a response with a frequency derivative which alternates in sign, and the system comprises an inverter for inverting the measured value output of the wavelength locker at turning points in the response of the wavelength locker.
[0037] In a further embodiment, the wavelength locker has a response with a frequency derivative which is always of the same sign (e.g. sawtooth), for example a locker based on phase shift interferometry.
[0038] The control input values for each target frequency may be stored in a look up table.
[0039] Preferably, the system uses variable gain enhancement so as to normalise the wavelength locker slope. This can be achieved by incorporation of variable gain potentiometer values in the look up table.
[0040] An offset may be applied to normalise a desired locking value from the controller. The offset may be stored as part of the lookup table of the laser for each target frequency.
[0041] The invention also provides a method of sweeping a multisection diode laser in a pre-determined frequency direction through a series of frequency points by asserting a pre-calibrated series of sets of control input values to the sections of the diode laser and using a wavelength locker having a characteristic response period to lock to each of the frequency points, where there are at least 2 frequency points in each response period of the wavelength locker and wherein the frequency points are obtained from cavity modes in a plurality of different supermodes, and the sets of control input values are pre-determined to take account of thermal transients that are known to arise from jumps in the output modes that occur when sweeping through the pre-calibrated series of sets of control input values in the pre-determined frequency direction.
[0042] The multisection diode laser has a plurality of sections that are drivable by control inputs to select a desired output mode from among a plurality of available output modes.
[0043] In a further embodiment, a linear filter, more especially a low ripple response linear filter, preferably of low temperature and polarisation sensitivity, can be used as the frequency-referencing element A filter similar to the SANTEC OWL-30, with polarisation fibre input, would meet such requirement.
[0044] It will be appreciated that the invention can be implemented in a variety of multisection laser diodes, such as SG-DBR, SSG-DBR, GCSR etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] For a better understanding of the invention and to show how the same may be carried into effect reference is now made by way of example to the accompanying drawings in which:
[0046] FIG. 1 shows a sampled grating distributed Bragg reflector (SG-DBR) laser diode, as known in the prior art;
[0047] FIG. 2 is a schematic representation of the mode map of a SG-DBR laser as a function of the currents applied to the front and back reflectors (I f and I b respectively);
[0048] FIG. 3 shows a SG-DBR with an associated feedback control system including a wavelength locker, as known in the prior art;
[0049] FIG. 4 shows a sinusoidal etalon response of a wavelength locker as percentage throughput T as a function of frequency f;
[0050] FIG. 5 shows a portion of the etalon response curve of FIG. 4 with three target frequencies (f 1 , f 2 , f 3 ) indicated;
[0051] FIG. 6 shows a SG-DBR with an associated feedback control system according to a first embodiment of the invention;
[0052] FIG. 7 shows various operating points on a sinusoidal etalon response to explain principles of a first aspect of the invention;
[0053] FIG. 8 shows an example of the effects of thermal transients when switching from one cavity mode to another to explain principles of a second aspect of the invention;
[0054] FIG. 9 shows another example of the effects of thermal transients when switching from one cavity mode to another to further explain the second aspect of the invention;
[0055] FIG. 10 shows an example set of laser output points of a laser system of the first embodiment marked on an actual etalon response;
[0056] FIG. 11 is a graph for the same example as FIG. 10 showing the frequency tuning path of the laser system by plotting the sum of the front, back and gain currents in bits against frequency f, where each contiguous curve relates to one supermode, with the alternating light and dark curve portions relating to the alternating 20 and 30 GHz sections of the actual etalon response of FIG. 10 ;
[0057] FIG. 12 shows a SG-DBR with an associated feedback control system according to a second embodiment of the invention; and
[0058] FIGS. 13 a and 13 b show a non-inverted etalon response according to the first embodiment and an inverted etalon response according to the second embodiment.
DETAILED DESCRIPTION
[0059] FIG. 6 shows a SG-DBR with an associated feedback control system according to a first embodiment of the invention. Most of the components are the same as in the prior art example described further above. Common components are labelled with the same reference numerals, and are not generally described again for the sake of brevity. However, it is noted that the system uses the same standard 50 GHz wavelength locker 14 as in the prior art example. Notwithstanding retention of this component, the system allows quasi-continuous tuning of frequency over a 2 GHz grid, i.e. operation at any one of 25 points per etalon response. To make this performance possible, the system's control hardware and software is modified in several respects in the manner now described.
[0060] The system hardware differs from that already described by virtue of additional control components relating to regulation of the phase current I ph . The PD 1 , PD 2 conditioning circuitry 22 provides an output which is proportional to the instantaneous etalon transmission T. This is applied to one side “B” of a phase current control unit 34 as an “actual” value through a line 32 . A “desired” value of the same parameter is supplied to the other side “A” of the phase current control unit 34 via a line 33 from the microprocessor 24 . The desired value corresponds to the phase current value that the laser should receive when in thermal equilibrium. The phase current control unit 34 determines the difference between the desired and actual values. The difference is determined both as (A-B) and (B-A). Because of speed considerations, the phase current control unit 34 is preferably implemented purely in hardware, most preferably as an analogue circuit. At any given time, only one of the signals (A-B) and (B-A) is connected through to the driver circuit 30 . Which one of the two is supplied depends on the position of a switch 38 , which is controlled by a signal from the microprocessor 24 supplied through a control line 36 . The switch is also preferably implemented as a hardware component to provide high operational speed. The switch position is toggled each time the etalon response goes through a maximum or minimum, i.e. each time the sign of dT/df changes, as determinable by the microprocessor 24 . The toggling of the switch 38 ensures that the feedback is stable both sides of the turning points in the etalon response. The output from the switch 38 , namely (B-A) or (A-B), is then supplied to the phase part of the driver circuit 30 as a correction signal DELTA V ph 40 which is summed with the basic phase voltage V ph to lock the phase voltage to provide a desired output. Having described the hardware changes, the software changes are now discussed.
[0061] The system software embedded in the microprocessor 24 differs from standard configuration in the way it is changed to take account of switching transients when moving through a set of finely spaced grid points in frequency space to perform a quasi-continuous frequency sweep.
[0062] FIG. 7 shows various operating points on a sinusoidal etalon response to explain principles behind how the system software is modified according to a first aspect of the invention.
[0063] The largest thermal transients, and associated errors in operating frequency, occur when the operating point is switched between a cavity mode in one supermode to a cavity mode in a different supernode. Significant thermal transients can also arise when switching between non-adjacent cavity modes belonging to the same supermode. This is because mode switching of these types generally involves significant changes in the operating currents I f , I b and I g . On the other hand, tuning of the phase current I ph is associated with relatively minor thermal transients. Phase tuning is typically used to lock the laser output to a given output frequency within a single cavity mode. The phase currents supplied to a SG-DBR laser are typically two orders of magnitude smaller than gain current I g .
[0064] In view of this, and in accordance with the present invention, the laser system is calibrated such that supermode jumps occur only at points on the etalon response which have a large available locking range, preferably the largest. As described above, these points correspond to frequencies which lie at an intermediate point on the etalon response curve midway between adjacent maximum and minimum points of a cyclical response function.
[0065] Tuning from grid point to grid point in between these points is achieved primarily by phase current tuning. This ensures that when tuning near to the extrema of the etalon, the output frequency is generally under close control since I f and I b have already been selected within the appropriate cavity mode and will only be changed by relatively small amounts, if at all, so that no significant thermal transients are expected.
[0066] Confining large mode jumps to midpoints in the locking range is usually effective to prevent loss of correct feedback. However, the transient thermal effects may nevertheless result in the initial output frequency of the laser after the mode jump being relatively far away from where it should be, so that the phase current feedback compensation has to work hard to relocate the output to the target frequency.
[0067] Referring to FIG. 7 , it is assumed that the laser has previously been operating in a first cavity mode and is initially tuned to a frequency equal to f 1 . The laser now jumps to a cavity mode in a different supermode (or to a distant cavity mode in the same supermode), with a target frequency equal to f 1 . The intention is that the ranges in frequency serviced by the first and second cavity modes be contiguous. In the present example, it is assumed that the operating currents I f , I b and I g at the first cavity mode are generally smaller than those at the second cavity mode. Accordingly, on jumping between supermodes, it is expected that there will be an overshoot in frequency such the actual output frequency f output directly after the jump is higher than f 1 .
[0068] For initial values of f output between f 1 and f upper (such as f output =f 6 ), a larger frequency overshoot will lead to a longer time being required to pull f output back to the target frequency. This delay is increased for frequencies close to f upper since the sensitivity of the feedback circuit is reduced. While these effects do not destabilise the feedback loop, they increase the time needed to stabilise the output after a large mode jump, which in turn reduces the achievable sweep rate of the system. In order to alleviate the problems associated with frequency overshoot/undershoot, and in accordance with an embodiment of the present invention, a policy of skewing the set frequency away from the target frequency is adopted at mode jumps, where the size of the skewing correction depends on the magnitude of the difference between the sum of the gain, forward and back currents before and after the jump, i.e. mod[(I f +I b +I g ) before -(I f +I b +I g ) after ], and the direction of the skewing correction depends on the sign of the difference between these sums, i.e. whether the thermal load on the diode increases or decreases following the jump.
[0069] In the illustrated example, since it is known that on jumping from the first to the second supermode there will in general be a frequency overshoot, the set point in the second cavity mode is chosen to be lower than the intended target frequency. Here, the set point is chosen to be f 5 , f 5 being a frequency lower than f 1 . This has the effect of compensating for the expected frequency overshoot; the output frequency of the laser directly after switching may for example be in the region of f 7 . For an initial set point of f 1 , and assuming similar thermal transients, the value of f output directly after switching may well have been greater than f upper . In any case, it is clear from the illustrated example that f output =f 7 is significantly nearer to f 1 than f output would have been in the absence of frequency skewing of the set point. After the mode jump, the remaining difference in frequency between f 6 and f 1 may be compensated for by conventional phase tuning. It will be appreciated that directly after switching, thermal transients still exist within the laser. In this example (moving from high to low current) these will tend to force f output to lower frequencies. However, this may now be dealt with (again by phase tuning) from a position of advantage since the value of f output is already close to f 1 .
[0070] The laser system is therefore calibrated twice for tuning between a minimum frequency and a maximum frequency, once for scanning in the direction of increasing frequency and once for scanning in the direction of decreasing frequency. In both cases, supermode jumps are confined to frequencies that lie in central portions of the etalon locking range, but in the two cases, the frequency skewing will be opposite. Using the illustrated example, the set point will be chosen to be f 6 when jumping from the second to the first supermode, instead of f 5 when jumping from the first to the second supermode.
[0071] The frequency skewing policy can be implemented in a LUT-based control by firstly calibrating the laser on a fine frequency grid, i.e. one that is much smaller than the step frequency grid that the sweep function will operate. In this situation, the frequency skewing is implemented by setting frequency points which are lower in value that the ultimate value which the overall laser output will lock to when stable. The benefit in doing this is that thermal transients which last longer than the step time of the wavelength sweep are compensated by the “effective” decreased frequency error when moving from one desired frequency to the next desired frequency. For example, for implementation of a frequency sweep over the C band of telecommunication wavelengths in a frequency step size of 8.33 GHZ, the tunable laser is first calibrated on a 2 GHz frequency grid. The transient frequency, when the system is operated in the unlocked condition, is tested to locate the largest transient frequency regions in the output sweep. Using the 2 GHz calibration data, the actual values used to update the laser output are selected on the basis of: (i) the actual transient frequency behaviour of the device under sweep conditions, (ii) the locking range of the frequency referencing element (e.g. the 50 GHz locker) at that frequency point in the sweep and (iii) the discontinuity of the net current change in the laser. The latter factor refers to the segmentation of the calibration of the laser into regions where the locking range of the frequency referencing element (e.g. the locker) is optimum.
[0072] The software control also implements a further concept for modifying the voltages asserted to the driver circuit by the microprocessor to take account of transient effects. The further concept is to take account of the distortions in the mode map pattern which occur on supermode jumps or distant cavity mode jumps where significant discontinuities in the current load occur. On such jumps each cavity mode shifts to different values of I f and I b . This shifting appears over a relatively short time scale (microseconds). However, once shifted, the mode map then takes a much longer time (of order 1 second) to return to its steady state position.
[0073] FIG. 8 shows an example of the distortion experienced by a cavity mode in the presence of thermal transients. Cell 110 is shown in its steady state position, with a point 112 at the centre. In this example, it is assumed that the laser is initially operating in a different cell 120 , and that a jump in current is to be made to reach target cell 110 . As is apparent from the figure, cell 120 occupies lower values of I f and I b than cell 110 . On jumping from cell 120 to cell 110 , thermal transients are expected to occur due to the relatively large and abrupt increase in operating currents. As described above, these transients cause the mode map to distort, and cell 110 shifts to lower values of I f and I b , becoming shifted cell 130 . Consequently, point 112 does not appear at the centre of the shifted cell 130 and the laser output frequency will differ initially from the target frequency (namely, that at point 112 in unshifted cell 110 ) and so will have to be arrived at by tuning the phase current I ph . For certain technologies, this output mode map distortion is greater than others. In certain circumstances compensation for the step currents applied to the front and back tuning sections of the device may be required. After the jump, the shifted cell 130 will gradually return to the steady state position (cell 110 ) and point 112 will once again appear at the cell centre. This leads to a variation in frequency with time while the thermal transient effects decay. This variation in the frequency with time can be compensated for by time varying I ph .
[0074] FIG. 9 shows a second example of mode distortion in which the difference in operating currents between the initial operating cell 160 and the target cell 110 is larger than that of the previous example, as depicted by shifted cell 140 . In the second example, the mode pattern distortion is so great that the target cell is shifted to a position that does not overlap with point 112 . In this case, if, on jumping towards cell 110 from cell 160 , point 112 were chosen for operation, the operating point upon arrival would in fact lie outside the shifted target cell 140 and thus not be obtainable by phase current adjustment. Furthermore, a different cell 150 , which previously occupied higher currents than cell 110 , will have shifted into position over point 112 . Accordingly, the set point arrives in a different cell to that which was intended. This is likely to have disastrous consequences since cell 150 will typically have a very different frequency range associated with it than that of the intended cell. Consequently, the locking circuit will not be able to drag the output frequency to the intended target frequency.
[0075] In order to avoid the events described in relation to the second example, the operating points are skewed away from the cell centre in a direction (as viewed in current space) matched to the direction of the expected thermal shift in the target cell when jumping to a given other cell. This skewing is performed in anticipation of effects due to thermal transients and can be adjusted to suit the transients predicted for a given cell to cell jump. This measure is only necessary for extreme cases in which the current discontinuity is so large that there is a risk that the target cell will not be reached initially. In other words, the off-centre skewing of the operating point may only be adopted by the control system for a limited number of the supermode jumps.
[0076] In the illustrated example, set point 114 is a skewed set point within cell 110 , chosen such that it also lies within shifted cell 140 . Therefore, upon jumping from initial cell 160 , towards target cell 110 , the operating point upon arrival still lies within the shifted cell 140 , albeit at a non-central position. In addition to this, a value of I ph can be chosen such that the initial output frequency of the laser upon arrival at high currents is close or equal to the output frequency produced at target operating point 112 . After arrival of the operating currents at point 114 , the shifted cell 140 will distort back to the original steady state position of cell 110 as the thermal transient effects take their course. The frequency drift associated with the return of the cell to the steady state position may be compensated for by phase tuning.
[0077] The direction of the skewing in current space and the magnitude of the skewing will depend on, and be determined according to, the difference in drive current sets between the initial cell and target cell. It will also be appreciated that the current space considered during the calibration will in general be three-dimensional to take account of gain current, not only two-dimensional for forward and back currents as illustrated. It will also be appreciated that for different laser types the relevant current space may take account of other current components. It will be understood that the supermode jumping policy, the frequency skewing policy and the current space skewing policy are all implemented together in determining a single series of sets of control input values which will typically be stored in a LUT, although other forms of storage could be used.
[0078] An example portion of a LUT is as follows:
Gain Phase Front Back Etalon Etalon Sign 11159 1859 6286 6087 15885 0 11284 2029 6361 6164 15571 0 11354 2150 6400 6203 15236 0 11710 2653 6599 6402 14891 1 11710 2653 6599 6402 15144 1 11865 2846 6678 6481 15652 1 12011 3076 6754 6560 16007 1 12160 3263 6830 6642 16169 1 12327 3506 6909 6729 16260 1 12327 3506 6909 6729 16219 1 12848 4180 7140 6938 16189 0 12971 4359 7192 6975 16219 0 13195 4669 7290 7058 16017 0 11803 1417 7267 7064 15660 0 11939 1539 7358 7148 15307 0 11939 1539 7358 7148 14881 0 12474 2018 7619 7378 14242 1 12584 2118 7672 7422 15288 1 8541 2713 362 7310 15834 1 8636 2982 373 7385 16098 1 8736 3232 390 7459 16230 1 8784 3343 399 7498 16209 1
The columns labelled gain, phase, front and back give the control input values for the different control currents in terms of the numbers of bits fed to the DAC 28 to produce the drive voltages V g V ph V f and V b . The column labelled etalon gives the target DAC bit value of the signal T received via ADC 22 from the wavelength locker 14 . The column labelled etalon sign indicates whether the gradient of the response function of the wavelength locker is positive or negative at the frequency associated with the revelent set of control input values. It will be understood that the example LUT portion is specific for sweeping in one frequency direction only and is only calibrated for jumping one column at a time through the LUT. A separate LUT will be provided for sweeping in the opposite frequency direction.
[0079] An example of a quasi-continuous scanning range according the present embodiment is now described.
[0080] FIG. 10 shows an example set of laser output points of a laser system of the first embodiment marked on an actual etalon response. This type of response function is typical of a Fabry-Perot etalon. The etalon has a 50 GHz period. Each period is calibrated with 50 grid points spaced apart equally in frequency by 1 GHz for quasi-continuous frequency scanning. Due to the asymmetric nature of the Fabry-Perot response function, the scanning range is split into alternate 20 and 30 GHz sections.
[0081] FIG. 11 is a graph for the same example showing the frequency tuning path of the laser system. The graph plots the sum of the front back and gain currents in bits against frequency f, where each contiguous curve relates to one supermode, with the alternating light and dark curve portions relating respectively to the alternating 20 and 30 GHz sections of the etalon response.
[0082] It is apparent from the figure that the laser can be quasi-continuously scanned from around 1.92 THz to 196 THz in 1 GHz increments by jumping through around a dozen supermodes. Most if not all of the supermodes are followed through several cavity modes.
[0083] A further policy is also apparent from the figure. This policy is that of keeping the sum of the drive currents within as narrow a range as possible throughout the whole sweep. In terms of bits, it can be seen that the current sum is kept between about 12000 and 30000 throughout.
[0084] FIG. 12 shows a SG-DBR with an associated feedback control system according to a second embodiment of the invention. The second embodiment differs from the first embodiment in the hardware approach adopted to cope with the changes in sign of the etalon response at the response maxima and minima. Instead of switching the sign of the correction signal supplied from the phase current control unit, as in the first embodiment, the response from the wavelength locker is electronically processed so that the response from the locker is unipolar over a full FSR of the etalon, which allows the control loop to be simpler by emulating the optical transmission response more typically found in a frequency referencing element such as a locker based on PSI techniques. The wavelength locker 14 conditioning circuitry incorporates an analogue inverter circuit that is either bypassed or not, as triggered by the microprocessor 24 , co-incident with the set values on the tunable laser. This trigger signal is set/reset based on the state of the etalon sign bit of the LUT stored on the microprocessor. See the LUT example earlier.
[0085] FIG. 13 a shows the transmission response T for an etalon measured over a range of 100 GHz. The etalon has an FSR of 50 GHz and a finesse greater than 1. Suppose for example that the etalon is to be used in the tuning of the laser diode between f 1 =194020 GHz and f 2 =194050 GHz (15 grid point steps marked as points on the response curve on a 2 GHz frequency grid). Starting at f 1 , the phase current I ph (and, perhaps one or more of the other operating currents) is varied in a stepwise manner so as to increase the output frequency towards f 2 . As the phase current is incremented for each successive grid point, the feedback circuit keeps the frequency locked to the desired operating frequency by supplying a feedback signal which is determined at least in part by the difference between the value of T at the current output frequency f output and the expected value of T at the target output frequency f target . However, as f output reaches and passes through the extremum in T located at approximately 194036 GHz, the slope in T changes sign. Accordingly, for frequencies higher than 194036 GHz, a small deviation in the output frequency would be met with a change in the feedback signal opposite to that which would be required to drag the operating frequency back to the target frequency. Consequently, the locking circuit is only able to function for one half of the overall lineshape.
[0086] FIG. 13 b shows how this problem is addressed in the second embodiment. The problem is addressed by inverting all portions of the etalon response curve that are of either one or the other sign in gradient. In the illustrated example, all portions of the response curve with a positive slope are inverted such that the entire line shape consists of portions which have a negative gradient. This means that, within a single period, the feedback circuit will always be able to drag f output in the right direction towards the target frequency. Accordingly, only a single feedback circuit is required. It is also worth noting that after inversion, the effective locking range of the etalon has been doubled. A full period of the response curve is now available for locking. This also has a beneficial effect when jumping between supermodes since overshoots and undershoots in landing frequency that are twice as big can now be accommodated.
[0087] A further measure that can be taken to facilitate locking to a fine frequency grid is to introduce a variable gain envelope on the feedback signal, which matches the varying slope of the etalon response curve. In this example, the sensitivity of the locking circuit to deviations in frequency is far greater at f 3 =194060 GHz than at f 4 =194042 GHz. Accordingly, the feedback signal at f 4 should be enhanced over that at f 3 . Equalisation can be imposed on the signals provided by photodiodes PD 1 and PD 2 with an analogue amplifier arranged prior to the ADC. The use of variable gain enhancement on the feedback signal greatly improves the sensitivity of the locking circuit near the extremes of the etalon response curve, thereby reducing the time taken for an erroneous output frequency to be dragged back to the target frequency. This feature is normally implemented by incorporation of variable gain potentiometer values in the LUT of the microprocessor, where the gain for each set point in the sweep has associated with it, in the most general case, a potentiometer value. This potentiometer value compensates for the variation of the loop gain due to the variable slope of the frequency-referencing element rather than using a transformation such as a Ln (natural log) which is much more complicated to achieve and cannot be simply done with analogue circuitry, or than using a non-linear electronic element as a transfer function to normalise the gain.
[0088] The gain described above can be used to adjust the response of the etalon so that the desired frequency occurs at the same or similar response value. This reduces the need to adjust the target locking value by large amounts and can reduce any switching transients as the laser is switched from one channel to the next and hence allows faster switching of the laser.
[0089] In addition to the gain, an offset can also be used to achieve exact matching between the target response value and the effective slope of the etalon response for all target frequencies so as to normalise the desired locking value from the controller.
[0090] In a further implementation of this variable gain updating, a policy of having more that one gain value associated with specific steps in the frequency sweep may be employed. This two step updating of the loop gain ensures better loop stability in cases where the frequency transient is large and the locking range is small or decreasing. For example, for frequency greater than the ITU frequency of the etalon response and where a supermode jump has just been experienced. In this situation each value (row) in the standard LUT would have two gain potentiometer values associated with it.
[0091] An alternative to gain equalisation is to use an etalon with a sawtooth response as may be provided by a phase shift interferometer (PSI). A sawtooth function has a unipolar slope dT/df which can be almost constant as the number of phase shifting elements in the PSI technique employed increases. For example, for a 4 term PSI strategy, where four signals with π/2 phase shift between each quadrature signal, are processing the slope is unipolar and the slope value is virtually constant over the free spectral range of the PSI locker. Employing this type of frequency referencing element foregoes the need for gain equalisation required when a standard 50 GHz FSR etalon is employed.
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A system in which the controller ( 24 ) of a multi section diode laser such as a SG-DBR ( 10 ) is configured so that the laser can be swept rapidly in a pre-determined frequency direction through a series of frequency points by asserting a pre-calibrated series of sets of control input values to the sections of the diode laser, wherein the frequency points are obtained from cavity modes in a plurality of different supermodes, and the sets of control input values are pre-determined to take account of thermal transients that are known to arise from jumps in the output modes that occur when sweeping through the pre-calibrated series of sets of control input values in the pre-determined frequency direction.
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FIELD OF INVENTION
[0001] The present invention relates to methods and compositions for treating plants in order to enhance the growth and yield of plants, hardiness, as well as aiding in a plants recovery during and following a transplant shock incidence. The methods and compositions of the invention are suitable for topical application and are useful in increasing the rate of growth of plants, increasing the yield, hardening of the plants, and aiding in the recovery of plants during and following transplantation.
BACKGROUND OF THE INVENTION/RELATED ART
[0002] Plants depend on light and carbon dioxide to produce the simple sugar, glucose. The produced glucose is then used as the energy source to build the leaves, flowers, fruits, and seeds of the plant. Plant growth and product yield are important factors in the horticulture business. In order to maximize the potential of each plant the “ideal” growing environment must be created. Creating the “ideal” environment is often a process that is not feasible to many growers. Therefore, fertilization with natural and artificial substances plays an important role.
[0003] In the area of plant fertilization many compounds have been used, including nitrogen, phosphorus, potassium as well as others. Effective fertilization can play a critical role in the growth of plants and is frequently the determining factor in the quality and quantity of the outcome. Past research has investigated which fertilizers or combinations thereof promote the optimal growth of the plant. For example, it has been shown that fertilization with nitrogen increased plant growth and yield, in addition to improving seed quality and nutritional value 1 . Further, another study demonstrated that phosphorus fertilization can significantly increase plant weight, seed yield, seed mucilage content, and seed protein content 2 . In the same study, fertilization with a combination of phosphorus and potassium resulted in the highest seed yield, seed mucilage content, and seed protein content 2 . Fertilization of plants with a combination of nitrogen, phosphorus, and potassium is so widely recognized that the concentration of each is printed on the label of many (if not all) plant fertilization products.
[0004] New findings in the area of fertilization are of great interest. For example, it is unknown to what extent various additives maybe substituted for, replace, show synergistic effects or interfere with the benefit derived from a fertilizer given alone. This is the main motivator for pursuing the investigations leading to this invention.
[0005] All commercially grown plants (potted plants, annuals, shrubs, trees, etc) are exposed to transplant shock during their existence, as well as hardening during re-implantation of a plant. The term transplant shock is usually reserved for replanted annual plants; however, it is not exclusive to this state, and can cover anything from severe wilting to healthy-looking plants with a mysterious reluctance to resume growth after transplantation. The suspected cause of transplant shock is the failure of the plant to root well or a diminished root system (due to removal from its original site) and consequently the plant becomes poorly established in the new landscape soil. The plant can incur additional stress/shock following transplantation from lack of sufficient nutrients and/or water requirements following re-implantation into the soil.
[0006] The period of slow growth following transplantation will vary from species to species of the variety of plants. For example, it is not uncommon for a large tree to experience a period of stagnant growth for several years following transplantation due to inadequate initial conditions or continual absence of key nutrients.
[0007] During transplantation of plants, much of the plant's root system is often left behind during the harvestation of the desired plant. Once re-implanted, the reduced root system is unable to supply an adequate amount of nutrients, as well as a necessary root arrangement, and water for adequate normal growth. The increase and decrease of root growth potential paralleled the rise and fall of carbohydrate concentrations in the roots, not reflecting the subsequent stem evolution.
[0008] Hardening of a plant is also important during and following transplantation. Hardening relates to the acclimation to cold temperatures and/or inclement weather patterns. Tinus et al. (2000) reported a close correspondence between the level of cold hardiness and absolute concentration of sugars. 3 Cold does not merely mean sub-thermal temperatures, but does reflect the change in state that a plant experiences when it is plucked from its normal inhabitant into a climate of different conditions. The increase and decrease of root growth potential paralleled the rise and fall of carbohydrate concentration in the roots, not reflecting the subsequent stem evolution. As temperatures drop, sugars tend to concentrate and then decrease in concentration. Upon this decrease in sugar availability, the plant turns to a dormancy state. Enzyme activity of the plant is also maintained when sugars are available, providing that the environmental conditions are acceptable. As temperature decreased, enzyme activity also decreased. However, enzyme patterns may be maintained with adequate substrate base. The combination of optimal enzyme patterns and substrate bases would ensure an ideal condition for the plant to accept and subsequently maintain or enhance its root/stem growth, leading to a more prolific plant. 4
[0009] Further, not only does the addition of ribose, other pentose sugars, their derivatives, or a combination of pentose sugars with other nutrients aid in the above, but has additional factors in providing aided features in hardening of essential fundamental parts of the plant, necessary in its initial and continual growth, such as roots, stem, and shoot characteristics.
SUMMARY OF THE INVENTION
[0010] The present invention relates to methods and compositions for supplementing the soil/diet of plants in order to enhance plant growth, yield, hardening, as well as the recovery of plants which undergo transplantation. The present invention provides ribose and other pentose sugars and their derivatives, alone or in combination with other carbohydrates, electrolytes, minerals, enzymes, micronutrients, macronutrients, or other ingredients to enhance plant growth, yield, hardening, and aid in the recovery during and following transplantation.
DESCRIPTION OF THE DRAWINGS
[0011] Table 1 represents plant growth data with various feeding combinations. Table 2 represents plant growth data and hardening following transplantation. Table 3 represents plant growth/height data. Table 4 represents root weight and measured length from seeds planted in soil.
[0012] [0012]FIG. 1 depicts bar representation of plant growth data following transplantation.
[0013] [0013]FIG. 2 depicts bar representation of mean plant growth data following transplantation.
[0014] [0014]FIG. 3 graphically represents plant growth data during light conditions.
[0015] [0015]FIG. 4 graphically represents plant growth data during dark conditions.
DETAILED DESCRIPTION OF THE INVENTION
[0016] While it is not known which factors are most important for a plant to fully reach it's production potential, it has been found that fertilization with ribose, other pentose sugars, or their derivatives is effective in enhancing both plant growth, yield, hardening, and recovery from their subsequent transplantation process.
[0017] Photosynthesis is the process by which green plants and other organisms use light energy to convert carbon dioxide and water into the simple sugar glucose. Plants use much of this glucose, a carbohydrate, as an energy source to build leaves, flowers, fruits, seeds, and hardiness during stress and transplantation. They also convert glucose to cellulose, the structural material used in their cell walls. Most plants produce more glucose than they use, which can be stored in the form of starch and other carbohydrates in their roots, stems, and leaves. The plants can then draw on these reserves for needed extra energy or building materials. As disclosed in U.S. Pat. No. 5,366,954, a storage solution containing 5-deoxy-5-ethylthio-D-ribose (a derivative of ribose) has been found to extend bloom life of a cut flower. Now, it is herein disclosed that, in spite of not fully understanding the mechanisms by which it might operate, it has been discovered that fertilization with ribose and possibly other pentoses and/or their derivatives, alone or in conjunction with other fertilizer ingredients, can enhance a plant's growth, yield, hardening, and its recovery from transplantation.
[0018] This invention provides ribose, other pentose sugars, or their derivatives for enhanced plant growth, yield, hardening, and recovery during and following transplantation. This invention also provides ribose in combination with nitrogen, phosphorus, potassium, or any combination of the three. Possible amounts of pentoses: (5 g/1000 mL: 33 mM, 5/500: 66 mM, 51250:132 mM, 5/125: 264 mM).
[0019] Ribose is a simple 5-carbon sugar, with a slightly sweet taste. It is a white to light yellow crystalline powder. The amount necessary to have the desired effects on enhanced plant growth can vary with the amount depending on the species of the plant. The ribose can be mixed with water or a liquid fertilizer and applied directly to the soil during the regular watering routine.
[0020] For photosynthesis to continue at high rates, the pools of intermediates must be maintained within the chloroplast as the pathway operates as a cycle. At appropriate concentrations, ribose will cause chloroplasts to shrink as a result of exosmosis of water. This volume change brings about a rapid increase in absorbance. There is a fairly fast recovery indicating that exosmosis is followed be endodiffiusion of ribose and a consequent increase in turgor within the plant cell.
[0021] Photosynthesis can be divided into two separate reactions, the light reaction and the dark reaction. It is in the light reactions that light (light in the range of the red and blue wavelengths have been found to be most effective) creates energy in the form of NADPH and ATP. The NADPH and ATP molecules are then used as the energy source to run the dark reactions.
[0022] The dark reactions (commonly called the Calvin Cycle) occur during the daytime and are strictly dependent on the light reactions, i.e., the formation of reductive power as NADPH. Overall, the Calvin Cycle is the process in which carbon is fixed, reduced, and utilized. It is involved in the formation of sugar phosphate intermediates in a cyclic sequence. One complete cycle incorporates three molecules of carbon dioxide and produces one Molecule of the three-carbon compound glyceraldehyde-3-phosphate. The fate of glyceraldehyde-3-phosphate is to be converted to starch or exported out of the chloroplast where it is used for the biosynthesis of products needed by the plant. 5
[0023] We have found that the application of ribose, other pentoses, their derivatives, or combinations of pentoses and other nutrients as a fertilizer, preferably every other day in these experiments, over the course of seven days is enough to observe notable differences in plant growth, yield, hardening, and aids in the recovery from transplantation of its species. In order to maintain the gains, it is necessary to continue ribose, other pentoses, their derivatives, or combinations of pentoses and other nutrients must be administrated throughout the period during which is desirable to maintain the continued or improved growth, yield, and hardening alone or following transplantation of the plant. When ribose, other pentoses, their derivatives, or combinations of pentoses and other nutrients as a fertilization medium is discontinued, a slow decline to base line growth rates, yields, hardening, as well as a transplant shock demise ensues.
[0024] The fertilizers nitrogen, phosphorus, and potassium when combined with ribose, provides slight incremental improvements over solutions of ribose alone.
[0025] The following examples are included to demonstrate the preferred embodiment of the invention. D-ribose is the preferred embodiment, however, to those skilled in the art it is known that certain pentose carbohydrates, such as xylitol and ribulose, are readily converted to D-ribose in vivo. Therefore, the term “ribose” is intended to include D-ribose and such precursors thereof and other pentose sugars and derivatives. It should be appreciated by those skilled in the art that the methods and dosages in the examples that follow represent methods and dosages discovered by the inventors to fiction well in the practice of this invention, and thus can be considered to constitute preferred modes for its practice. However, those skilled in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments that are disclosed and still obtain a like or similar result without departing from the concept and scope of the invention. All such changes are considered to be within the spirit, scope, and concept of the invention as defined by the appended claims.
Example 1
Ribose Alone or in Combinations of Other Pentoses, Their Derivatives, and Other Fertilizer Components Such as Nitrogen, Phosphorus, or Potassium Aids in the Hardening and Recovery During and Following Transplantation.
[0026] Hosta (H. plantaginea grandiflora) plants were transplanted. The protocol was designed such that half of the plants were supplied with water alone and half of the plants received a ribose based solution, in which powdered ribose was mixed in water. All plants were transplanted at the same level in the soil and in like soil. All plants were watered at the same times of day, mid-morning and at dusk. Each plant received the same amount of water/watering (½ liter water at each watering). Table 1 represents plant growth data using various feeding combinations. Results of plant growth data following transplantation are represented in Table 2 and graphically depicted in FIGS. 1 and 2.
Example 2
Plant Growth and Yield
[0027] Three different treatments were explored on bean seeds to determine the effects of ribose (at two different doses) on plant growth and proliferation. [The three treatments include control (plain water), a 0.1332 M solution of ribose (5 g ribose dissolved in 250 ml water), and a 0.0666 M solution of ribose (5 g ribose dissolved in 500 ml water)]. The plants were kept under two different conditions, normal daylight and darkness. A total of six plants will be tested, with the conditions that each plant were tested at listed below.
Treatments: Plant 1-5 - placebo, daylight Plant 4 - placebo, dark Plant 6-10 - 0.1332 M ribose, daylight Plant 5 - 0.1332 M ribose, dark Plant 3 - 0.0666 M ribose, daylight Plant 6 - 0.0666 M ribose, dark
[0028] Each seed was planted under identical conditions (soil and pot size) and all at the same time. The environmental conditions (such as temperature and humidity), except for lighting, were kept constant for all the plants. Once potted, each seed received one to two tablespoons of treatment liquid (as mentioned above). A daily record was kept of the activity of each plant. Watering was done on every other day (or sooner if the soil was deemed too dry by the researcher), each again receiving one tablespoon of treatment liquid. Assessment of the effects of ribose fertilization was determined by measuring the time to the first appearance of a plant from the soil, the rate of growth, and leaf size. Table 3 represents the accumulated plant growth data from Example 2 and FIGS. 3 and 4 are graphic presentations of plant growth during light and dark conditions.
Example 3
Root Growth
[0029] Often times when trying to grow new plants, stems are cut from the parent plant and placed in water to grow roots before being put in soil. Variable factors and conditions, such as age of the existing plant, diameter and density of the cut stem, can be responsible for the enhanced root growth in one stem from another. Furthermore, obviously new plants can also be grown from seeds or pods planted in soil. The implantation of a seed into soil stabilizes the above mentioned variability. The development of short, thick roots have been shown to aid in a plant's stability, subsequent growth, and ultimate production from the plant.
[0030] Identical sized pots, containing the same consistency of soil media, were used in assessing root growth. Bean seeds of similar size were chosen. One seed was planted in each pot. The depth in the soil for each seed that was planted was the same. Paired pots (total of 3 pairs, 6 pots), each containing one bean seed, were used. One pair of pots received 2 teaspoons of water every other day (Group A). The second pair of pots received a low Ribose solution (1 teaspoon of ribose in 16 oz of water), each pot received 2 teaspoons of this low dose of Ribose every other day (Group B). The final pair of pots received a higher dose of Ribose (1 teaspoon of Ribose in 4 oz of water), each pot received 2 teaspoons of this higher dose of Ribose every other day (Group C). In each pair of pots, roots were examined at week 1 and 2, by removing the roots of one pot only in each group at the designed test time point with soil emersion in a bucket of water. At week 2 all remaining pots had shoots emerging from the top soil. The roots were weighed and measured for length Table 4 reports this data at weeks 1 and 2 following seed implantation. At one week, the Ribose treated seeds had roots that were slightly shorter in length in comparison to the water pots, however, the weight of the Ribose treated roots were heavier than the water treated seeds. This discrepancy expanded when the roots were analyzed at 2 weeks. The low dose Ribose treated roots were thicker, shorter roots, represented by a shorter length and a heavier weight. The high dose Ribose treated roots were thick, however, were less in weight than both the low dose Ribose and water groups. The weight of the roots treated with high dose Ribose were appreciably less in weight than both the water and low dose Ribose treated groups. The water treated roots at 2 weeks demonstrated a thin, spindly, and longer consistency than both the low and high dose Ribose seeds.
Example 4
Comparison with other Carbohydrates
[0031] Three seeds were planted and watered with one of the three following treatments: water, 0.1332 M ribose and water, and 0.1332 dextrose and water. Each seed were planted under identical conditions (soil and pot size) and all at the same time. The environmental conditions (such as temperature and humidity), except for lighting, was kept constant for all the plants. Once potted, each seed received one to two tablespoons of treatment liquid (as mentioned above). A daily record was kept of the activity of each plant. Watering was done on every other day (or sooner if the soil was deemed too dry by the researcher), each again receiving one tablespoon of treatment liquid. Assessment of the effects of ribose fertilization was determined by measuring the time to the first appearance of a plant from the soil, the rate of growth, and leaf size.
Example 5
Fertilization with Ribose and Nitrogen
[0032] Ribose plus nitrogen, nitrogen alone, or placebo was administered to bean seeds and measurements of growth and yield was made as in Example 2.
Example 6
Fertilization with Ribose and Phosphorus
[0033] Ribose plus phosphorus, phosphorus alone, or placebo was administered to bean seeds and measurements of growth and yield was made as in Example 2.
Example 7
Fertilization with Ribose and Potassium
[0034] Ribose plus potassium, potassium alone, or placebo was administered to bean seeds and measurements of growth and yield was made as in Example 2.
Example 8
Fertilization: Ribose and Combination of Nitrogen, Phosphorus, and Potassium. Ribose Plus the Combination, the Combination Alone, or Placebo was Administered to Bean Seeds and Measurements of Growth and Yield was made as in Example 2.
[0035] All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods have been described in terms of preferred embodiments, it will be apparent to those skilled in the art that variations may be applied to the compositions and methods described herein without departing from the concept and scope of the invention.
REFERENCES
[0036] [0036] 1 Elsheikh EA, AA Elzidany. Effects of Rhizobium inoculation, organic and chemical fertilizers on yield and physical properties of faba bean seeds. Plant Foods Hum Nutr. 1997;51(2): 137-144.
[0037] [0037] 2 Omer EA, A Fattah, M Razin, SS Ahmed. Effect of cutting, phosphorus and potassium fertilization on guar plant ( Cyamoposis tetragonoloba ) in newly reclaimed soil in Egypt. Plant Foods Hum Nutr. 1993 November; 44(3): 277-284.
[0038] [0038] 3 Tinus RW. Relationship between carbohydrate concentration and root growth potential in coniferous seedlings from three climates during cold hardening and dehardening. Tree Physiology. 2000 October; 20(16): 1097-1104.
[0039] [0039] 4 Hlluner NP, FD Macdowall. The effects of low temperature acclimation of winter rye on catalytic properties of its ribulose bisphosphate carboxylase-oxygenase. Can J Biochem. 1979 July; 57(7): 1036-1041.
[0040] [0040] 5 “Photosynthesis,” Microsoft® Encarta® Online Encyclopedia 2001.
TABLE 1 Plant feeding with ribose for growth Planting date: 4 June 5 seeds per plot Ribose from container #1, opened on 4 Jun. 2001 Each seed/plant receives 2 tablespoons every other day of the week (3× per week) Plots rotated weekly to minimize location influence Measured to the Y Water = WT Miracle Grow™ = MG Miracle grow™ plus stock ribose = MGR Ribose 1: 1 teaspoon ribose per 4 oz water (stock solution) = R1 Ribose 2: cut stock in half with water = R2 Ribose 3: cut ribose #2 in half with water = R3 Ribose 4: cut ribose #3 in half with water = R4 W: Wilted and died Sprout 11 June all plots Measured in inches Plant measures taken 23 June Plant # WT MG MGR R1 R2 R3 R4 1 3 0 0.25 0 0 1.75 6.5 2 7 0 5.5 0 3 4.75 8 3 8.25 4.75 5.5 2.25 4 7.5 8.25 4 9.25 7 8.25 2.5 4.75 7.75 9.5 5 9.75 7.75 9 3.5 4.75 8.5 10 Mean 7.45 3.9 5.7 1.65 3.3 6.05 8.45 STD 2.7 3.7 3.4 1.6 2.0 2.8 1.4 Unsprouted 0 2 0 2 1 0 0 Measured 8 July 1 W 0 0 0 0 3.5 8.75 2 8.5 0 7 0 4.25 6.5 10 3 9 6.5 6.75 3 5.5 9.75 10.5 4 11 9 10 3.75 6.5 10 11.75 5 11.25 8.75 10.25 4.75 6.75 10.75 12 Mean 9.9 6.1 8.5 2.9 5.8 9.3 11.1 STD 1.4 4.2 1.9 2.0 1.1 1.9 1.0 #Plants/blossom 2 1 2 1 3 4 5
[0041] [0041] TABLE 2 TRANSPLANTS IN GARDEN WITH BEANS (B) AND KOHLRABI (K) (plant order from left to right in plot) Bean measures to Y = total height: 9*20 would be 9 cm to the Y and 25 cm overall height; W: Wilt and died 9 Sep measures were made before moving/29 Sep was first measure after transplant Feedings (2T) took place on Monday, Wednesday, Friday Miracle Grow feeding took place on every other Monday with water given to those lants on Wed and Fri B B B K K K K WATER 9-Sep 8*25 10*26 8*23 11 14 10 13 29-Sep 9.75*27 10.5*27 10*25 W 14 11 16 19-Oct 10*28 10.5*28 11*27 0 15 11 17 1-Nov 10*28 11*28.5 11*27 0 16 11 18 MG 9-Sep 9*27 7*20 8*21 9*25 12 14 9 29-Sep 10*29 8.5*22 9*22 W 14 16 13 19-Oct 11*30 9*22.5 10*23 W 15 16 13 1-Nov 11*30.5 9*23 10.5*24 W 15.5 17 13 LOW RIB (R4) 9-Sep 6*21 8*22 12 13 17 17 11 29-Sep 7.5*24 10.5*26 14 16 19 19.5 13 19-Oct 8.75*26 12*28 15 18 19.5 20 14.5 1-Nov 10*27 13*30 16.5 19 22 21 15 HIGH RIB (R1) 9-Sep 9*24 10*26 6*11 4 9 6 13 29-Sep W 14*30 9.5*14 7 13 7 17 19-Oct W 16*32 10*15 9.5 14.5 8 17.5 1-Nov W 17*33.5 12*18 11 15.5 9.8 18
[0042] [0042] TABLE 3 PLANT GROWTH-HEIGHT 17- 20- 22- 24- 25- 26- 27- 28- 29- 30- 3- 6- Sep Sep Sep Sep Sep Sep Sep Sep Sep Sep Oct Oct Day 0 3 5 7 8 9 10 11 12 13 16 19 Placebo - Light 0 0 0 1.6 3.2 12.6 17.8 22.8 26.1 27.4 28.7 28.7 5/500 - Light 0 0 0 0 0.5 2.1 10.5 16.6 22.5 26.3 28.4 29 5/250 - Light 0 0 1.1 5.5 15 19.1 23.1 25.7 26.4 26.6 28.3 27.6 Placebo - Dark 0 0 0 2.3 6.9 13.9 21.8 27.3 30.8 34.3 36.3 36.7 5/500 - Dark 0 0 0 5.2 11.1 20.8 30.6 35.8 39.3 44.8 46.8 46.8 5/250 - Dark 0 0 0 4.4 8.5 13.2 15.3 17.6 19.6 21.1 24.7 Amount of Between Growth Measurements Placebo - Light 0 0 0 1.6 1.6 9.4 5.2 5 3.3 1.3 1.3 0 5/500 - Light 0 0 0 0 0.5 1.6 8.4 6.1 5.9 3.8 2.1 0.6 5/250 - Light 0 0 1.1 4.4 9.5 4.1 4 2.6 0.7 0.2 1.7 −0.7 Placebo - Dark 0 0 0 2.3 4.6 7 7.9 5.5 3.5 3.5 2 0.4 5/500 - Dark 0 0 0 5.2 5.9 9.7 9.8 5.2 3.5 5.5 2 0 5/250 - Dark 0 0 0 4.4 4.1 4.7 2.1 2.3 2 1.5 3.6 Between Rate of Growth Measurements Placebo - Light 0 0 0 0.80 1.60 9.40 5.20 5.00 3.30 1.30 0.43 0.00 5/500 - Light 0 0 0 0 0.50 1.60 8.40 6.10 5.90 3.80 0.70 0.20 5/250 - Light 0 0 0.55 2.20 9.50 4.10 4.00 2.60 0.70 0.20 0.57 −0.23 Placebo - Dark 0 0 0 1.15 4.60 7.00 7.90 5.50 3.50 3.50 0.67 0.13 5/500 - Dark 0 0 0 2.60 5.90 9.70 9.80 5.20 3.50 5.50 0.67 0.00 5/250 - Dark 0 0 0 2.20 4.10 4.70 2.10 2.30 2.00 1.50 1.20 Overall Thru Rate of Growth Date Placebo-Light 0 0.23 0.40 1.40 1.78 2.07 2.18 2.11 1.79 1.51 5/500 - Light 0 0.00 0.06 0.23 1.05 1.51 1.88 2.02 1.78 1.53 5/250 - Light 0.22 0.79 1.88 2.12 2.31 2.34 2.20 2.05 1.77 1.45 Placebo - Dark 0 0.33 0.86 1.54 2.18 2.48 2.57 2.64 2.27 1.93 5/500 - Dark 0 0.74 1.39 2.31 3.06 3.25 3.28 3.45 2.93 2.46 5/250 - Dark 0 0.63 1.06 1.47 1.53 1.60 1.63 1.62 1.54
[0043] [0043] TABLE 4 ROOT GROWTH ASSESSMENT Weight (gm) Length (cm) Week 1 Water 1.32 14.6 Low Ribose 1.55 13.4 High Ribose 1.46 13.8 Week 2 ** Water 0.57 22.8 Low Ribose 1.01 16.0 High Ribose 0.26 14.7
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The present invention relates to methods and compositions for supplementing the soil/diet of plants in order to enhance plant growth, yield, hardening, as well as the recovery of plants which undergo transplantation. The present invention provides ribose and other pentose sugars and their derivatives, alone or in combination with other carbohydrates, electrolytes, minerals, enzymes, micronutrients, macronutrients, or other ingredients to enhance plant growth, yield, hardening, and aid in the recovery during and following transplantation
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TECHNICAL FIELD
[0001] The present invention relates to an input device.
BACKGROUND ART
[0002] As shown in Patent Document 1, a non-contact input device is known for which an input operation such as switching display images by a user moving his/her hand in a space in front of a display panel is performed. In this device, movements of the user's hand (that is, gestures) are captured by camera, and this image data is used to recognize gestures.
RELATED ART DOCUMENT
Patent Document
[0003] Patent Document 1: Japanese Patent Application Laid-Open Publication No. 2010-184600
Problems to be Solved by the Invention
[0004] In gesture recognition using a camera, hand movement parallel to the surface of the display panel is easy to recognize, but hand movement perpendicular to the display surface (that is hand movement back and forth with respect to the display surface) is difficult to recognize due to reasons such as the difficulty in measuring distance of movement.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide a non-contact input device having excellent input operability.
Means for Solving the Problems
[0006] An input device of the present invention includes: a reference surface; a position detection unit that forms a detection region in a space in front of the reference surface and detects position coordinates in the detection region of a detection object such as a finger that has entered the detection region; a comparison unit that compares a position coordinate in a front-to-rear direction of a virtual plane set so as to partition the detection region front and rear, with a position coordinate in the front-to-rear direction of the detection object, the position coordinate having been detected by the position detection unit; and a determination unit that determines an input operation of the detection object on the basis of comparison results of the comparison unit.
[0007] By comparing a position coordinate in a front-to-rear direction of a virtual plane set so as to partition the detection region front and rear, with a position coordinate in the front-to-rear direction of the detection object, the position coordinate having been detected by the position detection unit, the input device can determine the input operation of the detection object. In other words, the input device can determine the input operation in the front-to-rear direction of the detection object, and has excellent input operability.
[0008] In the input device, when the comparison results by the comparison unit indicate that the position coordinate of the detection object is less than or equal to the position coordinate in the virtual plane, the determination unit may determine that the input operation is a click operation that passes through the virtual plane in a direction towards the reference surface.
[0009] Furthermore, an input device of the present invention includes: a reference surface; a position detection unit that forms a detection region in a space in front of the reference surface and detects position coordinates in the detection region of a detection object such as a finger that has entered the detection region; a virtual plane that partitions the detection region in a front-to-rear direction such that the detection region is divided into a first detection region and a second detection region; a standby detection unit that detects that the detection object has stayed in the second detection region for a prescribed time in accordance with detection results of the position detection unit; a change amount detection unit that detects, in accordance with the detection results of the position detection unit, an amount of change in position of the detection object from the second detection region towards the first detection region after staying in the second detection region for the prescribed time; and a determination unit that determines an input operation of the detection object in accordance with the detection results of the change amount detection unit.
[0010] In the input device, the detection region is divided front and rear into the first detection region and the second detection region by the virtual plane, and thus, the input device can determine the input operation in the front-to-rear direction of the detection object, and has excellent input operability.
[0011] Furthermore, an input device of the present invention includes: a reference surface; a position detection unit that forms a detection region in a space in front of the reference surface and detects position coordinates in the detection region of a detection object such as a finger that has entered the detection region; a virtual plane that partitions the detection region in a front-to-rear direction such that the detection region is divided into a first detection region and a second detection region; a standby detection unit that detects that the detection object has stayed in the first detection region for a prescribed time in accordance with detection results of the position detection unit; a change amount detection unit that detects, in accordance with the detection results of the position detection unit, an amount of change in position of the detection object from the first detection region towards the second detection region after staying in the first detection region for the prescribed time; and a determination unit that determines an input operation of the detection object on the basis of detection results of the change amount detection unit.
[0012] In the input device, the detection region is divided front and rear into the first detection region and the second detection region by the virtual plane, and thus, the input device can determine the input operation in the front-to-rear direction of the detection object, and has excellent input operability.
[0013] In the input device, the reference surface may be a display surface of a display unit that displays images.
[0014] The input device may include a display switching unit that switches an image displayed on the display surface of the display unit to another image corresponding to the input operation, on the basis of determination results of the determination unit.
[0015] Furthermore, an input device of the present invention includes: a display unit that displays a three-dimensional image so as to float in front of a display surface; a position detection unit that forms a detection region in a space in front of the display surface and detects position coordinates in the detection region of a detection object such as a finger that has entered the detection region; a comparison unit that compares a position coordinate in a front-to-rear direction of a virtual plane partitioning the detection region in the front-to-rear direction and overlapping a position of the three-dimensional image that floats in front of the display surface with a position coordinate in the front-to-rear direction of the detection object as acquired by the position detection unit; and a determination unit that determines an input operation of the detection object in accordance with comparison results of the comparison unit.
[0016] In the input device, the position of the virtual plane that partitions the detection region front and rear is set so as to overlap in position the three-dimensional image, which appears to float in front of the display surface of the display unit, and by the user performing an input operation in the front and rear direction using a finger or the like, the user can perform an input operation with the sense of directly touching the three-dimensional image.
[0017] In the input device, when the comparison results by the comparison unit indicate that the position coordinate of the detection object is less than or equal to the position coordinate in the virtual plane, the determination unit may determine that the input operation is a click operation that passes through the virtual plane in a direction towards the reference surface.
[0018] The input device may include a display switching unit that switches a three-dimensional image displayed so as to float in front of the display surface of the display unit to another three-dimensional image corresponding to the input operation, on the basis of determination results of the determination unit. If the three-dimensional image is switched to another three-dimensional image in this manner, the user can experience the sense of having switched the original three-dimensional image to the other three-dimensional image by directly touching the original three-dimensional image.
[0019] In the input device, it is preferable that the position detection unit have a sensor including a pair of electrodes for forming the detection region by an electric field, the position coordinates of the detection object being acquired on the basis of static capacitance between the electrodes. In other words, the position detection unit constituted by capacitance sensors or the like has excellent detection accuracy in the front and rear direction of the reference surface (or display surface) compared to other general modes of position detection units. Thus, it is preferable that a position detection unit including such capacitive sensors be used.
Effects of the Invention
[0020] According to the present invention it is possible to provide a non-contact input device having excellent input operability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a descriptive drawing that schematically shows the outer appearance of a display operation device of Embodiment 1.
[0022] FIG. 2 is a function block diagram showing main components of the display operation device of Embodiment 1.
[0023] FIG. 3 is a descriptive drawing that schematically shows an electric field distribution formed to the front of the display surface.
[0024] FIG. 4 is a descriptive drawing that schematically shows a signal strength of a capacitive sensor in the Z axis direction.
[0025] FIG. 5 is a flowchart showing steps of an input process of the display operation device based on a click operation by a fingertip.
[0026] FIG. 6 is a descriptive drawing that schematically shows a single click operation.
[0027] FIG. 7 is a descriptive drawing that schematically shows a double click operation.
[0028] FIG. 8 is a flowchart showing steps of an input process of the display operation device based on a forward movement operation by a fingertip.
[0029] FIG. 9 is a descriptive drawing that schematically shows a state in which a fingertip is held still in a second detection region prior to forward movement.
[0030] FIG. 10 is a descriptive drawing that schematically shows a state in which the fingertip moves forward to a first detection region.
[0031] FIG. 11 is a flowchart showing steps of an input process based on a backward movement operation by a fingertip.
[0032] FIG. 12 is a descriptive drawing that schematically shows a state in which a fingertip is held still in the first detection region prior to backward movement.
[0033] FIG. 13 is a descriptive drawing that schematically shows a state in which the fingertip moves backward to the second detection region.
[0034] FIG. 14 is a descriptive drawing that schematically shows the outer appearance of a display operation device of Embodiment 2.
[0035] FIG. 15 is a function block diagram showing main components of the display operation device of Embodiment 2.
[0036] FIG. 16 is a descriptive drawing that schematically shows the relationship between a three-dimensional image and a detection region formed to the front of the display operation device.
[0037] FIG. 17 is a flowchart showing steps of an input process of the display operation device based on a click operation by a fingertip.
[0038] FIG. 18 is a front view that schematically shows Modification Example 1 of electrodes included in the capacitive sensor.
[0039] FIG. 19 is a cross-sectional view along the line A-A of FIG. 18 .
[0040] FIG. 20 is a front view that schematically shows Modification Example 2 of electrodes included in the capacitive sensor.
[0041] FIG. 21 is a cross-sectional view along the line B-B of FIG. 20 .
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiment 1
[0042] Embodiment 1 of the present invention will be explained below with reference to FIGS. 1 to 13 . The present embodiment illustrates a display operation device 1 as an example of an input device. FIG. 1 is a descriptive drawing that schematically shows the outer appearance of a display operation device 1 of Embodiment 1. FIG. 1 shows the display operation device 1 as viewed from the front. In the display operation device 1 , a user can directly operate an image displayed in the display surface 2 a of the display unit 2 without touching the display surface 2 a (reference surface) through hand motions (so-called gestures). The display unit 2 includes the horizontally long rectangular display surface 2 a as shown in FIG. 1 . Electrodes 3 a and 3 b used for detecting hand motions are provided in the periphery of the display surface 2 a as will be described later. The display operation device 1 is supported by a stand ST.
[0043] FIG. 2 is a function block diagram showing main components of the display operation device 1 of Embodiment 1. The display operation device 1 includes the display unit 2 , a finger position detection unit 3 (position detection unit), a CPU 4 , ROM 5 , RAM 6 , a timer 7 , a display control unit 8 (display switching unit), a storage unit 9 , and the like.
[0044] The CPU 4 (central processing unit) is connected to each hardware unit through a bus line 10 . The ROM 5 (read-only memory) has stored in advance various control programs, parameters for computation, and the like. The RAM 6 (random access memory) is constituted by SRAM (static RAM), DRAM (dynamic RAM), flash memory, and the like, and temporarily stores various data generated when the CPU 4 executes various programs. The CPU 4 constitutes the determination unit, comparison unit, standby detection unit, change amount detection unit, and the like of the present invention.
[0045] The CPU 4 controls various pieces of hardware by loading control programs stored in advance in the ROM 5 onto the RAM 6 and executing the programs, and operates the device as a whole as the display operation device 1 . Additionally, the CPU 4 receives process command input from a user through the finger position detection unit 3 , as will be described later. The timer 7 measures various times pertaining to processes of the CPU 4 . The storage unit 9 is constituted by a non-volatile storage medium such as flash memory, EEPROM, or HDD. The storage unit 9 has stored in advance various data to be described later (position coordinate data (threshold α, β) for a first virtual plane R 1 and a second virtual plane R 2 , and prescribed time data such as Δt).
[0046] The display unit 2 is a display panel such as a liquid crystal display panel or an organic EL (electroluminescent) panel. Various information (images or the like) is displayed on the display surface 2 a of the display unit 2 according to commands from the CPU 4 .
[0047] The finger position detection unit 3 is constituted by a capacitive sensor 30 , an integrated circuit such as a programmable system-on-chip, or the like, and detects position coordinates P (X coordinate, Y coordinate, Z coordinate) of a user's fingertip located in front of the display surface 2 a . In the present embodiment, the origin of the coordinate axes is set to the upper left corner of the display surface 2 a as seen from the front, with the left-to-right direction being a positive direction along the X axis and the up-to-down direction being a positive direction along the Y axis. The direction perpendicular to and moving away from the display surface 2 a is a positive direction along the Z axis. The position coordinates P of the fingertips or the like to be detected, which are acquired by the position detection unit 3 , are stored as appropriate in the storage unit 9 . The CPU 4 reads the position coordinate P data from the storage unit 9 as necessary, and performs computations using such data.
[0048] As shown in FIG. 1 , the finger position detection unit 3 includes the pair of electrodes 3 a , 3 b for detecting the fingertip position coordinates P. One of the electrodes 3 a is a transmitter electrode 3 a (drive-side electrode), and has a frame shape surrounding a display area AA (active area) of the display surface 2 a . A transparent thin-film electrode member is used as the transmitter electrode 3 a . A transparent insulating layer 3 c is formed on the transmitter electrode 3 a . The other electrodes 3 b are receiver electrodes 3 b that are disposed in the periphery of the display surface 2 a so as to overlap the transmitter electrode 3 a across the transparent insulating layer 3 c . In the present embodiment, there are four receiver electrodes 3 b , which are respectively disposed on all sides of the rectangular display surface 2 a . The electrodes 3 a and 3 b are set so as to face the same direction (Z axis direction) as the display surface 2 a.
[0049] FIG. 3 is a descriptive drawing that schematically shows an electric field distribution formed to the front of the display surface 2 a . When a voltage is applied between the electrodes 3 a and 3 b , an electric field having a prescribed distribution is formed to the front of the display surface 2 a . FIG. 3 schematically shows electric force lines 3 d and equipotential lines 3 e . In this manner, the space to the front of the display surface 2 a where the electric field is formed is a region (detection region F) where a detection object such as a fingertip is detected by the finger position detection unit 3 . If a fingertip or the like to be detected enters this region, then the capacitance between the electrodes 3 a and 3 b changes. The capacitive sensor 30 including the electrodes 3 a and 3 b forms a prescribed capacitance between the electrodes 3 a and 3 b according to the entry of a fingertip in the region, and outputs an electric signal corresponding to this capacitance. The finger position detection unit 3 can detect the capacitance formed between the electrodes 3 a and 3 b on the basis of this output signal, and can additionally calculate the position coordinates P (X coordinate, Y coordinate, Z coordinate) of the fingertip in the detection region on the basis of this detection result. The detection of the position coordinates P of the fingertip by the finger position detection unit 3 is executed steadily, repeating at a uniform time interval. A well-known method is employed to calculate the fingertip position coordinates P from the capacitance formed between the electrodes 3 a and 3 b.
[0050] FIG. 4 is a descriptive drawing that schematically shows a signal strength of the capacitive sensor 30 in the Z axis direction. In the present embodiment, the display surface 2 a has a 7-inch diagonal size, and if the drive voltage of the capacitive sensor 30 is set to 3.3V, then the signal value (S 1 ) at the detection limit is at approximately 20 cm (greater than 20 cm) in the Z axis direction from the display surface 2 a . In the present embodiment, the rectangular cuboid space measured out as the (length in the horizontal direction (X axis direction) of the display surface 2 a )×(vertical direction (Y axis direction) length of the display surface 2 a )×(length (20 cm) in the Z axis direction) is set as the detection region F.
[0051] The detection region F has two virtual planes having, respectively, uniform Z axis coordinates. One of the virtual planes is a first virtual plane R 1 set at a position 9 cm from the display surface 2 a in the Z axis direction, and the other virtual plane is a second virtual plane R 2 that is set at a position 20 cm from the display surface 2 a in the Z axis direction. In the present embodiment, the second virtual plane R 2 is set at the Z coordinate detection limit. The first virtual plane R 1 is set between the display surface 2 a and the second virtual plane R 2 .
[0052] The detection region F is partitioned into two spaces by the first virtual plane R 1 . In the present specification, the space in the detection region F from the first virtual plane R 1 to the display surface 2 a (between the display surface 2 a and the first virtual plane R 1 ) is referred to as the first detection region F 1 . The space between the first virtual plane R 1 and the second virtual plane R 2 is referred to as the second detection region F 2 . The first detection region F 1 is used, for example, in order to detect click operations based on fingertip movements in the Z axis direction as will be described later. By contrast, the second detection region F 2 is used in order to detect input operations based on fingertip movements in the Z axis direction or operations based on fingertip movements in the X axis direction and Y axis direction (flick movements, for example) as will be described later. In this manner, the detection region F is divided into two detection regions F 1 and F 2 in sequential order according to distance from the display surface 2 a (reference surface).
[0053] The CPU 4 recognizes finger movements by the user by comparing fingertip position coordinates P detected by the finger position detection unit 3 with various preset thresholds (a, etc.), and receives processing content that has been placed in association with such movements in advance. Furthermore, in order to execute the received processing content, the CPU 4 controls respective target units (such as the display control unit 8 ).
[0054] The display control unit 8 displays a prescribed image in the display unit 2 according to commands from the CPU 4 . The display control unit 8 reads appropriate information from the storage unit 9 according to commands from the CPU 4 corresponding to fingertip movements by the user (such as changes in Z coordinate of the fingertip), and controls the image displayed in the display unit 2 so as to switch to an image based on the read-in information. The display control unit 8 may be a software function realized by the CPU 4 executing a control program stored in the ROM 5 , or may be realized by a dedicated hardware circuit. The display operation device 1 of the present embodiment may include an input unit (button-type input unit) or the like that is not shown.
[0055] The steps of the input process based on movements (Z axis direction movements) of a user U's fingertip in the display operation device 1 of the present embodiment will be described. The content indicated below is one example of an input process based on movements of the user U's fingertip (Z axis direction movements), and the present invention is not limited to such content. First, the steps of an input process based on two types of click operations (single click and double click) will be described.
[0056] (Input Operation by Click Movement)
[0057] FIG. 5 is a flowchart showing steps of an input process of the display operation device 1 based on a click operation by a fingertip, FIG. 6 is a descriptive drawing that schematically shows a single click operation, and FIG. 7 is a descriptive drawing that schematically shows a double click operation. Before entering an input by click operation, the user U first performs a prescribed operation on the display operation device 1 and causes the CPU 4 to execute a process of displaying a prescribed reception image (not shown) in the display surface 2 a of the display unit 2 .
[0058] In step S 10 , the finger position detection unit 3 acquires the fingertip position coordinates P of the user U according to a command from the CPU 4 . When a finger enters the detection region F, in step S 10 , the finger position detection unit 3 acquires the fingertip position coordinates P (X coordinate, Y coordinate, Z coordinate). In the present embodiment, as shown in FIGS. 6 and 7 , the user U's hand is formed such that only the index finger extends towards the display surface 2 a from a clenched hand. Thus, the position coordinate of the tip of the index finger is acquired by the finger position detection unit 3 . Regarding movements of the user U's hand (finger) for input operations on the display operation device 1 , a case in which the hand approaches the display surface 2 a is referred to as “forward movement” and a case in which the hand moves away from the display surface 2 is referred to as “backward movement”.
[0059] After the fingertip position coordinates P are acquired, the CPU 4 determines in step S 11 whether the Z coordinate among the acquired position coordinates P is less than or equal to a preset threshold α. The threshold α is the Z coordinate of the first virtual plane R 1 , and indicates a position 9 cm away from the display surface 2 a in the Z axis direction. If the Z coordinate among the acquired position coordinates P is greater than the threshold α (Z>α), then the process returns to step S 10 . If the Z coordinate among the acquired position coordinates P is less than or equal to the threshold α (Z≦α), then the process progresses to step S 12 . As shown in FIGS. 6 and 7 , if the fingertip crosses the first virtual plane R 1 and enters the first detection region F 1 , then the Z coordinate (Z 1 ) among the fingertip position coordinates P 1 is less than or equal to α.
[0060] The detection of the position coordinates P of the fingertip by the finger position detection unit 3 is executed steadily, repeating at a uniform time interval, regardless of the presence or absence of a detection object (finger) in the detection region F. Every time the detection of position coordinates P is performed, the process progresses to step S 11 , and as described above, the CPU 4 compares the detection results (Z coordinate) with the threshold α.
[0061] In step S 12 , the CPU 4 starts the timer 7 and measures the time. Then, in step S 13 , detection of the fingertip position coordinates P is performed again, as in step S 10 . After detection of the position coordinates P, the CPU 4 determines whether or not a preset prescribed time Δt has elapsed since the timer 7 has started. If the CPU 4 has determined that the prescribed time Δt has not elapsed, then the process returns to step S 13 and detection of the position coordinates P of the finger is once again performed. By contrast, if the CPU 4 has determined that the prescribed time Δt has elapsed, then the process progresses to step S 15 . In other words, after the timer 7 has started with the fingertip entering the first detection region F 1 , the finger position detection unit 3 repeatedly performs detection of the fingertip position coordinates P until the prescribed time Δt has elapsed. In the present embodiment, the prescribed time Δt, the detection interval and the like for the position coordinates P are set such that the detection of the fingertip position coordinates P in step S 13 is performed a plurality of times (twice or more).
[0062] In step S 15 , after the Z coordinate among the fingertip position coordinates P reaches α<Z within the prescribed time Δt, the CPU 4 once again determines whether Z has reached Z≦α. As shown in FIG. 6 , if the fingertip crosses the first virtual plane R 1 and enters the first detection region F 1 for a period of Δt, then the Z coordinate among the position coordinates P is always less than or equal to α. In such a case, the process progresses from step S 15 to S 16 , and the movement of the user U's fingertip (Z axis direction movement) in the detection region F is recognized as a single click operation, and a process associated therewith in advance is executed. In the present embodiment, by such a click operation (single click operation), a command is inputted to the display operation device 1 so as to switch the above-mentioned reception image (not shown) to another image (not shown), for example.
[0063] By contrast, as shown in FIG. 7 , if during the prescribed time Δt the fingertip moves backward towards the second detection region F 2 (position coordinate P 2 ) and then once again crosses the first virtual plane R 1 and enters the first detection region F 1 (position coordinate P 3 ), the Z coordinate of the fingertip position coordinates P, after attaining α<Z, once again becomes Z≦α. In other words, the Z coordinate (Z 2 ) among the position coordinates P 2 is at α<Z 2 , and the Z coordinate (Z 3 ) among the position coordinates P 3 is at Z 3 ≦α. In such a case, the process progresses from step S 15 to S 17 , and the movement of the user U's fingertip (Z axis direction movement) in the detection region F is recognized as a double click operation, and a process associated therewith in advance is executed. In the present embodiment, by such a click operation (double click operation), a command is inputted to the display operation device 1 so as to switch the above-mentioned reception image (not shown) to another image (not shown), for example.
[0064] In such a display operation device 1 , the Z coordinate of the first virtual plane R 1 set in the detection region F is used as the threshold α for recognizing a click operation (movement of user U's finger in the Z axis direction). Thus, the user U can use the first virtual plane R 1 as the “click surface” to input clicks, and by movement back and forth of the fingertip (movement along the Z axis direction), it is possible to perform input operations with ease on the display operation device 1 without directly touching the display unit 2 . In the display operation device 1 of the present embodiment, the amount of data that the CPU 4 needs to process is less than in conventional devices where user gestures were recognized by analyzing image data.
[0065] (Input Operation by Forward Movement)
[0066] Next, the steps of the input process based on forward movement of the user U's fingertip will be described. In the present embodiment, a command in which the image displayed in the display unit 2 is switched to an enlarged image is inputted to the display operation device 1 by forward movement of the fingertip. FIG. 8 is a flowchart showing steps of an input process of the display operation device 1 based on a forward movement operation by a fingertip, FIG. 9 is a descriptive drawing that schematically shows a state in which a fingertip is held still in the second detection region F 2 prior to forward movement, and FIG. 10 is a descriptive drawing that schematically shows a state in which the fingertip moves forward to the first detection region F 1 .
[0067] Before entering an input by forward movement to increase magnification of the display, the user U first performs a prescribed operation on the display operation device 1 and causes the CPU 4 to execute a process of displaying a prescribed image (not shown) in the display surface 2 a of the display unit 2 .
[0068] Next, in step S 20 , the finger position detection unit 3 acquires the fingertip position coordinates P of the user U according to a command from the CPU 4 . After the fingertip position coordinates P are acquired, the CPU 4 determines in step S 21 whether the Z coordinate among the acquired position coordinates P is within a preset range (α<Z<β). The threshold α is as described above. The threshold β is the Z coordinate of the second virtual plane R 2 , and indicates a Z coordinate corresponding to a distance of 20 cm away from the display surface 2 a in the Z axis direction. By using such thresholds α and β, it can be determined whether the fingertip position coordinates P are within the second detection region F 2 .
[0069] If as shown in FIG. 9 the user U's fingertip is within the second detection region F 2 , for example, then the Z coordinate of the fingertip among the position coordinates P 11 satisfies α<Z<β. If the Z coordinate among the acquired fingertip position coordinates P is within this range, then the process progresses to step S 22 . By contrast, if the Z coordinate among the acquired fingertip position coordinates P is outside of this range, then the process progresses to step S 20 , and detection of the finger position coordinates P is once again performed.
[0070] The detection of the position coordinates P of the fingertip by the finger position detection unit 3 is, as described above, executed steadily, repeating at a uniform time interval, regardless of the presence or absence of a detection object (finger) in the detection region F. Every time the detection of position coordinates P is performed, the process progresses to step S 21 .
[0071] In step S 22 , the CPU 4 starts the timer 7 and measures the time. Then, in step S 23 , detection of the fingertip position coordinates P is performed again, as in step S 20 . After detection of the position coordinates P, the CPU 4 determines whether or not a preset prescribed time Δt 1 (3 seconds, for example) has elapsed since the timer 7 has started. If the CPU 4 has determined that the prescribed time Δt 1 has not elapsed, then the process returns to step S 23 and detection of the position coordinates P of the finger is once again performed. By contrast, if the CPU 4 has determined that the prescribed time Δt 1 has elapsed, then the process progresses to step S 25 . In other words, after the timer 7 has started with the fingertip entering the second detection region F 2 , the finger position detection unit 3 repeatedly performs detection of the fingertip position coordinates P until the prescribed time Δt 1 has elapsed. The timer 7 , in addition to being used to measure the prescribed time Δt 1 , is also used to measure the prescribed time Δt 2 to be described later.
[0072] In step S 25 , the CPU 4 determines whether or not the Z coordinate among the plurality of position coordinates P detected within the prescribed time Δt 1 is within an allowable range D 1 (±0.5 cm, for example) for which a change amount ΔZ 1 is set in advance. The change amount ΔZ 1 is determined in step S 21 by taking the difference between the Z coordinate (reference value) determined to satisfy the range α<Z<β, and the Z coordinate among the position coordinates P detected within the prescribed time Δt 1 . If all change amounts ΔZ 1 for Z coordinates of all position coordinates P detected after the timer 7 has started are within the allowable range D 1 , then the process progresses to step S 26 . By contrast, if the change amount ΔZ 1 of even one Z coordinate exceeds the allowable range D 1 , then the process returns to step S 20 . In other words, in step S 25 , it is determined whether or not the fingertip of the user U is within the second detection region F 2 and has stopped moving at least in the Z axis direction.
[0073] In step S 26 , detection of the fingertip position coordinates P is performed again. As indicated in step S 27 , such detection is repeated until the prescribed time Δt 2 has elapsed since the timer 7 has started. The prescribed time Δt 2 is longer than the prescribed time Δt 1 , and if Δt 1 is set to 3 seconds, then Δt 2 is set to 3.3 seconds, for example. If the CPU 4 has determined that the prescribed time Δt 2 has elapsed, then the process progresses to step S 28 .
[0074] In step S 28 , the CPU 4 determines whether the Z coordinates among the plurality of position coordinates P detected within the prescribed time Δt 2 have become less than or equal to α (Z≦α). In other words, in step S 28 , it is determined whether the user U's fingertip has moved (forward) from the second detection region F 2 to the first detection region F 1 within Δt 2 −Δt 1 (0.3 seconds, for example). If as shown in FIG. 10 the user U's fingertip is within the second detection region F 2 for the prescribed time Δt 1 and then moves forward and enters the first detection region F 1 by Δt 2 , for example, then the Z coordinate of the fingertip among the position coordinates P 12 becomes less than or equal to α (Z≦α). In another embodiment, it may be determined whether the Z coordinates among the plurality of position coordinates P detected during Δt 2 −Δt 1 (0.3 seconds, for example) have become less than or equal to α (Z≦α).
[0075] In step S 28 , if the CPU 4 determines that there are no Z coordinates at or below α (Z≦α), then the process progresses to step S 20 . By contrast, if in step S 28 the CPU 4 determines that there is at least one Z coordinate at or below α (Z≦α), then the process progresses to step S 29 . In step S 29 , the CPU 4 receives a command to switch the image displayed in the display unit 2 to an enlarged image. A command in which the image displayed in the display unit 2 is switched to an enlarged image can be inputted to the display operation device 1 by such forward movement of the user U's fingertip (example of a gesture). When the CPU 4 receives such an input, the display control unit 8 reads information pertaining to an enlarged image from the storage unit 9 and then switches from an image displayed in advance in the display unit 2 to the enlarged image on the basis of the read-in information, according to the command from the CPU 4 . In such a display operation device 1 , it is possible for an input operation to be performed with ease by forward movement of the user U's fingertip (movement of fingertip in Z axis direction) without directly touching the display unit 2 .
[0076] (Input Operation by Backward Movement)
[0077] Next, the steps of the input process based on backward movement of the user U's fingertip will be described. In the present embodiment, a command in which the image displayed in the display unit 2 is switched to a shrunken image is inputted to the display operation device 1 by backward movement of the fingertip. FIG. 11 is a flowchart showing steps of an input process of the display operation device 1 based on a backward movement operation by a fingertip, FIG. 12 is a descriptive drawing that schematically shows a state in which a fingertip is held still in the first detection region F 1 prior to backward movement, and FIG. 13 is a descriptive drawing that schematically shows a state in which the fingertip moves backward to the second detection region F 2 .
[0078] Before entering an input by backward movement to decrease magnification of the display, the user U first performs a prescribed operation on the display operation device 1 and causes the CPU 4 to execute a process of displaying a prescribed image (not shown) in the display surface 2 a of the display unit 2 .
[0079] Next, in step S 30 , the finger position detection unit 3 acquires the fingertip position coordinates P of the user U according to a command from the CPU 4 . After the fingertip position coordinates P are acquired, the CPU 4 determines in step 31 whether the Z coordinate among the acquired position coordinates P is within a preset range (Z≦α). The threshold α is as described above. By using such a threshold α, it can be determined whether the fingertip position coordinates P are within the first detection region F 1 .
[0080] If as shown in FIG. 12 the user U's fingertip is within the first detection region F 1 , for example, then the Z coordinate of the fingertip among the position coordinates P 21 satisfies Z≦α. If the Z coordinate among the acquired fingertip position coordinates P is within this range, then the process progresses to step S 32 . By contrast, if the Z coordinate among the acquired fingertip position coordinates P is outside of this range, then the process progresses to step S 30 , and detection of the finger position coordinates P is once again performed.
[0081] The detection of the position coordinates P of the fingertip by the finger position detection unit 3 is, as described above, executed steadily, repeating at a uniform time interval, regardless of the presence or absence of a detection object (finger) in the detection region F. Every time the detection of position coordinates P is performed, the process progresses to step S 31 .
[0082] In step S 32 , the CPU 4 starts the timer 7 and measures the time. Then, in step S 33 , detection of the fingertip position coordinates P is performed again, as in step S 30 . After detection of the position coordinates P, the CPU 4 determines whether or not a preset prescribed time Δt 3 (3 seconds, for example) has elapsed since the timer 7 has started. If the CPU 4 has determined that the prescribed time Δt 3 has not elapsed, then the process returns to step S 33 and detection of the position coordinates P of the finger is once again performed. By contrast, if the CPU 4 has determined that the prescribed time Δt 3 has elapsed, then the process progresses to step S 35 . In other words, after the timer 7 has started with the fingertip entering the first detection region F 1 , the finger position detection unit 3 repeatedly performs detection of the fingertip position coordinates P until the prescribed time Δt 3 has elapsed. The timer 7 , in addition to being used to measure the prescribed time Δt 3 , is also used to measure the prescribed time Δt 4 to be described later.
[0083] In step S 35 , the CPU 4 determines whether or not the Z coordinate among the plurality of position coordinates P detected within the prescribed time Δt 3 is within an allowable range D 2 (±0.5 cm, for example) for which a change amount ΔZ 2 is set in advance. The change amount ΔZ 2 is determined in step S 31 by taking the difference between the Z coordinate (reference value) determined to satisfy the range Z≦α, and the Z coordinate among the position coordinates P detected within the prescribed time Δt 13 . If all change amounts ΔZ 2 for Z coordinates of all position coordinates P detected after the timer 7 has started are within the allowable range D 2 , then the process progresses to step S 36 . By contrast, if the change amount ΔZ 2 of even one Z coordinate exceeds the allowable range D 2 , then the process returns to step S 30 . In other words, in step S 35 , it is determined whether or not the fingertip of the user U is within the first detection region F 1 and has stopped moving at least in the Z axis direction.
[0084] In step S 36 , detection of the fingertip position coordinates P is performed again. As indicated in step S 37 , such detection is repeated until the prescribed time Δt 4 has elapsed since the timer 7 has started. The prescribed time Δt 4 is longer than the prescribed time Δt 3 , and if Δt 3 is set to 3 seconds, then Δt 4 is set to 3.3 seconds, for example. If the CPU 4 has determined that the prescribed time Δt 4 has elapsed, then the process progresses to step S 38 .
[0085] In step S 38 , the CPU 4 determines whether or not there is at least one case in which a difference ΔZ 3 between the Z coordinate among the plurality of position coordinates P detected within the prescribed time Δt 4 and the Z coordinate of the first virtual plane R 1 (that is, α) is greater than or equal to a predetermined prescribed value D 3 (3 cm, for example). In other words, in step S 38 , it is determined whether the user U's fingertip has moved (forward) from the first detection region F 1 to the second detection region F 2 within Δt 4 −Δt 3 (0.3 seconds, for example). In another embodiment, it may be determined whether there is at least one case in which a difference ΔZ 3 between the Z coordinates among the plurality of position coordinates P detected during Δt 4 −Δt 3 (0.3 seconds, for example), and α is greater than or equal to a predetermined prescribed value D 3 .
[0086] After the fingertip of the user U stays in the first detection region F 1 for the prescribed time Δt 3 as shown in FIG. 12 , the fingertip moves back by Δt 4 to a position (position coordinate P 22 ) that is at a distance of the prescribed value D 3 or greater from the first virtual plane R 1 along the Z axis direction as shown in FIG. 13 , for example. In step S 38 , if the CPU 4 determines that if there are no cases in which the difference ΔZ 3 is greater than or equal to the prescribed value D 3 , then the process progresses to step S 30 . By contrast, if in step S 38 the CPU 4 determines that if there is at least one case in which the difference ΔZ 3 is greater than or equal to the prescribed value D 3 , then the process progresses to step S 39 .
[0087] In step S 39 , the CPU 4 receives a command (input) to switch the image displayed in the display unit 2 to a shrunken image. A command in which the image displayed in the display unit 2 is switched to a shrunken image can be inputted to the display operation device 1 by such backward movement of the user U's fingertip (example of a gesture). When the CPU 4 receives such an input, the display control unit 8 reads information pertaining to a shrunken image from the storage unit 9 and then switches from an image displayed in advance in the display unit 2 to the shrunken image on the basis of the read-in information, according to the command from the CPU 4 . In such a display operation device 1 , it is possible for an input operation to be performed with ease by backward movement of the user U's fingertip (movement of fingertip in Z axis direction) without directly touching the display unit 2 .
Embodiment 2
[0088] Next, a display operation device 1 A of Embodiment 2 will be described with reference to FIGS. 14 to 17 . FIG. 14 is a descriptive drawing that schematically shows the outer appearance of a display operation device 1 A of Embodiment 2, and FIG. 15 is a function block diagram showing main components of the display operation device 1 A of Embodiment 2. The display operation device 1 A of the present embodiment includes a three-dimensional image display unit 2 A instead of the display unit 2 of the display operation device 1 of Embodiment 1, and has a three-dimensional image display control unit 8 A instead of the display control unit 8 . Furthermore, the display operation device 1 A of the present embodiment stores information corresponding to three-dimensional images in the storage unit 9 . Other components are similar to those of Embodiment 1, and therefore, the same components assigned the same reference characters and descriptions thereof are omitted.
[0089] As shown in FIG. 14 , the display operation device 1 A displays a three-dimensional image 100 to the front of the three-dimensional image display unit 2 A. The three-dimensional image display unit 2 A displays the three-dimensional image 100 by the parallax barrier mode, and is constituted by a liquid crystal display panel, a parallax barrier, and the like. The three-dimensional image 100 is perceived by the user U to be floating in front of the display surface 2 Aa of the three-dimensional image display unit 2 Aa. The three-dimensional image display control unit 8 A displays a prescribed three-dimensional image 100 in the three-dimensional image display unit 2 A according to commands from the CPU 4 . The three-dimensional image display control unit 8 A may be a software function realized by the CPU 4 executing a control program stored in the ROM 5 , or may be realized by a dedicated hardware circuit.
[0090] The display operation device 1 A of the present embodiment also includes a finger position detection unit 3 similar to the above-mentioned display operation device 1 , and as shown in FIG. 16 , a detection region F similar to that of Embodiment 1 is formed to the front of the display operation device 1 A. The three-dimensional image 100 is displayed at the first virtual plane R 1 in front of the three-dimensional image display unit 2 A. In other words, the three-dimensional image 100 is perceived by the user U to be floating 9 cm (Z=α) from the display surface 2 Aa of the three-dimensional image display unit 2 A.
[0091] Next, the steps of the input process based on a click operation (single click operation) by the user U's fingertip will be described. FIG. 17 is a flowchart showing steps of an input process of the display operation device 1 A based on a click operation by a fingertip.
[0092] First, in step S 40 , the user U performs a prescribed operation on the display operation device 1 A, and causes the CPU 4 to execute a process in which the three-dimensional image display unit 2 A displays the prescribed three-dimensional image 100 on the first virtual plane R 1 .
[0093] Next, in step S 41 , the CPU 4 determines whether or not there has been a click input. The processing content in step S 41 is the same as the processing content for the click operation of Embodiment 1 (steps S 10 to S 16 in the flowchart of FIG. 5 ). However, in the case of the present embodiment, the user U can perform click input using the first virtual plane R 1 while experiencing the sense of directly touching the three-dimensional image 100 .
[0094] In step S 41 , if the CPU 4 determines that an input by click operation (single click operation) has been received, it progresses to step S 42 , and a new three-dimensional image (not shown) that has been placed in association with the click input in advance is displayed by the three-dimensional image display unit 2 A. The three-dimensional image 100 of the rear surface of a playing card shown in FIG. 14 may be switched to the front surface of the playing card by click input, for example. In this manner, in the display operation device 1 A, the three-dimensional image 100 displayed by the three-dimensional image display unit 2 A is arranged on the first virtual plane R 1 (click surface), and thus, it is possible for the user U to perform an input operation to switch to another three-dimensional image while experiencing the sense of directly touching the three-dimensional image 100 with his/her fingertip. In the display operation device 1 of Embodiment 1, it would be difficult for the user U to recognize the object to be operated (click surface of the first virtual plane R 1 ), but such a problem is solved in the display operation device 1 A of the present embodiment.
OTHER EMBODIMENTS
[0095] The present invention is not limited to the embodiments shown in the drawings and described above, and the following embodiments are also included in the technical scope of the present invention, for example.
[0096] (1) In a display operation device of another embodiment, the display unit may include touch panel functionality. In other words, the display operation device may include both a non-contact-type input method and a contact-type input method.
[0097] (2) There is no special limitation on the arrangement of electrodes (transmitter electrode, receiver electrode) included in the capacitive sensor as long as a prescribed detection region as illustrated in the embodiments above can be formed to the front of the display unit (towards the user).
[0098] (3) FIG. 18 is a front view that schematically shows Modification Example 1 of electrodes 3 Aa and 3 Ab included in the capacitive sensor, and FIG. 19 is a cross-sectional view along the line A-A of FIG. 18 . In Modification Example 1, one of the electrodes 3 Aa (transmitter electrode) is arranged to overlap the display area AA (active area) of the display unit 2 , and the other electrodes 3 Ab (receiver electrodes) are arranged to overlap the electrode 3 Aa across a transparent insulating layer 3 Ac. The electrodes 3 Ab are constituted by four parts, each of which is triangular in shape. The electrodes 3 Aa and 3 Ab may be arranged to overlap the display area AA as in Modification Example 1. In such a case, the electrode material forming the electrodes 3 Aa and 3 Ab would be a transparent conductive film.
[0099] (4) FIG. 20 is a front view that schematically shows Modification Example 2 of electrodes 3 Ba and 3 Bb included in the capacitive sensor, and FIG. 21 is a cross-sectional view along the line B-B of FIG. 20 . In Modification Example 2, one of the electrodes 3 Ba (transmitter electrode) has a frame shape surrounding a display area AA (active area) of the display unit 2 . In other words, the electrode 3 Ba is arranged in the non-display area (frame region). A frame-shaped insulating layer 3 Bc is formed on the electrode 3 Ba. By contrast, the other electrodes 3 Bb (receiver electrodes) are arranged so as to overlap the electrode 3 Ba across an insulating layer 3 Bc. The electrodes 3 Bb form a frame shape overall, but include four portions that are disposed, respectively, at the sides of the rectangular display area AA. The electrodes 3 Ba and 3 Bb may be arranged only in the non-display area (frame region) surrounding the display area AA as in Modification Example 2.
[0100] (5) The display operation device of the embodiments received input operation by the finger position detection unit detecting the position coordinates of the user's hand (fingertip), but the present invention is not limited thereto, and in other embodiments, a detection object such as a stylus may be what is detected by the finger position detection unit.
[0101] (6) In the embodiments, the second virtual plane is set as the position in the Z axis direction where the signal strength was at the detection limit, but in other embodiments, the position of the second virtual plane may be set closer to the display operation device than the detection limit.
[0102] (7) There is no special limitation on the first virtual plane as long as the first virtual plane is set between the display surface (reference surface) of the display unit and the detection limit position in the Z axis direction. However, for purposes such as ensuring a large second detection region, it is preferable that the first virtual plane be set closer towards the display surface (display operation device) than the midway point between the display surface and the detection limit position. By setting the first virtual plane closer towards the display surface in this manner, it is easier for the user to move his/her fingertip in and out of the first detection region, and for the user to more easily perform an input operation (click operation) on the first virtual plane (click surface).
[0103] (8) In Embodiment 1, the displayed image was switched to an enlarged image by an input operation based on forward movement of the fingertip, and then by an input operation based on backward movement thereafter, the displayed image was switched to a shrunken image, but in other embodiments, a configuration may be adopted in which an input operation based on forward movement results in the displayed image being switched to a shrunken image, and an input operation based on backward movement results in the displayed image being switched to an enlarged image. Alternatively, forward and backward movement by a fingertip may be associated with a command to the display operation device to perform another process besides enlarging or shrinking the displayed image.
[0104] (9) In the embodiments, the displayed image was switched by an input operation based on fingertip movement, but in another embodiment, fingertip movement can result in a process for another component (such as volume adjustment for speakers) besides the switching of displayed images being executed.
[0105] (10) In the embodiments, only the Z coordinate was used among the acquired position coordinates P of the fingertip, and only fingertip movement in the Z axis direction was recognized, but in other embodiments, fingertip movement may be recognized using not only the Z coordinate but furthermore, as necessary, the X coordinate and Y coordinate. It is preferable that a capacitive sensor be used as the sensor for the finger position detection unit for reasons such as being able to detect with ease movement of the fingertip, which is the detection object, in the Z axis direction.
[0106] (11) In Embodiment 2, the three-dimensional image was switched to another three-dimensional image (static image) according to movement of the user's fingertip (click operation), but the present invention is not limited thereto, and the display operation device may be configured such that after receiving the fingertip movement (click operation) by the user, the three-dimensional image (such as a globe) undergoes movement such as rotation, for example. Furthermore, a configuration may be adopted in which a switch image is displayed as the three-dimensional image, with the user being able to recognize the image as a virtual switch.
DESCRIPTION OF REFERENCE CHARACTERS
[0000]
1 display operation device (input device)
2 display unit
2 a display surface (reference surface)
3 finger position detection unit (position detection unit)
3 a , 3 b electrode
30 sensor
4 CPU (determination unit, comparison unit, standby detection unit, change amount detection unit)
5 ROM
6 RAM
7 timer
8 display control unit (display switching unit)
9 storage unit
10 bus line
F detection region
R 1 first virtual plane (virtual plane)
R 2 second virtual plane
U user
P position coordinate of detection object
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An input device includes: a position detection unit that defines a detection region in a space in front of a prescribed reference surface and detects a position coordinate in the detection region of a detection object that has entered the detection region for an input operation on a coordinate axis perpendicular to the reference surface; and a processor that defines a virtual plane in parallel to the reference surface so as to partition the detection region in a direction of the coordinate axis, and that compares the position coordinate on the coordinate axis of the detection object as detected by the position detection unit with a position coordinate on the coordinate axis of the virtual plane, the processor further determining the input operation of the detection object in accordance with a result of the comparison.
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FIELD OF THE INVENTION
This invention relates to wear surfaces for withstanding strong frictional forces, and more particularly to curved skid shoes for helicopters.
BACKGROUND OF THE INVENTION
The skids on which helicopters rest when they are on the ground are exposed to severe wear because helicopters generally do not land exactly vertically but rather with a certain amount of forward or sideways motion. This imposes a considerable frictional stress on the skids when the helicopter touches the ground. Skids are expensive components and have weight limitations; consequently, it has been customary to attach wear-resistant skid shoes to the underside front, center and rear, or even the entire length of the skid tubes. These shoes typically have a welded hard-faced surface, and they are readily replaceable when they wear through.
As shown in U.S. Pat. No. 4,544,116 to Shwayder, it has previously been proposed to use as helicopter shoes a steel channel containing crushed tungsten carbide particles in a copper-based binder. Similarly, in U.S. Pat. No. 3,117,845 to Reed, a steel plate is coated with a coating of tungsten carbide particles distributed in a copper-based binder and covered with a flame-sprayed copper-nickel alloy.
The prior art wear surfaces described above have several disadvantages. For one, the crushed tungsten carbide particles embedded in a softer binder form a rough surface which produces considerable friction. This is undesirable because a pilot has better control over the helicopter if it slides smoothly on the ground when landing. Secondly, both the channel of U.S. Pat. No. 4,544,116 and the plate of U.S. Pat. No. 3,117,845 have sharp side edges. These can catch in a gouge or groove in a runway surface when there is a transverse component to the helicopter's motion on landing, and cause a serious accident. Thirdly, as the surface wears, tungsten carbide particles break loose from the binder and reduce the life of the shoe. Fourthly, the clamp mounting of U.S. Pat. No. 4,544,116 is unsatisfactory because it allows the shoe to shift on the skid under strong impacts.
It has previously been proposed in the street sweeping industry to braze small blocks of tool-tip grade tungsten carbide into a groove milled in a sweeper drag shoe. This approach, however, is unsuitable for helicopter skids because it suffers from the same disadvantages as the channel of U.S. Pat. No. 4,554,116. Furthermore, tool-tip grade tungsten carbide tends to fracture under the impact of a helicopter landing.
There consequently exists a need for a smooth, wear-resistant helicopter skid shoe that has no sharp edges that can catch on lateral movement, and that can be bolted directly to the skids.
SUMMARY OF THE INVENTION
The present invention fills the above-identified need by providing a skid shoe in which a mosaic of smooth-surfaced impact-resistant tungsten carbide blocks is brazed onto a steel base curved around the axis of the skid. Front shoes are additionally curved to follow the curvature of the front end of the skid. During manufacture, the carbide blocks are held on the steel base by steel rails or other barriers that are then ground to an edgeless taper. The blocks are separated from each other by a thin wall of ductile nickel brazing material that is flowed between the blocks to further prevent the blocks from breaking on impact. A manufacturing method is disclosed which results in a strong, unitary shoe construction and is also usable for the recycling and rehabilitation of worn skid shoes, as well as for the manufacture of curved wear surfaces in general.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a helicopter showing the location of the skid shoes of this invention;
FIG. 2 is a perspective view of a front skid shoe for the helicopter of FIG. 1;
FIG. 3 is a perspective view of a rear skid shoe for the helicopter of FIG. 1;
FIGS. 4 and 5 are perspective views of other embodiments of the invention illustrating the taper of the retaining rails; and
FIGS. 6-11 are perspective views illustrating the successive steps in the manufacture of a curved wear surface according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a helicopter 10 whose body 12 rests on skids 14 when on the ground. The skids 14 are held spaced from the ground by skid shoes 16, 18 attached to the underside of the skids 14 in the front and rear. Additional skid shoes may be attached to the central portion of skids 14 if desired.
As best seen in FIGS. 2 and 3, the skid shoes 16, 18 are built on a curved base 20, preferably of steel, which is shaped to conform to the circumference and longitudinal bend of the skids 14. The base 20 preferably has integral ears 22 which can receive appropriate bolts for bolting the shoes 16, 18 to the skids 14.
The wear surface 24 of the shoes 16, 18 follows the curvature of the base 20 through an arc which is determined by the intended use of the helicopter but may typically vary between about 20° for normal travel usage and about 40-50° for training usage. The wear surface 24 is formed of a mosaic of virgin tungsten carbide blocks 26 with a smooth, uniform surface. The material of the blocks 26 is preferably 89% tungsten carbide of mixed grain size and 11% cobalt, with a density of about 14.5 gm/cc.
The blocks 26 are preferably rectangular in shape and are oriented in the longitudinal direction of the shoe. The dimensions of the blocks 26 are chosen so as to maximize the wear surface of each block 26 while minimizing the bending stress imposed upon the block 26 by expansion, contraction or changes in the curvature of the base 20 as a result of temperature changes and mechanical stresses. Typically, the blocks 26 may be about 20×10×3 mm in size.
FIGS. 4 and 5 illustrate skid shoe configurations 28 and 30, respectively, to fit various types of commercial helicopters. Each of these figures shows the base 20 which bolts to the skids 14 of FIG. 1; the wear surface 24 composed of tungsten carbide blocks 26; and tapered side rails 32 and end rails 34 which provide a gradual, edgeless transition in all directions from the elevated wear surface 24 to the surface of base 20.
FIGS. 6 through 11 illustrate a preferred method of manufacturing the skid shoes of FIGS. 2 through 5 or other curved wear surfaces. In FIG. 6, a curved steel base plate 20 is shown in generic form, i.e. without the mounting ears 22 of FIGS. 2 through 5. In FIG. 7, steel side rails 32 are first spot welded at 36 to the base plate 20. Curved steel end rails 34 are then spot welded to the side rails 32 at 38.
With the rails 32, 34 thus in place, the interior of the enclosure 40 formed by the rails 32, 34 is coated with an appropriate brazing flux, preferably a water and salt flux active at 760-1200° C. such as Welco 17 flux. Both the base plate 20 in the enclosure 40 and the inner surfaces of the rails 32, 34 are so coated. The area of the plate 20 outside the rails 32, 34 is coated with an anti-adhesion compound such as Stop-Off™ to prevent brazing material from adhering to it.
The tungsten carbide blocks 26 are now placed into the enclosure 40 as shown in FIG. 8. Because the side faces of adjacent blocks 26 in a circumferential row such as 42 are not quite parallel, due to the curvature of the plate 20, a small space 42 will naturally exist between the side faces of the blocks 26 in the row 42. Adjacent rows 42 are slightly spaced from each other and from the end rails 34 by judicious placement of the blocks 26. The final arrangement of the blocks 26 in the enclosure 40 is shown in FIG. 9. It should be noted that the rails 32, 34 are at least as high as the blocks 26, for a purpose detailed below.
When the blocks 26 are in place, they are coated with flux, and a nickel brazing material 46 with a melting temperature of about 925° C. and a tensile strength of about 278,000 kg/cm 2 , such as Welco 17 Bare, is flowed (FIG. 10) over the enclosure 40 along the spaces between the blocks 26, and along the rails 32, 34. The braze seeps underneath the blocks 26 and the rails 32, 34, thus providing a flat metallic bed for each block 26 to rest on. The braze 46 also fills the spaces along the side and end faces of the blocks 26 to form a solid yet somewhat ductile wear surface 24. The filling of all spaces under the blocks 26 and the rails 32, 34 prevents water and other substances from penetrating the enclosure 40 Under the blocks 26 and corroding the block-supporting steel plate 20.
The manufacture of the shoe is completed (FIG. 11) by grinding away all nickel braze 46 above the surface of the blocks 26, and grinding the rails 32, 34 into the edgeless tapered shape shown in FIGS. 4, 5 and 11. For this operation, the rails 32, 34 must be at least as high as the surface of blocks 26 so that they can be ground down even with that surface, thereby avoiding the formation of a hard 90° edge on the outermost blocks 26. The tapered rails 32, 34 and the portion of the plate 20 outside the rails 32, 34 may finally be painted as desired with a protective paint.
The present invention is useful not only in the manufacture of skid shoes and other curved wear surfaces, but also in the recycling and rehabilitation of worn-out steel skid shoes. Because the exact curvature of the base plate 20 is not critical (and can include curvature in a plurality of mutually orthogonal planes) in the manufacturing process of FIGS. 6-11, the wear surface of this invention can be built up even on worn or patched base plates.
It is understood that the exemplary curved wear surface described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. Thus, other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications.
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A wear surface for helicopter shoes is constructed by forming a railed enclosure on a curved base plate, placing a mosaic of smooth-surfaced tungsten carbide blocks on the base plate within the enclosure, brazing the blocks to the plate and rails, and grinding the rails to form a smooth, edgeless transition between the wear surface and the plate surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 12/151,948, filed May 9, 2008.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a material handling system for a manufacturing line, and more particularly to a modular material handling system including a dual track assembly.
BACKGROUND
[0003] During a manufacturing process, a product is typically advanced through a plurality of manufacturing stations of a manufacturing chain. Specifically, the product is transported through each of the manufacturing stations along an article transportation device. At each manufacturing station, a specific one of a plurality of tasks in the manufacturing process is performed. All equipment and other components necessary to perform the assigned task are positioned, and often permanently affixed, at each manufacturing station. As a result, and dependent upon the number of tasks and the complexity of the manufacturing process, a manufacturing chain is typically a large structure that is permanently situated inside a manufacturing facility.
[0004] At least partially as a result of its permanency, a manufacturing chain is typically inflexible, such that modifying, removing, or replacing the manufacturing chain may be an expensive and time-consuming process. Therefore, even minor improvements to the manufacturing process, such as, for example, changes to the equipment positioned at one manufacturing station, may be too expensive and time consuming to implement. Further, if the manufacturing process performed by the manufacturing chain becomes unnecessary, it may not be feasible to alter the manufacturing chain to perform a different manufacturing process. Ultimately, the manufacturing chain may only be cost effective in performing the specific manufacturing process for which it was designed. As a result, the significant amount of costs and efforts to design and construct the manufacturing chain may be wasted.
[0005] Another drawback with conventional manufacturing chains involves the article transportation system along which the products are transported. Since the products are typically carried along one article transportation device having a single driving source, such as a common monorail conveyor, the entire manufacturing chain must be stopped in order to correct a problem occurring at any point along the manufacturing chain. Power and free conveyors offer one solution by allowing carriers to be routed off of the main line, such as if a defect is identified, but still provide continuous movement of the main line. In either case, stopping the main line can result in significant down time and, therefore, reduced efficiency and, ultimately, throughput of the manufacturing chain. This may further increase process time for manufacturing processes that already require a significant amount of time. For example, it is known that a drying or curing stage of a paint process may require a significant amount of time, thus greatly increasing the minimal process time for the manufacturing process.
[0006] U.S. Pat. No. 6,120,604 teaches a powder coating chain having a plurality of conveyors for transporting parts through a plurality of processing areas. Specifically, each processing area includes a separate motor driven conveyor, sensors for providing information on conditions within the processing area, and a control circuit coupled to both the sensors and an operator interface. A user may manipulate the operator interface to monitor sensed conditions within each processing area. Although the reference suggests an aspect of modularity that may offer certain limited benefits, it does not contemplate improvements to the overall process flow within the manufacturing chain. In fact, the reference does not disclose modifications to the exemplary high-speed blank powder coating process, but rather seeks to quickly identify a source of a mechanical problem associated with the process. As should be appreciated, there is a continuing need for manufacturing chains providing improved quality and efficiency with respect to a manufacturing process. In addition, there is a continuing need for manufacturing chains, or manufacturing stations thereof, that may be more easily modified, removed, or replaced.
[0007] The present disclosure is directed to one or more of the problems set forth above.
SUMMARY OF THE DISCLOSURE
[0008] In one aspect, a material handling system includes a first track assembly configured to transport a forward trolley along a first path. The material handling system also includes a second track assembly configured to transport a trailing trolley along a second path. The second path is substantially parallel to the first path. A carrier is configured to support an article and has a first end pivotably supported by the forward trolley and a second end pivotably supported by the trailing trolley.
[0009] In another aspect, a method of operating a material handling system includes transporting an article along the material handling system, at least in part, by supporting the article on a carrier. The carrier has a first end pivotably supported by a forward trolley and a second end pivotably supported by a trailing trolley. The forward trolley is moved along a first track assembly defining a first path, while the trailing trolley is moved along a second track assembly defining a second path. The first path and the second path are parallel.
[0010] In yet another aspect, a manufacturing line includes a plurality of manufacturing modules positioned in series and defining at least one main path through the manufacturing line. Each manufacturing module including a material handling system for transporting an article along the main path. The material handling system of at least one manufacturing module includes a first track assembly configured to transport a forward trolley along a first path and a second track assembly configured to transport a trailing trolley along a second path. The second path is parallel to the first path. A carrier is configured to support the article and has a first end pivotably supported by the forward trolley and a second end pivotably supported by the trailing trolley.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a diagrammatic perspective view of a manufacturing chain, according to the present disclosure;
[0012] FIG. 2 is a diagrammatic perspective view of a manufacturing module of the manufacturing chain of FIG. 1 , according to the present disclosure;
[0013] FIG. 3 is a side diagrammatic view of an alternative embodiment of the manufacturing module of FIG. 2 , according to the present disclosure;
[0014] FIG. 4 is a side diagrammatic view of an alternative embodiment of the manufacturing module of FIG. 2 including a first vertical lift device, according to the present disclosure;
[0015] FIG. 5 is a side diagrammatic view of an alternative embodiment of the manufacturing module of FIG. 2 including a second vertical lift device, according to the present disclosure;
[0016] FIG. 6 is a block diagram of one embodiment of a control system for operating the manufacturing chain of FIG. 1 , according to the present disclosure;
[0017] FIG. 7 is a block diagram of an alternative embodiment of a control system for operating the manufacturing chain of FIG. 1 , according to the present disclosure; and
[0018] FIG. 8 is a perspective view of one embodiment of a modular material handling system, according to the present disclosure;
[0019] FIG. 9 a is a cross-sectional view of a first exemplary composite beam for use with the modular material handling system of FIG. 8 , according to the present disclosure;
[0020] FIG. 9 b is a cross-sectional view of a second exemplary composite beam for use with the modular material handling system of FIG. 8 , according to the present disclosure;
[0021] FIG. 9 c is a cross-sectional view of a third exemplary composite beam for use with the modular material handling system of FIG. 8 , according to the present disclosure;
[0022] FIG. 10 is a partially exploded view of a manufacturing module including the modular material handling system of FIG. 8 , according to the present disclosure;
[0023] FIG. 11 a is plan view of a modular material handling system including a dual track assembly, according to the present disclosure;
[0024] FIG. 11 b is a side diagrammatic view of a trolley assembly configured to support a carrier along the dual track assembly of FIG. 11 a, according to the present disclosure;
[0025] FIG. 12 is a side diagrammatic view of a buffer, according to the present disclosure;
[0026] FIG. 13 is a block diagram of a first line, according to the present disclosure; and
[0027] FIG. 14 is a plan view of a second line, according to the present disclosure.
DETAILED DESCRIPTION
[0028] An exemplary embodiment of a manufacturing chain 10 is shown generally in FIG. 1 . The manufacturing chain 10 may be disposed within a manufacturing area 12 , such as, for example, a manufacturing area defined by a building 14 . According to one embodiment, the manufacturing chain 10 may be secured to, and positioned above, a planar floor 16 of the manufacturing area 12 . However, numerous locations and arrangements are contemplated for the manufacturing chain 10 . According to the exemplary embodiment, the manufacturing chain 10 may be used to perform a paint process, such as, for example, a powder coating process, and, therefore, may also be referred to as a paint line. Although a paint process is described, however, it should be appreciated that the manufacturing chain 10 may be designed to perform any of a variety of manufacturing processes.
[0029] The manufacturing chain 10 , also referred to as a modular manufacturing chain, may include several modular manufacturing stations, such that each modular manufacturing station is configured to perform at least one task in the manufacturing process. Specifically, and according to one example, the manufacturing chain 10 may include a wash station 18 , a blow off station 20 , an inspection station 22 , a paint application station 24 , a curing station 26 , and an unload station 28 . Although six modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 are shown, it should be appreciated that the manufacturing chain 10 may include any number of modular manufacturing stations necessary to perform the designated manufacturing process. It should also be appreciated that the paint process, as described herein, has been simplified for ease of explanation, and is in no way meant to be limited to the specific tasks described.
[0030] The modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 may be positioned in series, as shown, or the manufacturing chain 10 may include one or more of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 positioned in parallel, as dictated by the specific tasks of the manufacturing process. Further, the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 may include equipment, and other components, necessary to accomplish the task to be performed at the respective one of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . It should be appreciated that multiple tasks may be performed at one modular manufacturing station or, alternatively, a more complex task may be performed over a plurality of modular manufacturing stations. Ultimately, one or more tasks may be performed on an article, or product, as it is transported through the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 along an article transportation system 30 , described later in greater detail.
[0031] The equipment and other components necessary to perform a task at a respective one of each of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 may be supported by a framework or, more specifically, a manufacturing module 32 . For example, the manufacturing chain 10 may include a plurality of manufacturing modules 32 positioned and configured to accommodate the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . As shown in the embodiment of FIG. 1 , the manufacturing modules 32 may be positioned in series, as dictated by the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . However, the size and geometry of the manufacturing chain 10 , comprising the manufacturing modules 32 , may include any of a variety of possible sizes and configurations, such as, for example, an “L” shaped configuration or a “U” shaped configuration. Further, although FIG. 1 illustrates exactly one of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 associated with each manufacturing module 32 , it should be appreciated that each manufacturing module 32 may support more than one of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 .
[0032] According to the exemplary embodiment, the wash station 18 may be configured to perform a wash and/or rinse task of the paint process. Specifically, the wash station 18 may include a water tank 34 , supported by the manufacturing module 32 , for supplying water, or a solvent mixture, to the wash station 18 . Alternatively, however, water may be supplied directly to the wash station 18 from a utility infrastructure of the building 14 or, alternatively, from an external utility connection 36 disposed outside the manufacturing area 12 and connected to the manufacturing chain 10 via a conduit 38 . The external utility connection 36 may, therefore, include a source of water or, alternatively, may include a source of another utility, such as, for example, electric power or data.
[0033] According to the current embodiment, the conduit 38 may provide water to a utility transfer module 40 supported by the manufacturing module 32 . The utility transfer module 40 may be configured to transfer a utility, such as, for example, electric power, fluid, or data, through the manufacturing module 32 . The utility may be used at the wash station 18 and, further, may be transferred to a contiguous manufacturing module 32 . For example, each of the other manufacturing modules 32 may include utility transfer modules 40 , such that a utility may be supplied at one manufacturing module 32 and used at another. Specifically, each manufacturing module 32 may receive a utility from a preceding manufacturing module 32 of the manufacturing chain 10 , and may transfer the utility to a succeeding manufacturing module 32 .
[0034] The wash station 18 may further include a water pump 42 for circulating the water or solvent mixture through the wash station 18 and/or pressurizing the water or solvent mixture. According to one embodiment, the water or solvent mixture may be directed through a plurality of water nozzles 44 , such that the water nozzles 44 are configured to spray an article as it passes through the wash station 18 to remove any foreign substances deposited on the article. Such foreign substances may include, for example, grease, dirt, dust, oils, or any other substances that may interfere with the paint application process. The wash station 18 may also include a plurality of water barrier panels 46 for preventing the water or the solvent mixture from escaping the wash station 18 , and a drain system for returning the used water or the solvent mixture to the water tank 34 . It should be appreciated that the wash station 18 may include any equipment useful in removing foreign substances from an article before paint, such as, for example, powdered paint, is applied.
[0035] The blow off station 20 may be configured to remove any water or solvent mixture remaining on the article after the article passes through the wash station 18 . Specifically, the blow off station 20 may include a fan 48 , or pump, for pressurizing air and a plurality of air nozzles 50 for directing the pressurized air toward the article. Either or both of the fan 48 and air nozzles 50 may be supported by the manufacturing module 32 . Further, the blow off station 20 may include a hose (not shown) available to an operator for manually directing pressurized air toward the article. According to one embodiment, pressurized air may be provided via the utility transfer module 40 . Specifically, pressurized air may be supplied to the utility transfer module 40 directly from a source, or indirectly via the utility transfer module 40 of a contiguous manufacturing module 32 .
[0036] Air barrier panels 52 , or walls, may also be provided at the blow off station 20 for preventing pressurized air blown from the air nozzles 50 from interfering with activities or equipment outside of the blow off station 20 . After the water or solvent mixture is sufficiently removed from the article at the blow off station 20 , the article may be transported to the inspection station 22 , which may provide a location for an operator 54 to inspect the article. The inspection may, for example, involve visual, physical, or chemical analyses to determine the presence of any remaining impurities on the surface of the article.
[0037] After inspection, the article may be transported along the article transportation system 30 to the paint application station 24 . The paint application station 24 may include a piece of paint application equipment 56 for coating the article with paint, such as, according to one example, a powdered paint. The paint application station 24 may further include a plurality of paint barrier panels 58 for restricting the paint to the confines of the paint application station 24 . Either or both of the paint application equipment 56 and the paint barrier panels 58 may be supported by the manufacturing module 32 . Alternatively, however, the paint application equipment 56 and the paint barrier panels 58 may be secured to the planar floor 16 . As should be appreciated, the equipment used at the paint application station 24 may vary, depending on the type of paint used and the application process that is implemented. For example, the paint may be sprayed onto the article or, alternatively, the article may be immersed in a tank containing paint.
[0038] From the paint application station 24 , the article may be transported to the curing station 26 . The curing station 26 may be configured to heat or otherwise cure the coating of freshly applied paint. According to one embodiment, the curing station 26 may include a plurality of infrared heaters 60 , which may contain a plurality of infrared heater lamps 62 for generating the heat necessary for causing the coating of paint on the article to cure. According to one embodiment, the infrared heaters 60 may be portable. For example, one or more sets of rollers 64 may be provided to facilitate movement of the infrared heaters 60 from one location, such as a storage location, and into the illustrated position relative to the paint application station 24 . It should be appreciated that “portable” equipment, as used herein, may refer to any equipment or component that may not be characterized as a fixture or otherwise permanently attached component. It should also be appreciated that any equipment useful in making the coating of paint applied to the article permanent is contemplated for use at the curing station 26 .
[0039] For simplicity, the exemplary paint process is described as having one paint application station 24 ; however, it should be appreciated that a paint process may often include coating the article with multiple coatings of paint. As a result, the manufacturing chain 10 may include additional paint applications stations 24 and, if necessary, manufacturing modules 32 to accommodate such a process. Ultimately, after the desired number of paint coatings are applied to the article, the article may be transported to the unload station 28 . At the unload station 28 , the article may be removed from the manufacturing chain 10 or, more specifically, the article transportation system 30 by an operator 66 . After passing through the manufacturing chain 10 , it is contemplated that the article may be transported to another manufacturing chain for further processing, if desired. According to one embodiment, the article may be routed to a buffer area before passing to another manufacturing chain. Alternatively, the article may be taken to a storage location for storage, or to a transportation vehicle for delivery to a customer.
[0040] Turning now to FIG. 2 , an exemplary manufacturing module 32 for supporting one or more of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 of FIG. 1 is shown in greater detail. Specifically, the manufacturing module 32 may consist of a plurality of beams, such as tubular beams, forming a framework or skeleton 80 . According to one embodiment, the skeleton 80 may include a plurality of vertically aligned support beams 82 , 84 , 86 , and 88 attached to the planar floor 16 using support plates 90 , 92 , 94 , and 96 , respectively. Although a bolted connection is shown, it should be appreciated that the support beams 82 , 84 , 86 , and 88 and/or support plates 90 , 92 , 94 , and 96 may be attached to the planar floor 16 using any secure connection.
[0041] The vertically aligned support beams 82 , 84 , 86 , and 88 may be interconnected using a plurality of additional support beams, such as horizontally aligned beams 98 , 100 , 102 , and 104 . The horizontally aligned support beams 98 , 100 , 102 , and 104 and vertically aligned support beams 82 , 84 , 86 , and 88 may define an entry 106 and an exit 108 of the manufacturing module 32 , and may provide structural support for one or more modular manufacturing stations, such as the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 of FIG. 1 . As such, the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 may be fabricated from steel, carbon composites, or any other material known in the art suitable for providing the desired support. According to one embodiment, it may be desirable to utilize a relatively lightweight material to ease the transport and/or construction of the manufacturing module 32 .
[0042] Additionally, it may be desirable to allow for expansion and/or contraction of one or more of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 . Such expansion and/or contraction may further ease the transport and/or construction of the manufacturing module 32 , and may also allow for a customized size and/or shape of each manufacturing module 32 . For example, the desired size and/or shape of the manufacturing module 32 may depend upon a number of factors including, but not limited to, the number of modular manufacturing stations, such as modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , disposed within the manufacturing module 32 .
[0043] To facilitate adjustment, one or more of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 may include a hollow tubular portion and a piston portion. For example, vertically aligned support beam 82 is shown having a tubular portion 82 a and a piston portion 82 b. As should be appreciated, the piston portion 82 b may be slidably received within the tubular portion 82 a and locked at a desired length. Locking may be accomplished using any known fastening devices, such as, for example, bolts, screw, pins, or spring-actuated bearings. Alternatively, however, each of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 may be fabricated to various desired lengths, as dictated by the design of the manufacturing module 32 . According to one embodiment, it may be desirable to expand and/or contract only the vertically aligned support beams 82 , 84 , 86 , and 88 .
[0044] Although the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 are illustrated as forming a cubic shape, they may, alternatively, be positioned to form any shape conducive to the specific manufacturing process being performed. Additionally, the number of support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 utilized to form the skeleton 80 may vary depending upon the shape of the manufacturing module 32 . The support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 of the manufacturing module 32 may be secured together by mechanical fasteners, welds, or any other devices known in the art that are used to secure components. Additionally, the skeleton 80 of the manufacturing module 32 may be attached to the framework of a contiguous manufacturing module 32 using similar fasteners. Alternatively, however, the manufacturing module 32 may be positioned adjacent a contiguous manufacturing module 32 and may not be attached thereto. A “contiguous” manufacturing module, as used herein, may refer to a manufacturing module, such as manufacturing module 32 , positioned in close proximity to another manufacturing module, such as, for example, a preceding or succeeding manufacturing module in the manufacturing chain 10 .
[0045] One or more of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 of the skeleton 80 may support the utility transfer module 40 . The utility transfer module 40 may be configured to transfer at least one of electric power, fluid, and data through the manufacturing module 32 . Specifically, the utility transfer module 40 may transfer and/or provide electric power, water, compressed air, gas, or other utilities to the one or more modular manufacturing stations, such as modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , supported by the manufacturing module 32 . According to one embodiment the utility transfer module 40 may include a collection of wires, cables, or other conduits capable of transferring one or more utilities.
[0046] The utility transfer module 40 may include an external port 110 for engaging an external utility connection, such as, for example, the external utility connection 36 of FIG. 1 . Although the external utility connection 36 is positioned outside the building 14 , it should be appreciated that the external utility connection 36 may be positioned within the building 14 , such as within the manufacturing area 12 . According to one embodiment, the external utility connection 36 includes a utility source, such as, for example, an electric power grid, a generator, a battery, a compressed air tank, a hydraulic tank, and/or a water supply. It should be appreciated that the external utility connection 36 may include any source of a utility that is utilized by the manufacturing chain 10 . Accordingly, each utility transfer module 40 may include multiple external ports 110 , depending on the number of utility sources to be engaged.
[0047] Each utility transfer module 40 may also include an entry port 112 for engaging a utility transfer module 40 of a preceding manufacturing module 32 , and an exit port 114 for engaging a utility transfer module 40 of a succeeding manufacturing module 32 . It should be appreciated that the entry port 112 of the utility transfer module 40 of the first manufacturing module 32 in the manufacturing chain 10 may remain unused and, similarly, the exit port 114 of utility transfer module 40 of the last manufacturing module 32 may remain unused. Such ports, however, may become necessary, such as, for example, when an additional manufacturing module 32 is added to the manufacturing chain 10 .
[0048] Additionally, the utility transfer module 40 may include one or more equipment ports, such as a first equipment port 116 , for providing a utility to the one or more modular manufacturing stations, such as the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , of the manufacturing module 32 . According to a more general example, manufacturing module 32 may support a first modular manufacturing station 118 that is configured to perform at least one task of a manufacturing process. Accordingly, the first modular manufacturing station 118 may include equipment, and other systems and/or components, necessary to accomplish the task to be performed. Specifically, and according to one example, the first modular manufacturing station 118 may include a piece of manufacturing equipment 120 , an article transportation device 122 representing a portion of the article transportation system 30 corresponding to the station 118 , and a station control system 124 . Although the manufacturing equipment 120 is exemplified as a plurality of air nozzles, similar to air nozzles 50 , it should be appreciated that any manufacturing equipment useful in performing a manufacturing task is contemplated.
[0049] One or more of the manufacturing equipment 120 , the article transportation device 122 , and the station control system 124 may receive utilities, such as electric power, fluid, and data, from the utility transfer module 40 . For example, the manufacturing equipment 120 may include a conduit 126 having a quick connect coupling member 128 for engaging the first equipment port 116 . Similarly, the article transportation device 122 may include a conduit 130 having a quick connect coupling member 132 for engaging a second equipment port 134 of the utility transfer module 40 . In addition, the station control system 124 may include conduit 136 having a quick connect coupling member 138 for engaging a third equipment port 140 of the utility transfer module 40 .
[0050] It should be appreciated that any of the ports or connections described herein, such as, for example, ports 110 , 112 , 114 , 116 , 134 , and 140 , may embody electrical outlets, quick connect coupling members, or any other known utility interfaces. In addition, each of the quick connect coupling members 128 , 132 , and 138 may embody any appropriate utility interface for engaging one or more of the ports 110 , 112 , 114 , 116 , 134 , and 140 . It should also be appreciated that quick connect coupling members may enable relatively quick and easy assembly and/or disassembly of the manufacturing stations, such as modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , and/or first modular manufacturing station 118 . Additional benefits may be recognized by utilizing common, or universal, interfaces throughout the entire manufacturing chain 10 .
[0051] According to one embodiment, the utility transfer module 40 may be secured to one of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 , such as support beam 102 , using one or more mounting devices 142 . Mounting devices 142 may, for example, include hooks, latches, sockets, or any other devices capable of securing the utility transfer module 40 to one or more of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 . Alternatively, however, the utility transfer module 40 may be positioned within a hollow portion, such as, for example, a central portion, of one or more of the tubular support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 . It should be appreciated that the utility transfer module 40 may be supported by and/or secured to any number of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 , as necessary to transfer a utility through and/or provide a utility to the manufacturing module 32 .
[0052] Turning now to FIG. 3 , an alternative embodiment of a manufacturing module 32 is shown. Specifically, one or more of the manufacturing modules 32 may include a second modular manufacturing station 160 disposed between the entry 106 and the exit 108 of the manufacturing module 32 . The second modular manufacturing station 160 may include similar systems and/or components as the first modular manufacturing station 118 . Specifically, the second modular manufacturing station 160 may include at least one piece of manufacturing equipment 120 , an article transportation device 122 representing a portion of article transportation system 30 corresponding to the second modular manufacturing station 160 , and a station control system 124 .
[0053] It should be appreciated that each of the systems and/or components of the second modular manufacturing station 160 may also receive a utility from the utility transfer module 40 in a manner similar to that described above. It should further be appreciated that either or both of the first and second modular manufacturing stations 118 and 160 may be representative of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 of FIG. 1 . Accordingly, each of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 may generally include one or more of the manufacturing equipment 120 , article transportation device 122 , and station control system 124 .
[0054] Each article transportation device 122 may include a friction drive system having one or more sets of carrier tracks, such as carrier tracks 162 , along which a carrier 164 may be transported. It should be appreciated that the one or more sets of carrier tracks 162 may define a transportation path 166 through a manufacturing chain, such as the manufacturing chain 10 of FIG. 1 . Friction drive systems are known, and may generally include one or more hanger rails 168 fixedly attached to the skeleton 80 for supporting one or more support rails 170 . At least one of the support rails 170 may provide support for a drive shaft 172 that may be mechanically coupled to a drive system 174 .
[0055] The drive system 174 may, for example, include an electric, hydraulic, or pneumatic motor, and may further include a transmission and controls, as necessary, for driving the drive shaft 172 at a desired speed and in a desired direction. For example, the drive shaft 172 may be rotated in a first direction for frictionally engaging wheels of the carrier 164 such that the carrier 164 is moved in a forward transport direction, represented by arrow “F”. Alternatively, however, the drive shaft 172 may be rotated, by the drive system 174 , in an opposite direction for frictionally engaging wheels of the carrier 164 to move the carrier 164 in a reverse transport direction “R” that is opposite the forward transport direction “F.” A similar friction drive system may be provided by OCS IntelliTrak, Incorporated of Cincinnati, Ohio.
[0056] Although a friction drive system is described, however, it should be appreciated that a variety of material handling systems may be used. For example, an air balancer, a series of hoists, an electrified monorail, or any other device capable of moving an article through the manufacturing chain 10 are also contemplated. Further, it should be appreciated that carriers, such as carriers 164 , may include any devices capable of gripping an article to be conveyed through the manufacturing chain 10 . Exemplary carriers may, for example, include hooks, clamps, latches, or any other devices capable of temporarily grasping the article. Although a single carrier 164 is depicted for transporting an article, it should be appreciated that multiple carriers may be necessary for transporting the article, depending on the size and weight of the article.
[0057] It is also contemplated that the article transportation system 30 may be substituted with a chain, belt, or any other device that may convey carriers 164 through the manufacturing chain 10 . According to one embodiment, the article transportation system 30 may be mounted to the planar floor 16 and/or contain a transport device, such as, for example, a conveyor belt to convey the article through the manufacturing chain 10 . Preferably, however, the article transportation devices 122 that define the article transportation system 30 may each include at least one drive system 174 , or similar means, for facilitating independent movement of the carrier 164 within the respective one of the manufacturing stations 118 and 160 .
[0058] Each station control system 124 may be configured to control operation of at least one of the article transportation device 122 and the manufacturing equipment 120 of the respective one of the modular manufacturing stations 118 and 160 . Specifically, the station control system 124 may be in communication with the article transportation device 122 or, more specifically, the drive system 174 , and may be configured to issue an operation signal, such as, for example, a forward signal, a reverse signal, and a stop signal. The forward signal may correspond to the forward transport direction “F,” the reverse signal may correspond to the reverse transport direction “R,” and the stop signal may correspond to a stationary position. It should be appreciated that the stationary position may represent a state in which the carrier 164 is not driven in either of the forward transport direction “F” or the reverse transport direction “R”.
[0059] According to one embodiment, the carrier 164 of the first modular manufacturing station 118 may be driven in the forward transport direction “F” while the carrier 164 of the second modular manufacturing station 160 is simultaneously driven in the reverse transport direction “R” or, alternatively, remains stationary. According to a specific example, it may be desirable to move the carrier 164 of the second modular manufacturing station 160 in the reverse transport direction “R” relative to the manufacturing equipment 120 . As should be appreciated, continuous forward and reverse movement relative to the manufacturing equipment 120 may prove beneficial in a variety of tasks of a manufacturing process, including, but not limited to, a wash task and a blow off task, as described above. According to an additional example, it may be desirable to stop the carrier 164 of the second modular manufacturing station 160 , such as in response to the identification of a defect, while one or more other carriers 164 continue to move. A variety of defects are contemplated, such as, for example, defects resulting from process problems and/or equipment failures.
[0060] Each modular manufacturing station 118 and 160 may also include one or more position tracking devices. According to one embodiment, a first position tracking device 176 , a second position tracking device 178 , and a third position tracking device 180 are each positioned for detecting a position of the carrier 164 as it is transported through the station 118 and 160 . Position tracking devices 176 , 178 , and 180 are known, and may include, for example, position sensors, proximity switches, bar code readers, or any other devices capable of detecting a position of the carrier 164 . In addition, the position tracking devices 176 , 178 , and 180 may be supported by the skeleton 80 , the article transportation device 122 , or may be otherwise positioned. Although three position tracking devices 176 , 178 , and 180 are shown, it should be appreciated that any number of position tracking devices may be used, as dictated by the manufacturing process.
[0061] Each station control system 124 may also be in communication with the position tracking devices 176 , 178 , and 180 , and may receive signals from one or more of the position tracking devices 176 , 178 , and 180 that are indicative of first, second, and third detected positions of the carrier 164 . Each station control system 124 may also be configured to issue one or more operation signals, such as, for example, the forward signal, reverse signal, and stop signal, to the article transportation device 122 based, at least in part, on one of the detected carrier positions. According to one example, it may be desirable for the station control system 124 to issue the stop signal to the article transportation device 122 when the carrier 164 has reached a predetermined position relative to the manufacturing equipment 120 . After a predetermined period of time, for example, the station control system 124 may then issue the forward signal to the article transportation device 122 . Further, the station control system 124 may issue one or more operation signals to the manufacturing equipment 120 based, at least in part, on one of the detected carrier positions.
[0062] Turning now to FIG. 4 , an alternative embodiment of a manufacturing module 32 is shown. Specifically, the transportation path 166 defined by the carrier tracks 162 may include a vertical discontinuity 200 . It should be appreciated that, according to one example, the vertical discontinuity 200 may occur where the transportation path 166 includes a first transport height 202 that is vertically spaced from a second transport height 204 . Specifically, the two sets of carrier tracks 162 of the first modular manufacturing station 118 may be positioned at the first transport height 202 , while the carrier tracks 162 of the second modular manufacturing station 160 are positioned at the second transport height 204 . Such a discontinuity along the transportation path 166 may occur as a result of the design of the manufacturing chain 10 , as dictated by a topography of the manufacturing area 12 or a variety of other factors. Additionally, it may be desirable to alter the height of the transportation path 166 relative to the manufacturing equipment 120 .
[0063] A first vertical lift device 206 may be provided for moving one of the sets of carrier tracks 162 in a vertical direction relative to the transportation path 166 . Specifically, the first vertical lift device 206 may be configured to move one of the sets of carrier tracks 162 , adjacent the vertical discontinuity 200 , from the first transport height 202 to the second transport height 204 . Vertical lift devices, such as vertical lift device 206 , are known, and may include, for example, electric or pneumatic lifts, and, as such, may receive any necessary utilities from the utility transfer module 40 . In addition, the first vertical lift device 206 may be supported by and/or secured to the skeleton 80 of the manufacturing module 32 .
[0064] A control system, such as, for example, the station control system 124 , may also be provided for controlling operation of the first vertical lift device 206 . Specifically, and according to one embodiment, the station control system 124 may also be in communication with the first vertical lift device 206 , and may be configured to issue operation signals thereto, such as, for example, a raise signal and a lower signal. For example, the first vertical lift device 206 may be configured to move the carrier tracks 162 from the first transport height 202 to the second transport height 204 in response to the raise signal. In addition, the first vertical lift device 206 may be configured to move the carrier tracks 162 from the second transport height 204 to the first transport height 202 in response to the lower signal.
[0065] Further, the station control system 124 may be configured to issue the raise signal and/or the lower signal in response to a carrier position that is detected by one of the position tracking devices 176 , 178 , and 180 . Specifically, and according to one example, it may be desirable to issue the raise signal when it is determined that the carrier 164 has reached a predetermined position relative to the carrier tracks 162 . After the carrier tracks 162 have been raised, the carrier 164 may continue to be transported along the transportation path 168 at the second transport height 204 , such as by the drive system 174 .
[0066] The transportation path 168 may include additional vertical discontinuities, such as, for example, a second vertical discontinuity 210 , shown in FIG. 5 . A second vertical lift device 212 , similar to first vertical lift device 206 , may, therefore, be provided to advance the carrier 164 through the second vertical discontinuity 210 . Specifically, the second vertical lift device 212 may move the carrier tracks 162 from the second transport height 204 to the first transport height 202 , such as in response to the lower signal issued from the station control system 124 . It should be appreciated that the station control system 124 may issue the lower signal in response to a carrier position detected by one of the position tracking devices 176 , 178 , and 180 . It should also be appreciated that any number of vertical lift devices, such as lift devices 206 and 212 that may be manually or automatically operated, may be used throughout the manufacturing chain 10 to accommodate vertical discontinuities and/or to move one of the carriers 164 in a vertical direction relative to the manufacturing equipment 120 .
[0067] According to one embodiment, it may be desirable to incorporate one or more vertical lift devices, such as the lift devices 206 and 212 , into the manufacturing chain 10 to accommodate manufacturing equipment 120 positioned above the planar floor 16 . Specifically, the manufacturing chain 10 may include one or more pieces of manufacturing equipment 120 that traditionally were positioned below the planar floor 16 , such as, for example, tanks or baths. For ease of deployment, the manufacturing chain 10 may position all equipment 120 , including such tanks or baths, above ground and, therefore, may advance the carriers 164 through the manufacturing chain 10 and relative to the manufacturing equipment 120 using one or more vertical lift devices 206 and 212 .
[0068] It should be appreciated that utilizing an article transportation device 122 having at least one of reverse, stop, and lift capabilities may allow a decrease in size and/or output capacity of the manufacturing equipment 120 . For example, a conventional curing station may require a relatively large infrared heater capable of generating a large amount of heat. Specifically, the infrared heater may be sized to adequately cure a coating of paint on an article as it passes through the curing station at a speed equal to an overall line speed. However, the article transportation device 120 , as described herein, may stop and/or reverse the article as it passes through the curing station 26 . Therefore, the manufacturing equipment 120 or, more specifically, the infrared heaters used therein may have a lower heat output requirement. As a result, significant cost savings relative to the manufacturing equipment 120 may be recognized.
[0069] An exemplary control system 220 for the manufacturing chain 10 is shown generally in FIG. 6 . Specifically, the control system 220 may include the station control systems 124 of each modular manufacturing station within the manufacturing chain 10 , such as the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . It should be appreciated that the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 of FIG. 1 may include configurations similar to any of the embodiments of the first and second modular manufacturing stations 118 and 160 of FIGS. 2-5 . Specifically, the manufacturing modules 32 of the manufacturing chain 10 , as shown in FIG. 1 , may each include one or more of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , as dictated by the manufacturing process to be performed.
[0070] The station control systems 124 may include any commercially available microprocessors that include means for controlling the operation of at least one of the article transportation device 122 and the manufacturing equipment 120 of the respective manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . Generally, each station control system 124 may include a processor 222 , a memory 224 , and any other components for running an application. Various circuits may also be associated with the station control systems 124 , such as utility supply circuitry, signal conditioning circuitry, and any other types of circuitry needed for the operation of the respective manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 .
[0071] The station control systems 124 may each receive input from an operator interface 226 , and may control and/or override the operation of the article transportation device 122 and/or manufacturing equipment 120 of the respective manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 in response to the input. As should be appreciated, the operator interface 226 may receive an operator input command that is indicative of a desired operation. Accordingly, the operator interface 226 may include a touch screen, keyboard, control panel, or any other device or mechanism capable of facilitating communication between the operator and the station control systems 124 . It is also contemplated that the input could alternatively be a computer-generated command from an automated system that assists the operator, or an autonomous system that operates in place of the operator.
[0072] According to one embodiment, the memory 224 of each station control system 124 may include a unique operation pattern corresponding to a specific task stored thereon. For example, the unique operation pattern may include one or more operation signals to be transmitted to at least one of the article transportation device 122 and the manufacturing equipment 120 via at least one communications conduit 228 . Such operation signals may, for example, include the forward signal, the reverse signal, and the stop signal, as described above. In addition, the raise signal and the lower signal may be issued to an article transportation device 122 that includes a vertical lift device, such as vertical lift devices 206 and 212 . Further, operation signals, such as, for example, a begin operation signal and a stop operation signal that may, intuitively, start or stop operation of the manufacturing equipment 120 , may also be issued. It should be appreciated that a “unique operation pattern,” as used herein, may generally refer to any sequence or pattern of movements or operations that facilitate the performance of a task, including such parameters as speed and direction of travel.
[0073] Each of the station control systems 124 may issue an operation signal, as describe above, in response to an operator input or, alternatively, automatically and according to a predetermined pattern, such as corresponding to the unique operation pattern stored thereon. According to one embodiment, the station control systems 124 may be in communication with the position tracking devices 176 , 178 , and 180 via the communications conduit 228 , and may be configured to receive signals indicative of detected carrier positions. The station control systems 124 may also be configured to issue at least one of the operation signals corresponding to the unique operation pattern, based, at least in part, on one or more of the detected carrier positions.
[0074] A main control system 230 may be provided for coordinating operation of the station control systems 124 of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 . Alternatively, however, one of the station control systems 124 may be designated a master control system for coordinating operation of the manufacturing chain 10 . The main control system 230 may be of standard design and may generally include a processor 232 , such as, for example, a central processing unit, a memory 234 , and an input/output circuit, such as the communications conduit 228 . It should be appreciated that the communications conduit 228 , as referenced herein, may represent any form of wired and/or wireless communications, and may generally represent the transmission of any of the operation signals and/or positions signals described above. According to one embodiment, one or more data communications may be transmitted via the utility transfer modules 40 .
[0075] The processor 232 may control operation of the main control system 230 by executing operating instructions, such as, for example, programming code stored in the memory 234 , wherein operations may be initiated internally or externally to the main control system 230 . As should be appreciated, a control scheme may be utilized that monitors outputs of the systems and/or components of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 , such as, for example, sensors, actuators, or control units, via the communications conduit 228 . Such information may, for example, be used to control inputs to the station control systems 124 and/or other systems and components of the each of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 .
[0076] According to one example, the memory 234 of the main control system 230 may store a plurality of unique operation patterns thereon. The main control system 230 may receive signals indicative of the first, second, and third detected carrier positions from each of the station control systems 124 . In response, the main control system 230 may independently transmit operation signals, such as operation signals corresponding to one of the unique operation patterns, to each of the station control systems 124 . The station control systems 124 may, in turn, transmit the operation signals to the article transportation device 122 and/or the manufacturing equipment 120 at the respective stations 18 , 20 , 22 , 24 , 26 , and 28 .
[0077] The main control system 230 may also index the carriers 164 of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 as each carrier 164 traverses to a contiguous station 18 , 20 , 22 , 24 , 26 , and 28 . According to one embodiment, the main control system 230 may simultaneously issue an index signal to the station control systems 124 of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 . As such, the processors 222 of each station control system 124 may be configured to await and/or anticipate the index signal from the main control system 230 after the task to be performed at the respective station has been completed.
[0078] According to one example, indexing may include detecting a desired position of the carrier 164 within each station 18 , 20 , 22 , 24 , 26 , and 28 , such as by using one or more of the position tracking devices 176 , 178 , and 180 . The main control system 230 may be configured to await signals from each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 that are indicative of the desired position and then simultaneously transfer each carrier 164 to a contiguous station 18 , 20 , 22 , 24 , 26 , and 28 . Additional operation signals, therefore, may also be useful for indexing, such as, for example, the stop signal, a speed adjust signal, a transfer signal, or any other signal useful for detecting and transferring the carriers 164 .
[0079] By coordinating operation of the entire manufacturing chain 10 , the main control system 230 may receive a carrier position signal from one modular manufacturing station and issue an operation signal to another manufacturing stations based, at least in part, on that carrier position signal. For example, it may be desirable to transfer the carrier 164 of modular manufacturing station 18 only when the carrier 164 of the modular manufacturing station 20 has reached a predetermined position, such as a position detected by one or more of the position tracking devices 176 , 178 , and 180 . It should be appreciated that the main control system 230 may utilize position signals from all of the position tracking devices 176 , 178 , and 180 , at least in part, to coordinate operation of the entire manufacturing chain 10 .
[0080] The main control system 230 may also include an operator interface, such as an interactive operator display 236 , for continuously monitoring and/or controlling operation of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 of the manufacturing chain 10 . According to one embodiment, the interactive operator display 236 may be used to continuously monitor a status of each article transportation device 122 of the manufacturing chain 10 . Further, the interactive operator display 236 may be configured to display a real-time visual representation of each carrier 164 being transported through the manufacturing chain 10 . The interactive operator display 236 may also be configured to receive an operator input command from an operator and transmit the operator input command to the article transportation device 122 or the manufacturing equipment 120 of at least one of the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 .
[0081] It should be appreciated that numerous applications and configurations of the control system 220 are contemplated. According to one embodiment, the main control system 230 , station control systems 124 , position tracking devices 176 , 178 , and 180 , article transportation devices 122 and manufacturing equipment 120 may all be interconnected through a local area network, as shown in FIG. 7 . As such, the main control system 230 may directly communicate with the systems and/or components of each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 , and, therefore, may not direct communications, including operation signals, through the station control systems 124 . Similarly, position signals may be communicated directly from the position tracking devices 176 , 178 , and 180 to the main control system 230 .
[0082] An exemplary embodiment of a material handling system for use with the modular manufacturing chain 10 , or modular manufacturing line, described herein is shown generally at 250 . The material handling system 250 , only a portion of which is shown, may include a composite beam 252 having an upper rail 254 and a lower track 256 connected through a plurality of spaced apart transverse members 258 . As shown later in greater detail, the lower track 256 may define two parallel channels 260 . A trolley 262 , several of which are shown, may include a lower set of wheels 264 that may be received within the two parallel channels 260 of the lower track 256 . The lower track 256 , along which the trolley 262 is movable, may define a rail of any standard size, including, for example, a 3″, 4″, or 6″ rail. An upper set of wheels 266 of the trolley 262 may be in frictional engagement with a drive tube 268 of a friction drive system 270 . The friction drive system 270 , which may include a spinning tube friction drive system as provided by OCS IntelliTrak of Cincinnati, Ohio, may be similar to an exemplary embodiment of the article transportation device 122 described above, and may generally include a plurality of drive tubes 268 supported along the material handling system 250 and positioned in series to define a path through the modular manufacturing chain 10 ( FIG. 1 ). Each of the plurality of drive tubes 268 may be independently driven, or rotated, by one of a plurality of motors, such as electric drive motor 272 . Therefore, depending on the number and length of independently driven drive tubes 268 , the material handling system 250 , or modular material handling system 250 , may be customized to independently control each article as it is transported through the manufacturing chain 10 .
[0083] As shown in the illustrated embodiment, a first trolley assembly 274 may be configured to support a first load bar 276 . Specifically, a first end 278 of the first load bar 276 may be pivotably supported from a first trolley 280 , while a second end 282 of the first load bar 276 may be pivotably supported from a second trolley 284 . Similarly, second trolley assembly 285 may be configured to support a second load bar 286 . More specifically, a first end 288 of the second load bar 286 may be piovtably supported from a third trolley 290 , and a second end 292 of the second load bar 286 may be pivotably supported from a fourth trolley 294 . A carrier 296 , which may include any devices capable of gripping an article to be conveyed along the modular material handling system 250 , may have a first end 298 pivotably supported from the first load bar 276 and a second end 300 pivotably supported from the second load bar 286 . While a carrier, such as carrier 296 , may be configured to support an article, load bars, such as first and second load bars 276 and 286 , may be configured to evenly distribute weight carried by the carrier 296 among a plurality of trolleys 262 . One skilled in the art should appreciate that a trolley assembly, such as first trolley assembly 274 and second trolley assembly 285 , may include any number of trolleys 262 configured to directly or indirectly support a carrier, such as carrier 296 . Further, a load bar assembly, such as the illustrated load bar assembly 302 , may include any number of trolleys 262 or trolley assemblies 274 and 285 supporting any number of load bars 276 and 286 . Such arrangements may be customized based on the weight to be supported by the carrier 296 .
[0084] According to another arrangement, one or more of the trolleys 262 may include a coupling mechanism for attaching the trolley 262 to another trolley 262 . For example, the front of one trolley 262 may include coupling means configured to attach to complementary coupling means provided on the back of another trolley 262 . Alternatively, similar coupling means may be provided to attach carriers, such as carrier 296 , or load bars, such as load bars 276 or 286 . Any such arrangements may be similar, in purpose, to conventional couplings for attaching train cars to one another for pulling the train cars in a train. As such, one or more trolleys 262 , or carriers 296 , may be transported along the material handling system 250 in a coupled configuration. Such a coupled configuration may, for example, be useful when transporting similar articles or when transporting different articles that may be later combined into an assembly or a sub-assembly.
[0085] Although not depicted, it should be appreciated that a single trolley 262 , which may also be referenced as a trolley assembly, may be configured to directly support a carrier, such as carrier 296 . As such, the friction drive system 270 , and trolley 262 , may be configured to ensure that at least one of the wheels of the upper set of wheels 266 continuously engages one of the drive tubes 268 . Specifically, the wheels of the upper set of wheels 266 may bridge any gaps, such as gap 304 , between drive tubes 268 of the friction drive system 270 . For trolley assemblies, such as trolley assemblies 274 and 285 , which may include one or more trolleys 262 connected through one or more load bars, such as load bar 276 , and/or carriers, such as carrier 296 , it may be important to ensure that at least one of the trolleys 262 continuously engages one of the plurality of drive tubes 268 .
[0086] The trolleys 262 , described herein, may be of standard design, requiring a lower set of wheels 264 , movable along the lower track 256 , and an upper set of wheels 266 that are configured to frictionally engage the plurality of drive tubes 268 . Such trolleys 262 , according to one embodiment, may be modified versions of conventional power and free conveyor trolleys, or other trolleys known to those skilled in the art. To incorporate such standard components, a drive adapter may be provided that attaches a standard trolley, having lower wheels that are movable within the lower track 256 , to the upper set of wheels 266 , described herein. The upper wheels 266 , as should be appreciated, are configured to frictionally engage the plurality of drive tubes 268 . By incorporating such conventional components, such as by slightly modifying standard trolleys as described herein, costs of implementing the material handling system 250 may be reduced.
[0087] Turning now to FIGS. 9 a - 9 c, cross-sectional views of alternative embodiments of the composite beam 252 are shown. Specifically, the composite beam 252 of FIG. 9 a may include the upper rail 254 and lower track 256 connected through transverse members 258 , as described above with reference to FIG. 8 . As shown, each of the transverse members 258 may have an inverted U-shaped cross-section defining a pair of free ends 320 . Each of the free ends 320 may support one of channels 260 , which may be generally C-shaped channels, of the lower track 256 . The channels 260 , according to one embodiment, may be welded, or otherwise permanently affixed, to each of the plurality of transverse members 258 . Although alternative attachment methods are contemplated, welding may be preferred to provide increased structural strength of the composite beam 252 and, further, may allow the transverse members 258 to be positioned at longer centers. The upper rail 254 , as shown in FIG. 9 a, may, according to one embodiment, include a T-shaped cross-section defining a central web 322 and a transverse flange 324 . The central web 322 , which may extend the length of the composite beam 252 , may be received, and permanently affixed, within a vertically aligned slot 326 of an upper portion 328 of each of the transverse members 258 .
[0088] According to alternative embodiments, shown in FIGS. 9 b and 9 c, the upper rail 254 of the composite beam 252 may include a pair of oppositely oriented structural members 330 . Each of the structural members 330 may include a vertically oriented web 332 that is secured to each of the transverse members 258 . Turning specifically to FIG. 9 b, each of the structural members 330 may be in the form of an angle iron having the vertically oriented web 332 and a horizontally oriented flange 334 . The horizontally oriented flange 334 , along with the transverse flange 324 of the embodiment of FIG. 9 a, may be used to secure a position of the composite beam 252 along the modular manufacturing chain 10 ( FIG. 1 ), as described below in greater detail. According to this embodiment, and alternative embodiments, the composite beam 252 may also include a horizontally aligned support plate 336 secured to each of the pair of free ends 320 of the transverse members 258 and/or the channels 260 of the lower track 256 .
[0089] The structural members 330 , according to the embodiment of FIG. 9 c, may include the vertically oriented webs 332 , which may be attached to the transverse members 258 , and the horizontally oriented flanges 334 , which may be used to attach the composite beam 252 to another structure. In addition, the structural members 330 , as shown in FIG. 9 c, may include horizontally oriented flanges 340 that may be fixedly attached to each of the plurality of transverse members 258 . Also shown in the embodiment of FIG. 9 c, the composite beam 252 may include a cable tray 342 supported, or defined, by the composite beam 252 . Specifically, the cable tray 342 may extend a length of the composite beam 252 and may be received, and secured, within openings 344 defined by the transverse members 258 . Alternatively, the cable tray 342 may not extend the length of the composite beam 252 , but may be defined only by the openings 344 of the transverse members 258 . The cable tray 342 may be provided to accommodate one or more cables or conduits provided along the manufacturing chain 10 . For example, the cable tray 342 may accommodate the utility transfer module 40 , described above, which may be configured to transfer a utility, such as, for example, electric power, fluid, or data, through the modular manufacturing chain 10 of FIG. 1 , or another similar chain or line.
[0090] The one or more composite beams 252 of the material handling system 250 may be provided in any desired length, and may include one or more straight and/or curved sections. According to one embodiment, the composite beams 252 , which may be made from iron, steel, aluminum, plastics, composites, and/or any other desired materials, may be provided in specific lengths selected to ease assembly of the modular manufacturing chain 10 of FIG. 1 . Specifically, the composite beams 252 may be pre-fabricated, or pre-constructed, prior to delivery to the manufacturing area 12 ( FIG. 1 ). Further, each composite beam 252 may be shipped with a predetermined length of cable 356 , an electric drive motor 272 , and a variable-frequency drive 358 for operating the electric drive motor 272 , each of which may be later repositioned. As shown in FIG. 10 , each composite beam 252 may, according to the exemplary embodiment, be provided in a length corresponding to a length of a manufacturing module 360 . The manufacturing module 360 , which may be similar to the manufacturing module 32 described above, may include, according to one embodiment, a pair of end frames 362 connected through one or more central beams that define a mid-frame 364 . One or more composite beams 252 may be supported from the manufacturing module 32 by attaching, such as by bolting, a plurality of connecting clamps 366 to the composite beam 252 and one or more of the mid-frame 364 and the end frames 362 . Once at least one composite beam 252 is attached to the mid-frame 364 and/or end frames 362 , according to the exemplary embodiment, the end frames 362 may be secured to floor supported beams (not shown). Specifically, end posts 368 may telescopically receive, or may be otherwise attached to, corresponding floor mounted beams (not shown) to form the manufacturing module 360 . Alternatively, rather than end posts 368 , the end frames 362 may include floor mounted support structures having an inverted “V-shape” oriented parallel to the composite beam 252 .
[0091] According to yet alternative embodiments, the one or more composite beams 252 may be supported directly by the building 14 , such as through cables suspended from a ceiling of the building 14 . According to one example, the material handling system 250 may include a combination of ceiling or structure supported composite beams 252 and floor supported composite beams 252 . The ceiling supported composite beams 252 , as should be appreciated, may provide additional clearance for accommodating equipment, such as manufacturing equipment. Yet alternatively, the one or more composite beams 252 may be inverted to provide an on-floor conveyor, rather than the overhead conveyor that has been described. As should be appreciated by those skilled in the art, such an on-floor conveyor may represent an inverted version of the material handling system 250 described herein, with articles and respective carriers positioned, or supported, above the composite beams 252 .
[0092] As described above, a plurality of manufacturing modules 360 may be positioned, such as in series, to define one or more paths through the modular manufacturing chain 10 of FIG. 1 . The modular material handling system 250 , including one or more composite beams 252 and the friction drive system 270 , described above, may be supported along the one or more paths defined by the manufacturing modules 360 . When supporting the material handling system 250 , it is important to note that the composite beams 252 and friction drive system 270 must be aligned to provide continuous paths, as necessary. It should be appreciated that the friction drive system 270 , as referenced herein, may comprise a plurality of friction drive modules, each of which includes one of the plurality of drive tubes 268 and a corresponding electric drive motor 272 . Therefore, friction drive system 270 , as used herein, may refer generally to the drive system, or material handling system 250 , used throughout the entire modular manufacturing chain 10 ( FIG. 1 ), or to a specific one or more of the modules, or segments, of the friction drive system 270 .
[0093] According to one implementation of the material handling system 250 , shown in FIG. 11 a, one or more manufacturing modules 360 of a manufacturing line, such as the manufacturing chain 10 of FIG. 1 , may include a dual track, or multiple track, assembly. Specifically, as shown in the simplified plan view of FIG. 11 a, the material handling system 250 may include a first track assembly 380 configured to transport a forward trolley assembly 382 , including one or more trolleys 262 , along a first path 384 , and a second track assembly 386 configured to transport a trailing trolley assembly 388 , including one or more trolleys 262 , along a second path 390 . Each track assembly 380 and 386 may include one or more composite beams 252 and a friction drive system 270 , as described above. The composite beams 252 of the first and second track assemblies 380 and 386 may be positioned, and/or secured, adjacent one another, without substantial modification, and, as such, may define paths 384 and 390 through one or more modules 360 that are substantially parallel. Together, the parallel paths 384 and 390 may define a transportation path 392 along which the forward trolley assembly 382 and the trailing trolley assembly 388 are spaced.
[0094] A carrier 394 , configured to support an article, may have a first end 396 pivotably supported by the forward trolley assembly 382 and a second end 398 pivotably supported by the trailing trolley assembly 388 . According to a specific arrangement, shown in FIG. 11 b, the first end 396 of the carrier 394 may be supported by the forward trolley assembly 382 through a first load bar assembly 410 , while the second end 398 of the carrier 394 may be supported by the trailing trolley assembly 388 through a second load bar assembly 412 . Such a multiple track assembly, including two or more track assemblies, may be used to support articles of a substantial weight, such as, according to some embodiments, up to about 80,000 pounds. According to such arrangements, it may be desirable for the modular material handling system 250 to include at least the first track assembly 380 and the second track assembly 386 throughout the entire manufacturing chain 10 , or line. However, it may be desirable to provide the multiple track assembly in only one or more modules of the manufacturing chain 10 , as will be described below. It should be appreciated that, in such multiple track arrangements, it may be desirable to utilize the friction drive system 270 described herein, which inherently allows slippage, to successfully navigate any curves along the transportation path 392 . Specifically, for example, one of the forward trolley assembly 382 and the trailing trolley assembly 388 may travel a greater distance than the other around such curves.
[0095] According to another implementation, the manufacturing chain 10 may include one or more buffers, such as a buffer 430 , as shown in FIG. 12 . Specifically, the buffer 430 , which may also be referred to as a sequencing buffer, may include a first track assembly 432 sized to receive at least two trolley assemblies 434 , and a second track assembly 436 that is also sized to receive and support at least two trolley assemblies 434 . According to some implementations, it may be desirable to provide a third track assembly 438 , similar to the first track assembly 432 and the second track assembly 436 , or any number of additional track assemblies. Each of the first, second, and third track assemblies 432 , 436 , and 438 may be vertically spaced, as shown, or may be otherwise positioned, as described below.
[0096] Each of the track assemblies 432 , 436 , and 438 may include any number of manufacturing modules 360 positioned such that the material handling system 250 of each track assembly 432 , 436 , and 438 , including one or more composite beams 252 and a friction drive system 270 , defines a continuous path along the respective track assembly 432 , 436 , or 438 . According to one embodiment, each module 360 may include one drive tube 268 and a corresponding electric drive motor 272 for transporting the trolley assemblies 434 along the first, second, and third track assemblies 432 , 436 , and 438 in a forward or reverse direction. As shown, each trolley assembly 434 may include a pair of trolleys 262 configured to support an article 440 using a carrier 442 . It should be appreciated, however, that any number of trolleys 262 may be configured to directly or indirectly support the carrier 442 .
[0097] The buffer 430 , illustrated as a stackable buffer, may also include a first movable track assembly 444 that may include the material handling system 250 described above. The first movable track assembly 444 may be supported by a manufacturing module 360 and may be movable between a plurality of positions. For example, the first movable track assembly 444 may have a first position that defines a continuous path along the first movable track assembly 444 and the first track assembly 432 . A “continuous path,” as used herein, may reference any path along which a trolley 262 may be continuously transported. The first movable track assembly 444 may also include a second position (shown) defining a continuous path along the first movable track assembly 444 and the second track assembly 436 . Further, for embodiments having a third track assembly 438 , the first movable track assembly 444 may have a third position defining a third continuous path along the first movable track assembly 444 and the third track assembly 438 .
[0098] A first programmable hoist 446 , or other similar transfer device, may be configured to move the first movable track assembly 444 between the first, second, and third positions described above. The first programmable hoist 446 may be of conventional design and, further, may be integrated with the control system 220 , described above. The first movable track assembly 444 may be positioned at a first end 448 of the buffer 430 , or at any other desired position along the buffer 430 . Further, the buffer 430 , according to the exemplary embodiment, may include a second movable track assembly 450 positioned at a second end 452 of the buffer 430 . The second movable track assembly 450 , similar to the first movable track assembly 444 , may be movable using a second programmable hoist 454 , or other similar transfer device. Specifically, the second movable track assembly 450 may be movable between a first position (shown) defining a continuous path along the second movable track assembly 456 and the first track assembly 432 , a second position defining a continuous path along the second movable track assembly 450 and the second track assembly 436 , and a third position defining a continuous path along the second movable track assembly 450 and the third track assembly 438 .
[0099] It should be appreciated that the track assemblies 432 , 436 , and 438 of the buffer 430 may, according to one alternative embodiment, be horizontally spaced, rather than vertically spaced. According to such implementations, the buffer 430 may utilize one or more lateral shuttles, described below, rather than programmable hoists 446 and 454 , to move the movable track assemblies 444 and 450 into alignment with one of the first, second, and third track assemblies 432 , 436 , and 438 . Such design choices, for example, may be based on spatial constraints of the manufacturing area 12 ( FIG. 1 ) and/or specific needs of the manufacturing processes that are supported. As such, the buffer 430 may include any number of stationary track assemblies, such as track assemblies 432 , 436 , and 438 , having any desired capacity, positioned and/or stacked according to a customized configuration. Further, the buffer 430 may include any number of movable track assemblies, such as movable track assemblies 444 ad 450 , positioned at any useful positions throughout the buffer 430 . Such a customized buffer 430 may be used to transport, store, sequence, and/or re-sequence carriers 442 and/or articles 440 supported thereon, as described below in greater detail.
[0100] During an exemplary operation, one or more of the trolley assemblies 434 may be distributed among the first track assembly 432 and the second track assembly 436 of the buffer 430 such that a first trolley assembly 456 is blocked from an exit position 458 . The exit position 458 may represent a position within the buffer 430 from which a trolley assembly 434 may be removed from the buffer 430 without having to move another trolley assembly 434 . For example, the exit position 458 may include a position that accommodates a continuous path onto a main path of a manufacturing line. To move the first trolley assembly 456 to the exit position 458 , the plurality of trolley assemblies 434 may be redistributed among the first track assembly 432 and the second track assembly 436 . For example, a second trolley assembly 460 , currently at the exit position 458 and blocking the first trolley assembly 456 from the exit position 458 , may be moved along the first track assembly 432 using the friction drive system 270 and onto the first movable track assembly 444 . The first movable track assembly 444 may then be raised, using the first programmable hoist 446 , from the first position to the second position (shown). At the second position of the first movable track assembly 444 , the second trolley assembly 460 may be moved from the first movable track assembly 444 and onto the second track assembly 436 , using the friction drive system 270 . As a result, the first trolley assembly 456 may be moved along the first track assembly 432 and into the exit position 458 .
[0101] It should be appreciated that, in the exemplary operation described above, the second track assembly 436 was not at its illustrated capacity of three trolley assemblies 434 and, therefore, the second trolley assembly 460 could more easily be moved onto the second track assembly 436 . However, if the second track assembly 436 were supporting a maximum number of trolley assemblies 434 , it may be necessary to move one of the trolley assemblies 434 from the second track assembly 436 to the first track assembly 432 . For example, the second movable track assembly 450 may be moved from the first position (shown) to the second position, described above. Next, a third trolley assembly 462 may be moved along the second track assembly 436 and onto the second movable track assembly 450 . The second movable track assembly 450 may then be lowered, such as by using the second programmable hoist 454 , from the second position to the first position, such that the third trolley assembly 462 may be moved from the second movable track assembly 450 and onto the first track assembly 432 .
[0102] It should also be appreciated that, if both the first track assembly 432 and the second track assembly 436 are at maximum capacity, trolley assemblies 434 may be simultaneously moved, or shifted, through the buffer 430 . For example, the friction drive system 270 of the first track assembly 432 may transport the trolley assemblies 434 in a first direction, while the friction drive system 270 of the second track assembly 436 may transport the trolley assemblies 434 in a second direction that is opposite the first direction. Specifically, the trolley assemblies 434 may be shifted in clockwise direction or a counterclockwise direction through the buffer 430 to move a desired trolley assembly 434 to the exit position 458 . As should be appreciated, to provide such re-sequencing when the buffer 430 is at, or near, maximum capacity, it may be preferable to utilize at least two or more movable track assemblies, such as movable track assemblies 444 and 450 . Further, it should be appreciated that the friction drive system 270 or, more specifically, friction drive modules corresponding to each of the track assemblies 432 , 436 , and 438 and movable track assemblies 444 and 450 may provide independent movement and control of each of the trolley assemblies 434 positioned therein.
[0103] Turning now to FIG. 13 , a high level view of a first line 480 is shown. The first line 480 may be similar to, or may include, the modular manufacturing chain 10 described above with reference to FIG. 1 . Specifically, the first line 480 may include a plurality of stationary modules, such as modules 32 ( FIGS. 1-5 ) or modules 360 ( FIG. 10 ), positioned in series, or in parallel, and defining at least one path 481 , which may include a main path, through the first line 480 . The first line 480 may utilize the material handling system 250 , as described above, including one or more composite beams 252 supporting the friction drive system 270 . Generally, according to one example, the first line 480 may include first operations 482 and a logistics area 484 , both of which may receive articles, such as parts, from suppliers 486 . From first operations 482 , parts, or other articles, may be transported to fabrications 488 , using the material handling system 250 , by supporting the parts using carriers, as described above. From both logistics 484 and fabrications 488 , articles may be transported to paint shop 490 or sub-assembly 492 .
[0104] As shown, the first line 480 may include a plurality of buffers 494 , which may be similar to the buffer 430 described above with reference to FIG. 12 . The buffers 494 may be positioned anywhere along the first line 480 , such that carriers, and articles supported thereon, may be routed off the one or more main paths 481 and into the buffers 494 . As described above, the buffers 494 may be used to store and/or re-sequence carriers and/or articles. A plurality of spurs 495 may also be provided throughout the first line 480 for storing and/or re-sequencing carriers, in a manner described in greater detail below. Further, the articles may remain on the same carriers continuously throughout the first line 480 , which may span one or more buildings or manufacturing areas. For example, parts and/or sub-assemblies may be stored in one of the buffers 494 , or other storage areas, until they are transported, such as by using a trolley assembly 496 , similar to those described above, to an assembly line 498 or to one or more stations 500 along the assembly line 498 . The articles and/or carriers may be tracked, such as by using barcodes, sensors, and the control system 220 described above, to access and route the parts to the assembly line 498 and/or stations 500 precisely when they are needed.
[0105] A mobile module 502 , having ground-engaging elements 504 , may be used to transport an article, such as a part, sub-assembly, or assembly, from the first line 480 to a second line 520 , as shown in FIG. 14 . Specifically, the mobile module 502 may be movable between, at least, a first position 506 , as shown in FIG. 13 , to a second position 522 , as shown in FIG. 14 . The mobile module 502 may include one or more modules, such as modules 32 ( FIGS. 1-5 ) or 360 ( FIG. 10 ) supported by a frame, such as an enclosed portion of a vehicle or other mobile device. For example, the mobile module 502 may represent a mobile version of one of the stationary modules 32 or 360 described above, and may be movable using any known transportation means. The mobile module 502 may also include a material handling system 250 , including one or more composite beams 252 supporting a friction drive system 270 , as described above. It should be appreciated that in both the first position 506 and the second position 522 , the material handling system 250 of the mobile module 502 may be aligned with a portion of the material handling system 250 of the respective line 480 or 520 , such that a trolley assembly, such as trolley assembly 492 , may be continuously transported along the respective material handling systems 250 . According to another embodiment, the material handling system 250 may provide a continuous path between adjacent buildings. Further, an enclosure may be provided to protect the material handling system 250 and any articles transported thereon from the weather, and other adverse conditions, to which they may be exposed between buildings. As should also be appreciated, transporting an article on its respective carrier may allow the carrier and, thus, article to be tracked while it is transported between remote buildings, locations, etc., as described herein.
[0106] Referring also to FIGS. 1-13 , the second line 520 of FIG. 14 may also include a plurality of stationary modules 32 or 360 positioned in series and defining at least one path through the second line 520 . The second line 520 may utilize the material handling system 250 , as described above, including one or more composite beams 252 supporting a friction drive system 270 . Generally, the second line 520 may include one or more track switches, which may each be positioned between two of the plurality of drive tubes 268 . According to one example, a first track switch 524 , which may include a movable track assembly 525 , may be movable between a first position defining a first path 526 , and a second position defining a second path 528 . As shown, the second path 528 may be positioned at an angle that is greater than zero with respect to the first path 526 . By moving the first track switch 524 from the first position to the second position, a carrier, such as carrier 530 , may be transported through the first track switch 524 and onto a spur 532 (as shown). It should be appreciated that the spur 532 , and additional spurs, may be positioned along the second line 520 and used for temporary storage and/or carrier re-sequencing. For example, the carrier 530 may be routed onto the spur 532 , the first track switch 524 may be moved back to the first position, and one or more additional carriers, such as carrier 534 , may proceed along the first path 526 in advance of carrier 530 .
[0107] The spur 532 may also provide a means for turning carriers around. For example, the carrier 530 may be transported, such as in a forward direction, along the second path 528 and past a second track switch 534 . The second track switch 534 may also include a movable track assembly 536 that is movable between a first position defining the second path 528 and a second position defining a third path 538 . After the carrier 532 is moved along the second path 528 and past the second track switch 534 , the second track switch 534 may be moved to the second position, such that the carrier 532 may be moved, in a reverse direction, along the third path 538 . Further, a third track switch 540 , also including a movable track assembly 542 , may be movable between a first position defining the first path 526 and a second position defining the third path 538 . Thus, when the third track assembly 540 is in the second position, the carrier 532 may be transported from the spur 532 , in the reverse direction, and back along the first path 526 , with the article supported by carrier 530 having an orientation that is 180° opposite its previous orientation.
[0108] Additional means for turning around a carrier, such as the carrier 530 , may include movement of a track assembly using a known gantry track, or crane. Specifically, for example, a gantry track, which may provide a fixed structure about which the track assembly may be pivoted, may be used alone or in combination with one or more track switches to reposition a track assembly with respect to a main path, such as the first path 526 . Due to the modularity of the material handling system 250 , gantry tracks, which may be traveling, portable, or fixed, may also be used to move a carrier, such as carrier 530 , between one or more alternative paths, thus operating as a shuttle. Such a shuttle, as should be appreciated, may be used to align a movable track assembly with one of a plurality of track assemblies, thus providing alternative paths for the carrier 530 .
[0109] Track switches, as described above, may be incorporated along the second line 520 for additional purposes. For example, a track switch, such as a fourth track switch 544 having a movable track assembly 546 , may be used to transition a carrier, such as carrier 548 , onto a dual track assembly, which may be similar to the dual track assembly described above with reference to FIGS. 11 a and 11 b. For example, a first trolley assembly 550 , supporting the carrier 548 may be transported through the fourth track switch 544 and along the first path 526 , while the fourth track switch 544 is in a first position. The fourth track switch 544 may then be moved into a second position, which defines a fourth path 552 . As such, a second trolley assembly 554 may be transported along the fourth path 552 , which may be substantially parallel to the first path 526 . It should be appreciated that movement of the first trolley assembly 550 and the second trolley assembly 554 may be controlled to position the carrier 548 , and the one or more articles supported thereon, at any desired angle with respect to the direction of travel. As should be appreciated, there may be one or more modules 360 through which it may be desirable to transport articles at alternative angles, such as, for example, paint or wash modules. Further, it should be appreciated that such diagonal orientation of the carrier 548 may be useful when storing a plurality of carriers, similar to carrier 548 , along a spur, such as spur 532 , or within a buffer, such as buffer 430 . Specifically, a substantial amount of space may be saved by accumulating carriers, such as carrier 548 , at diagonal orientations relative to the direction of travel by providing the dual paths 526 and 552 and track switch 544 , as described above.
[0110] After transporting the carrier 548 through one or more modules 360 at an alternative angle with respect to the direction of travel, a fifth track switch 556 may be positioned along the second line 520 to return the second trolley assembly 554 to the first path 526 . Track switches, such as a sixth track switch 558 , may also be used to route carriers through one or more alternative paths through the second line 520 . For example, the sixth track switch 558 may be used to route carriers along either of the first path 526 and a fifth path 560 . As shown, the first path 526 may include one or more curves, such as curves 562 and 564 . To navigate around such curves, according to one embodiment, a first trolley assembly 564 of a carrier 566 may be disengaged from a first drive tube 568 , while a second trolley assembly 570 of the carrier 566 may be engaged with the first drive tube 568 . As such, the first trolley assembly 564 may be pushed around the curve 562 using the second trolley assembly 570 . As the carrier 566 travels through the curve 562 , the first trolley assembly 564 may engage a second drive tube 572 . The second trolley assembly 570 may eventually disengage from the first drive tube 568 , thus allowing the first trolley assembly 564 to pull the second trolley assembly 570 around the curve 562 . Specifically, for example, such curves 562 may be navigated by positioning drive tubes 568 and 572 , such as linear drive tubes, such that at least one trolley assembly 564 or 570 continuously engages one of the drive tubes 568 and 572 .
[0111] If a carrier, such as a carrier 574 , is transported along the fifth path 560 , a first trolley assembly 576 and a second trolley assembly 578 may ultimately transition the carrier 574 around a curve 580 . When the carrier 574 is positioned along the curve 580 , and the first trolley assembly 576 and the second trolley assembly 578 are stopped, ends 582 and 584 of the carrier 574 may extend beyond a perimeter 586 defined by the curve 580 . When positioned as shown, the carrier 574 may be removed from the fifth path 560 using a programmable hoist 588 . The programmable hoist 588 , which may be of conventional design, may include one or more track assemblies 590 along which the programmable hoist 588 may be movable. Specifically, the programmable hoist 588 may move the carrier 574 , and the article supported thereon, through one or more modules 360 , lowering and raising the carrier 574 , as necessary. The programmable hoist 588 , according to one embodiment, may be supported on its own carrier, which may be supported by one or more trolleys that are movable along track assemblies 590 , as described herein. More specifically, the carrier and trolleys supporting the programmable hoist 588 may operate as a bridge crane moving along the track assemblies 590 , which may serve as runways for the bridge crane. Further, a track assembly, such as track assemblies 590 including one or more composite beams 252 , may be used as the bridge between the runways. Yet further, one of the track assemblies described herein may be configured as a gantry crane, in which one end of the track assembly is pivotable about the other.
[0112] After the carrier 574 is transported through one or more modules 360 using the track assemblies 590 and programmable hoist 588 , the carrier 574 , and article supported thereon, may again be supported on one or more trolley assemblies. Specifically, the carrier 574 may be supported by a first trolley assembly 592 and a second trolley assembly 594 , when the first trolley assembly 592 and the second trolley assembly 594 are positioned around a curve 596 of a sixth path 598 . The sixth path 598 may be positioned to route the carrier back to the first path 526 , as shown. It should be appreciated that the article may remain on the same carrier 574 throughout the transition of the carrier 574 to and from the programmable hoist 588 . It should also be appreciated that this transition, and others described herein, are intended as examples only and, therefore, should not limit the second line 520 , or material handling system 250 thereof, in any way.
[0113] An additional spur 600 may be positioned along the second line 520 to store and/or re-sequence carriers, as described above. Specifically, a seventh track switch 602 and an eighth track switch 604 may be movable to route one or more carriers into and out of the spur 600 . As shown, one or more modules 360 positioned along the spur 600 , and/or other modules, may include a zigzag support frame 606 . Specifically, as an alterative to the end frames 362 and mid-frame 364 of FIG. 10 , one or more modules 360 may include beams 608 , or headers, that are oriented at an angle, or cross-oriented, with respect to a travel direction through the module 360 . The beams 608 may be attached to end posts 368 , as shown, and may support one or more composite beams 252 , as described above. Although the modules 360 are shown as including two cross-oriented beams 608 , it should be appreciated that each module 360 may include only one beam having an angled orientation with respect to the direction of travel. For example, consecutive modules 360 may include headers, or beams, that are oriented at alternative angles, but that define a continuous zigzag support structure through the modules 360 . Such arrangements, as should be appreciated, may require fewer beams and, therefore, less material for construction of modules 360 . Further, in addition to reduced material cost, such arrangements, utilizing fewer beams, may require less time for assembly of the modules 360 .
[0114] A shuttle, such as a lateral shuttle 610 , may be positioned at an end 612 of the second line 520 , as shown. According to one embodiment, the lateral shuttle 610 may include one or more trolley assemblies, such as any of the trolley assemblies described herein, that are movable along one or more track assemblies, also described herein. The trolley assemblies may support an additional track assembly 614 , oriented perpendicular to the track assemblies along which the trolley assemblies are moved, which is movable to define alternative paths. According to the exemplary embodiment, for example, the track assembly 614 may include a position defining a seventh path 616 , a position defining a continuous path along the first path 526 (shown), and a position defining an eighth path 618 . However, as should be appreciated, such a shuttle 610 may be movable to define any number of alternative paths for one or more carriers, such as a carrier 620 , positioned thereon.
[0115] According to the illustrated embodiment, the track assembly 614 may be moved, such as by using the shuttle 610 , to align with the eighth path 618 of the second line 520 . When the track assembly 614 is positioned to define a continuous path, the carrier 620 , and article supported thereon, may be moved onto the eighth path 618 . As shown, the eighth path 618 may also include a curve 622 , from which the article may be removed from the second line 520 . According to one example, the article may be removed from the second line 520 only for delivery to a customer. Alternatively, however, the article may be transported to a customer using the mobile module 502 , as described herein. If the article is removed from the carrier 620 , the empty carrier 620 , according to one embodiment, may be returned to the track assembly 614 . The shuttle 610 may then be used to move the track assembly 614 to align with the seventh path 616 , which may route the empty carrier 620 to one or more desired locations, such as, for example, a storage buffer 624 , which may be similar to the buffer 430 of FIG. 12 . According to one example, the seventh path 616 may include one or more composite beams 252 , described herein, which may be supported from one or more modules 360 . Specifically, one or more modules 360 may support one or more composite beams 252 defining a first path through the modules 360 , and one or more composite beams 252 defining an additional path adjacent the modules 360 for empty carrier returns.
[0116] It should be appreciated that alternative arrangements may be used for carrier, or empty carrier, returns. For example, a buffer, such as the buffer 430 described above, may be used to define a first, main, path and a second, return, path. One or more movable track assemblies, such as movable track assemblies 444 and 450 of FIG. 12 , may be used to transition carriers from the main path to the return path, in a manner similar to that described above. Such transitions, also referred to as an over-under conveyance, may be incorporated, as needed, into the first line 480 and/or the second line 520 . For example, one of the stationary track assemblies of the buffer 430 of FIG. 12 may be positioned along a main path, such as the main path 481 of the first line 480 or the first path 526 of the second line 520 . Alternatively, one or more carriers may be routed off the main path 481 or first path 526 and into the buffer 430 , such as by actuating one or more track switches, as described herein.
[0117] The carrier 620 may, alternatively, be routed through the shuttle 610 along the first path 526 and, for example, onto a mobile module, such as the mobile module 502 . In a third position 626 (shown) of the mobile module 502 , the material handling system, such as material handling system 250 described herein, of the mobile module 502 may be aligned with the material handling system 250 of the second line 520 such that the carrier 620 may be continuously transported from the first path 526 and onto the mobile module 502 . From there, the mobile module 502 may return the carrier 620 , and article supported thereon, to the first line 480 . It should be appreciated that the first line 480 and the second line 520 may represent one or more manufacturing lines positioned in adjacent buildings or, alternatively, at remote locations.
[0118] The modular material handling system 250 , as described herein with reference to the preceding figures, may be used as a common material handling system throughout an entire manufacturing, or production, process. For example, the material handling system 250 may be used throughout the first line 480 ( FIG. 13 ), the second line 520 ( FIG. 14 ), and any number of mobile modules 502 that may be configured to transport articles between the first line 480 and the second line 520 . Specifically, the same material handling system 250 may be used to route an article through all of the implemented manufacturing processes, including, for example, first operations 482 , logistics 484 , fabrications 488 , paint 490 , sub-assembly 492 , and assembly 498 of the first line 480 . Although specific examples are provided, it should be appreciated that the modular material handling system 250 , as described herein, may be used to support any number and/or combination of manufacturing processes.
[0119] Further, the configuration of the material handling system 250 , including composite beams 252 and friction drive system 270 , as shown in FIG. 8 , may provide a modular material handling system that may be relatively quickly and easily assembled and/or modified. Specifically, as described with reference to FIG. 10 , each of a plurality of manufacturing modules 360 may be assembled by connecting a mid-frame 364 to a pair of end frames 362 , and supporting a pre-constructed composite beam 252 from the interconnected frames using one or more connecting clamps 366 . The friction drive system 270 , and other systems or controls, may be supported from the module 360 and, further, may be connected to any necessary utilities via a utility transfer module 40 , as described above. Further, an Andon system, as is known in the art, may be integrated with the any of manufacturing lines 10 , 480 , and 520 and, further, with the control system 220 . For example, a visual indication of a problem identified, either manually or automatically, at a specific module 32 or 360 may be provided. It should be appreciated that the systems, controls, and equipment used herein may all be provided with plug and play functionality to further ease assembly and/or modification of the manufacturing modules 360 .
[0120] The composite beams 252 , embodiments of which are illustrated in FIGS. 9 a - 9 c, and friction drive system 270 of material handling system 250 may support a wide range of weights. Specifically, for example, the composite beams 252 may support any of a variety of articles, ranging from small parts to large sub-assemblies, using one or more trolleys 262 of the friction drive system 270 , which may be configured to directly or indirectly support articles. By supporting such a wide range of weights, the material handling system 250 may be used in a variety of industries, and throughout processes that normally integrate multiple material handling systems or devices, including forklifts, to transport both small and large articles. According to one example, the material handling system 250 , as described herein, may be used to transport both large sub-assemblies and small parts along the main path 481 of the first line 480 ( FIG. 13 ). Specifically, for example, a large sub-assembly may be transported from sub-assembly 492 to the assembly line 498 along path 481 , while a plurality of small parts may be transported from one of the buffers 494 to stations 500 along the same path 481 . Alternatively, either or both of the first line 480 and the second line 520 may integrate a material handling system 250 sized to support lighter weights with a material handling system 250 sized to support heavier weights. Further, such embodiments may incorporate weigh stations along the material handling systems 250 to ensure that trolleys 262 are not routed along paths incapable of providing sufficient support. Alternatively, a control system, such as the control system 220 described above, may track the weight of each article transported along the one or more integrated material handling systems 250 and route respective trolleys 262 accordingly.
[0121] To increase the versatility of the material handling system 250 , a variety of devices and/or features, including, but not limited to track switches, spurs, buffers, programmable hoists, shuttles, and gantry tracks, examples of which are provided herein, may be integrated with the material handling system 250 , as described above. As should be appreciated, these devices and/or features may be utilized by the material handling system 250 to provide numerous and useful transitions of articles throughout a manufacturing, or production, process. Further, the material handling system 250 , and devices or features incorporated therein, may be integrated with a control system, such as the control system 220 , to coordinate the processes for and movements of each article transported along the material handling system 250 . Specifically, by tracking and controlling each article, flow throughout the manufacturing process can be better organized, thus reducing waste and improving efficiency.
INDUSTRIAL APPLICABILITY
[0122] The manufacturing chain 10 of the present disclosure may provide a portable and flexible manufacturing chain that supports an improved manufacturing process. Specifically, the manufacturing chain 10 includes manufacturing modules 32 that may be relatively quickly and easily transported and deployed. In addition, modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 may be readily added to and/or removed from the modules 32 of the manufacturing chain 10 . Further, the article transportation system 30 , and method of operation thereof, may allow independent process control at each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 and, therefore, may provide improved efficiency with respect to the manufacturing process. Although a paint process is described, it should be appreciated that the manufacturing chain 10 , as described herein, may be used to perform any of a variety of manufacturing processes.
[0123] Referring generally to FIGS. 1-14 , the manufacturing chain 10 , such as, for example, a paint line, may be deployed by erecting a plurality of manufacturing modules 32 , as needed. Specifically, a plurality of support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 may be secured to the planar floor 16 of a manufacturing area 12 and may be interconnected to provide a framework or skeleton 80 . One or more of the support beams support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 may be capable of expansion and/or contraction to further ease the transport and/or deployment of each manufacturing module 32 . The skeleton 80 may provide structural support for one or more modular manufacturing stations, such as, for example, the first modular manufacturing station 118 and the second modular manufacturing station 160 and/or the modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 . Further, the skeleton may include pre-constructed utilities, namely a utility transfer module 40 , supported by one or more of the support beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 .
[0124] Each modular manufacturing station, such as stations 118 and 160 , may include at least one piece of manufacturing equipment 120 , an article transportation device 122 representing a portion of the article transportation system 30 corresponding to the respective station, and a station control system 124 . It should be appreciated that the manufacturing equipment 120 may be positioned above the planar floor 16 and may be portable to facilitate movement of the equipment 120 from one location, such as a storage location, and into an operable position relative to the station. The manufacturing equipment 120 , as well as the article transportation device 122 , the station control system 124 , and various other systems and/or components of each station 118 and 160 may receive one or more utilities from the utility transfer module 40 .
[0125] It should be appreciated that modifying the manufacturing chain 10 , such as adding or removing a modular manufacturing station may also be accomplished with relative ease. Specifically, a modular manufacturing station, similar to manufacturing stations 116 and 180 , may be added to the manufacturing chain 10 by interconnecting a plurality of beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 to form a skeleton 80 . The skeleton 80 may be connected to or, alternatively, positioned adjacent a contiguous manufacturing module 32 . A utility transfer module 40 , which may be supported by one of the beams 82 , 84 , 86 , 88 , 98 , 100 , 102 , and 104 , may be connected to a utility transfer module 40 of the contiguous manufacturing module 32 to provide utilities to the added manufacturing station.
[0126] One or more of an article transportation device 122 , a piece of manufacturing equipment 120 , and a station control system 124 may be supported by the skeleton 80 , or otherwise positioned within an operable distance of the added manufacturing station. In addition, one or more of the article transportation device 122 , the manufacturing equipment 120 , and the station control system 124 may be connected to the utility transfer module 40 to receive one or more utilities therefrom, such as using quick connect coupling members, as described above.
[0127] Operation of the manufacturing chain 10 may be controlled and/or coordinated using the control system 220 . Specifically, one or more of the main control system 230 and the station control systems 124 may be configured to advance at least one carrier 164 from a beginning of the manufacturing chain 10 to an end of the manufacturing chain 10 , such as in the forward transport direction “F.” This advancement, according to a specific example, may include independently moving a carrier 164 of the first modular manufacturing station 118 according to a first unique operation pattern and a carrier 164 of the second modular manufacturing station 160 according to a second unique operation pattern. According to one embodiment, the first unique operation pattern may include the forward transport direction “F” and the reverse transport direction “R.” The second unique operation pattern may, for example, include moving the carrier 164 in the vertical direction relative to the transportation path 166 , such as by raising and/or lowering the carrier 164 .
[0128] The memory 234 of the main control system 230 may store the first and second unique operation patterns for controlling operation of the first and second modular manufacturing stations 118 and 160 , respectively, thereon. The first position tracking devices 176 of each modular manufacturing station 118 and 160 may detect a first position of each carrier 164 as it is transported through the respective one of the manufacturing stations 118 and 160 , and transmit first position signals to the main control system 230 . It should be appreciated that any of the operation signals, including position signals, may be transmitted through the station control systems 124 .
[0129] The processor 232 of the main control system 230 may be configured to independently transmit an operation signal corresponding to each of the first and second unique operation patterns to the respective one of the manufacturing stations 118 and 160 based, at least in part, on the detected first positions. For example, the processor 232 may independently transmit one or more operation signals, such as, for example, the forward signal, to each article transportation device 122 upon detecting that each carrier 164 is entering the respective one of the modular manufacturing stations 118 and 160 . Similarly, the processor 232 may be configured to independently transmit one or more operation signals to the manufacturing equipment 120 based, at least in part, on the detected first positions.
[0130] In addition, the second position tracking devices 178 and the third position tracking devices 180 of the manufacturing stations 118 and 160 may detect second and third positions, respectively, and transmit second and third position signals to the main control system 230 , such as through the station control systems 124 . The processor 232 may also be configured to independently transmit an operation signal corresponding to each of the first and second unique operation patterns to the respective one of the manufacturing stations 118 and 160 based, at least in part, on one of the detected second and third positions. Similarly, the processor 232 may be configured to independently transmit one or more operation signals to the manufacturing equipment 120 based, at least in part, on one of the detected second and third positions.
[0131] For example, the processor 232 may be configured to transmit the reverse signal to the article transportation device 122 of the first modular manufacturing station 118 upon detecting that the carrier 164 has reached a predetermined position relative to the manufacturing equipment 120 . Similarly, the processor 232 may be configured to transmit the lower signal to the article transportation device 122 , or second vertical lift device 212 , of the second modular manufacturing station 160 upon detecting that the carrier 164 has reached a predetermined position relative to the manufacturing equipment 120 . Determining that the carrier 164 has reached the predetermined position, in either example, may be based, at least in part, on one of the second and third position signals.
[0132] In addition, the processor 232 of the main control system 230 may be configured to index the carriers 164 of each modular manufacturing station 118 and 160 as each carrier 164 traverses to a contiguous manufacturing station. Indexing may, for example, include detecting one of the second and third positions, as described above, of each carrier 164 and simultaneously transferring each carrier 164 to a contiguous manufacturing station.
[0133] It should be appreciated that manufacturing chain 10 , including a plurality of modular manufacturing stations 18 , 20 , 22 , 24 , 26 , and 28 , as described herein, may be deployed and/or modified with relative ease. Each modular manufacturing station 18 , 20 , 22 , 24 , 26 , and 28 , as further exemplified by first and second modular manufacturing stations 118 and 160 , is characterized as having a separate article transportation device 122 that allows each carrier 164 to move independently through the respective station. The control system 220 coordinates the independent movements occurring at each station 18 , 20 , 22 , 24 , 26 , and 28 and synchronizes the transfer of each carrier 164 to a contiguous one of the modular manufacturing stations to define one overlying process flow for the manufacturing chain 10 .
[0134] It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present disclosure in any way. Thus, those skilled in the art will appreciate that other aspects of the disclosure can be obtained from a study of the drawings, the disclosure and the appended claims.
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A lobed bushing is provided for a track assembly of a track-type machine. The track assembly includes a first chain and a second chain coupled together with a track pin. A bushing, defining a longitudinal axis, includes a central bore oriented along the longitudinal axis and extending from a first end of the bushing to a second end of the bushing for receiving the track pin. The bushing includes a first lobe positioned at a first location about the longitudinal axis and a second lobe positioned at a second location about the longitudinal axis that is less than about 180° from the first location. The first end of the bushing has a substantially cylindrical shape.
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FIELD OF THE INVENTION
This invention pertains to methods and apparatus for treating arrhythmias with electrical therapy.
BACKGROUND
Tachyarrhythmias are abnormal heart rhythms characterized by a rapid rate, typically expressed in units of beats per minute (bpm), that can originate in either the ventricles or the atria. Examples of tachyarrhythmias include atrial tachyarrhythmias such as atrial flutter and atrial fibrillation (AF), and ventricular tachyarrhythmias such as ventricular tachycardia (VT), and ventricular fibrillation (VT). The most dangerous tachyarrhythmias are those that have their origin in the ventricles, namely ventricular tachycardia and ventricular fibrillation. Ventricular rhythms occur when re-entry of a depolarizing wavefront in areas of the ventricular myocardium with different conduction characteristics becomes self-sustaining or when an excitatory focus in the ventricle usurps control of the heart rate from the normal physiological pacemaker of the heart, the sino-atrial node. The result is rapid contraction of the ventricles out of electromechanical synchrony with the atria. Most ventricular rhythms exhibit an abnormal QRS complex in an electrocardiogram (ECG) because they do not use the specialized conduction system of the ventricles, the depolarization spreading instead from the excitatory focus or point of re-entry directly into the myocardium. In ventricular tachycardia, the ventricles contract rapidly and produce distorted QRS complexes in an ECG. Ventricular fibrillation, on the other hand, occurs when the ventricles depolarize at an even more rapid rate and in a chaotic fashion, resulting in QRS complexes of constantly changing shape and virtually no effective pumping action.
Implantable cardiac rhythm management devices may be configured to treat both atrial and ventricular tachyarrhythmias with electrical therapy. Devices known as implantable cardioverter/defibrillators (ICDs) deliver an electric shock to the heart which terminates the tachyarrhythmia by depolarizing all of the myocardium simultaneously and rendering it refractory. The most dangerous tachyarrhythmias are ventricular tachycardia and ventricular fibrillation, and ICDs have most commonly been applied in the treatment of those conditions. Both ventricular tachycardia and ventricular fibrillation are hemodynamically compromising, and both can be life-threatening. Ventricular fibrillation, however, causes circulatory arrest within seconds, is the most common cause of sudden cardiac death, and is usually treated with immediate delivery of a defibrillation shock. Ventricular tachycardia can be treated with either a defibrillation or a cardioversion shock, the latter referring to a shock delivered synchronously with an R wave. Another type of electrical therapy for ventricular tachycardia is antitachycardia pacing (ATP). In ATP, the ventricles are competitively paced with one or more pacing pulses in an effort to interrupt the reentrant circuit causing the tachycardia. ATP therapy can successfully treat VT, but it is not effective in terminating VF. Modern ICDs incorporate ATP capability so that ATP therapy can be delivered to the heart when a ventricular tachycardia is detected. Although cardioversion/defibrillation will also terminate ventricular tachycardia, it consumes a large amount of stored power from the battery and results in patient discomfort owing to the high voltage of the shock pulses. It is desirable, therefore, for the ICD to use ATP to terminate a tachyarrhythmia whenever possible. In most ICDs with ATP capability, VF is distinguished from VT using a rate-based criterion so that ATP or shock therapy can be delivered as appropriate, where the heart rate is determined by measurement of the time interval between successive ventricular depolarizations. In a typical device, a tachyarrhythmia with a heart rate in the VT zone is treated with ATP therapy in order to avoid an unnecessary painful shock to the patient, and a defibrillation shock is delivered if the heart rate is in the VF zone or if ATP pacing fails to terminate a tachyarrhythmia in the VT zone.
ICDs are also capable of detecting atrial tachyarrhythmias, such as atrial fibrillation and atrial flutter, and delivering a cardioversion shock pulse to the atria in order to terminate the arrhythmia. Although not immediately life-threatening, it is important to treat atrial fibrillation for several reasons. First, atrial fibrillation is associated with a loss of atrio-ventricular synchrony which can be hemodynamically compromising and cause such symptoms as dyspnea, fatigue, vertigo, and angina. Atrial fibrillation can also predispose to strokes resulting from emboli forming in the left atrium. Although drug therapy and/or in-hospital cardioversion are acceptable treatment modalities for atrial fibrillation, ICDs configured to treat atrial fibrillation offer a number of advantages to certain patients, including convenience and greater efficacy.
As noted above, ICDs detect tachyarrhythmias by measuring the time intervals between successive depolarizations of the atria or ventricles. Situations arise, however, where such devices are subjected to externally produced oscillating electromagnetic fields, referred to as electromagnetic interference or EMI, which are sensed by sensing electrodes and falsely interpreted as cardiac depolarizations. If the frequency at which the externally produced field oscillates is within a range similar to that of a tachyarrhythmia, inadvertent triggering of anti-tachyarrhythmia therapy, such as anti-tachycardia pacing or delivery of a cardioversion/defibrillation shock, can occur. One example of such a situation is during a surgical operation where the electro-cauterizing instruments used to control bleeding can produce EMI that triggers the delivery of anti-tachyarrhythmia therapy by the device. It is therefore common practice to de-activate such anti-tachyarrhythmia functions in ICDs when the patient is expected to be exposed to such electromagnetic interference. De-activating a device before a surgical operation, imaging procedure, or other event and then re-activating it afterwards, however, requires the use of an external programmer in both instances and can be inconvenient. It may even pose a risk to the patient if the re-activation is not done promptly. The present invention is directed toward an improved method and device for dealing with this problem.
SUMMARY
In accordance with the present invention, an implantable cardiac rhythm management device for delivering anti-tachyarrhythmia therapy in the form of cardioversion/defibrillation shocks and/or anti-tachycardia pacing is configured so that anti-tachyarrhythmia therapy may be temporarily disabled by a command via a wireless telemetry link from an external device such as an external programmer. In one embodiment, anti-tachyarrhythmia therapy is re-enabled after expiration of a specified time interval which may be either a fixed value or specified by the external device. In other embodiments, anti-tachyarrhythmia therapy is re-enabled by actuation of a magnetic switch or when the implantable device measures an activity level above a specified threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an exemplary physical configuration of an implanted cardiac rhythm management device.
FIG. 2 is a system diagram of an implantable cardiac rhythm management device.
FIG. 3 illustrates an exemplary algorithm for implementing the present invention.
DETAILED DESCRIPTION
The present invention may be embodied by an implantable cardiac rhythm management device for delivering anti-tachyarrhythmia therapy through one or more electrical stimulation channels which is configured for temporary disablement of the anti-tachyarrhythmia therapy when the need arises. Below is a description of an exemplary hardware platform followed by a detailed description of different techniques for implementing the temporary disablement feature.
1. Exemplary Device Description
Cardiac rhythm management devices such as ICDs and pacemakers are typically implanted subcutaneously on a patient's chest and have leads threaded intravenously into the heart to connect the device to electrodes used for sensing cardiac activity, delivering pacing pulses, and/or delivering defibrillation shocks. FIG. 1 depicts an implantable cardioverter/defibrillator device for treating atrial and ventricular tachyarrhythmias that also incorporates functionality for pacing the atria and/or the ventricles in a bradycardia pacing mode. The device includes a subcutaneously implantable housing or can 60 for enclosing the electronic circuitry of the device and a pair of leads L 1 and L 2 having electrodes incorporated therein. The lead L 1 has a tip electrode 33 a and ring electrode 33 b which are shown in the figure as disposed in the superior vena cava (SVC) for pacing or sensing of the atria. The lead L 2 has a tip electrode 43 a , a distal coil electrode 43 b , and a proximal coil electrode 43 c . Coil electrodes can be used to deliver pacing pulses but are designed especially for delivering cardioversion/defibrillation shocks. In the placement of the lead L 2 shown in the figure, tip electrode 43 a and distal coil electrode 43 b are disposed in the right ventricle (RV), and proximal coil electrode 43 c is disposed in the superior vena cava or right atrium. Sensing or pacing of the ventricles may be performed using tip electrode 43 a and/or coil electrode 43 b . A ventricular cardioversion/defibrillation shock may be delivered between coil 43 b and the can 60 , or between coil 43 b and the can 60 electrically in common with the coil 43 c , and an atrial cardioversion shock may be delivered between the coil 43 c and the can 60 .
FIG. 2 is a system diagram the implantable device shown in FIG. 1 . The controller of the device is made up of a microprocessor 10 communicating with a memory 12 , where the memory 12 may comprise a ROM (read-only memory) for program storage and a RAM (random-access memory) for data storage. A microprocessor-type controller 10 controls the overall operation of the device in accordance with programmed instructions stored in memory. The controller could be implemented by other types of logic circuitry (e.g., discrete components or programmable logic arrays) using a state machine type of design, but a microprocessor-based system is preferable. As used herein, the terms “circuitry” and “controller” should be taken to refer to either discrete logic circuitry or to the programming of a microprocessor. A telemetry interface 80 is provided by which the controller may wirelessly communicate with an external programmer 300 . The external programmer 300 is a computerized device that can interrogate the implantable device and receive stored data as well as adjust the device's operating parameters.
The device is equipped with multiple sensing amplifiers and pulse generators which can be configured as channels for pacing and/or sensing selected heart chambers. A MOS switch matrix 70 controlled by the microprocessor is used to configure a sensing or pacing channel by switching selected electrodes to the input of a sense amplifier or to the output of a pulse generator. The switch matrix 70 allows the device to employ either bipolar sensing/pacing using two closely spaced electrodes of a lead or unipolar sensing/pacing using one of the electrodes of a lead and the can 60 as a reference electrode. The switch matrix 70 can also connect atrial shock generator 75 to deliver an atrial cardioversion shock between coil electrode 43 c and the can 60 , and can connect ventricular shock generator 85 to deliver a ventricular cardioversion/defibrillation shock between coil electrode 43 b and the can 60 (or the can 60 connected in common with the coil electrode 43 c ). In the device shown in FIG. 2 , an atrial channel for sensing or pacing an atrial site is configured with tip electrode 33 a , ring electrode 33 b , sense amplifier 31 , pulse generator 32 , and an atrial channel interface 30 which communicates bidirectionally with a port of microprocessor 10 . A first ventricular channel for sensing or pacing a ventricular site is configured with tip electrode 43 a , coil electrode 43 b , sense amplifier 41 , pulse generator 42 , and ventricular channel interface 40 . A second ventricular channel for sensing or pacing a ventricular site is configured with tip electrode 43 a , coil electrode 43 b , sense amplifier 51 , pulse generator 52 , and ventricular channel interface 50 . A second ventricular sensing channel using ventricular channel interface 50 may be configured by connecting one of the differential inputs of sense amplifier 51 to the coil electrode 43 b and connecting the other input to the can 60 and coil electrode 43 c.
The channel interfaces may include comparators for comparing received electrogram signals to reference values, analog-to-digital converters for digitizing sensing signal inputs from the sensing amplifiers, registers that can be written to for adjusting the gain and sensing threshold values of the sensing amplifiers, and registers for controlling the output of pacing pulses and/or adjusting the pacing pulse energy by changing the pulse amplitude or pulse width. The controller uses the sensing channels in order to detect intrinsic cardiac activity in a heart chamber, referred to as a chamber sense (e.g., an atrial sense or a ventricular sense). In order to detect intrinsic cardiac activity, the signals emanating from the sense amplifier are compared with a reference potential. As described above, a sensing channel includes sense amplifier circuits for amplifying and filtering the electrogram signals picked up by an electrode disposed at a cardiac site. Only when an electrogram signal from the sense amplifier exceeds a reference potential, referred to as a sensing threshold, is it treated as a chamber sense. The sensing threshold may be implemented with analog circuitry, where the sense amplifier output is applied to one input of a comparator circuit whose other input is connected to a reference potential, or with digital circuitry operating on digitized samples of the sense amplifier output which are compared with a digitized reference value. In either case, the sensing threshold for each channel is adjustable by the controller. Detected chamber senses may be used for controlling the delivery of paces in accordance with a programmed pacing mode (e.g., bradycardia pacing or ventricular anti-tachycardia pacing) and/or for diagnostic purposes. By counting the number of chamber senses over a defined time period or measuring the time intervals between senses, the controller is able to measure heart rate and detect arrhythmias using rate-based criteria. The atrial and ventricular sensing channels described above are used to separately measure the atrial and ventricular rates in this embodiment.
When the measured atrial and/or ventricular rates exceed specified threshold values, the device detects a tachyarrhythmia and is programmed to respond with appropriate anti-tachyarrhythmia therapy. For example, if a ventricular rate is measured which is in the VF zone, the device delivers a ventricular defibrillation shock. If a ventricular rate is measured which is in the VT zone, the device decides whether VT or an atrial tachyarrhythmia is present using rate and/or electrogram morphology criteria. If the ventricular rate is greater than the atrial rate, VT is detected, and the device may be programmed to initiate ventricular anti-tachycardia pacing. If the atrial rate is greater than or equal to the ventricular rate and a specified minimum number of normally conducted beats are detected, an atrial tachyarrhythmia is detected, the device is programmed to deliver an atrial cardioversion shock. The device would also detect an atrial tachyarrhythmia and deliver an atrial cardioversion shock if the atrial rate is above a specified threshold value and the ventricular rate is in the normal range, as could occur in a patient without an intact AV conduction pathway. To lessen the risk of inducing a ventricular arrhythmia, the device may deliver the atrial cardioversion shock synchronously with a sensed ventricular depolarization (i.e., an R wave) and may delay delivering the shock until the intrinsic ventricular rhythm is below a specified maximum rate.
2. Temporary Disablement of Anti-Tachyarrhythmia Therapy
As described above, certain medical and surgical procedures involve the use of instrumentation capable of producing electromagnetic interference which can trigger the delivery of anti-tachyarrhythmia therapy by an implantable device. Such a device would typically include, as illustrated in FIG. 2 , a sensing channel for sensing an electrogram signal representing cardiac electrical activity and circuitry for generating a chamber sense when the electrogram signal exceeds a specified threshold, one or more stimulation channels for delivering electrical stimulation to a subject's heart, a controller programmed to detect a tachyarrhythmia from the rate at which chamber senses are generated and to cause delivery of ant-tachyarrhythmia therapy through one or more of the stimulation channels upon detection of a tachyarrhythmia, and a telemetry interface by which the controller may communicate with an external device. The one or more stimulation channels may include a pacing channel for delivering pacing therapy (eg., anti-tachycardia pacing or bradycardia pacing) and/or a shock channel for delivering cardioversion/defibrillation shocks, where the controller is programmed to cause delivery of anti-tachyarrhythmia therapy in the form of anti-tachycardia pacing and/or a cardioversion/defibrillation shock upon detection of a tachyarrhythmia. If the device is capable of delivering anti-tachycardia pacing and cardioversion/defibrillation shocks, the controller is programmed to deliver anti-tachycardia pacing upon detection of a tachyarrhythmia in a tachycardia zone and deliver a cardioversion/defibrillation shock upon detection of a tachyarrhythmia in a fibrillation zone. In accordance with the invention, the device is configured by appropriate programming of the controller to disable the delivery of anti-tachyarrhythmia therapy for a specified time interval upon receipt of a temporary suspend command from the external device via the telemetry interface and to re-enable the delivery of anti-tachyarrhythmia therapy upon expiration of the specified time interval. The specified time interval for which the delivery of anti-tachyarrhythmia therapy is disabled may be a fixed interval or a variable interval communicated to the implantable device by the external device via the telemetry link.
Disablement of anti-tachyarrhythmia therapy may be accomplished in different ways. In one embodiment, the device continues to sense cardiac activity but is prevented from delivering anti-tachyarrhythmia therapy if a tachyarrhythmia is detected while the disablement feature is active. In another embodiment, disablement of anti-tachyarrhythmia therapy is effected by disabling the device's sensing channels. A sensing channel may be disabled directly or indirectly such as by raising its sensing threshold to render it refractory. Raising the sensing threshold of a sensing channel to its maximum value (e.g., infinity) means that no cardiac activity, and hence no tachyarrhythmias, will be detected, and the device will therefore be disabled from delivering anti-tachyarrhythmia therapy.
Disabling anti-tachyarrhythmia therapy by disabling the sensing functions of a device may also be advantageous in the case where the device is also delivering bradycardia pacing therapy to the patient. Bradycardia pacing modes refer to pacing algorithms used to pace the atria and/or ventricles in a manner that enforces a certain minimum heart rate. Because of the risk of inducing an arrhythmia with asynchronous pacing, most pacemakers for treating bradycardia are programmed to operate synchronously in a so-called demand mode where sensed cardiac events occurring within a defined interval either trigger or inhibit a pacing pulse. Inhibited demand pacing modes utilize escape intervals to control pacing in accordance with sensed intrinsic activity. In an inhibited demand mode, a pacing pulse is delivered to a heart chamber during a cardiac cycle only after expiration of a defined escape interval during which no intrinsic beat by the chamber is detected. In an environment where electromagnetic interference is present, a device operating in an inhibited demand pacing mode may interpret the electromagnetic interference as intrinsic beats which then inhibit the delivery of paces. Some patients are not able to tolerate the complete cessation of pacing therapy, however. Disabling the sensing channels of the device deals with this problem by preventing the device from detecting cardiac activity. The device then delivers paces at the programmed lower rate limit, thus essentially reverting to an asynchronous pacing mode during the time the sensing channels are disabled.
FIG. 3 illustrates an exemplary algorithm for implementing this feature as it would be executed by the controller. At step A 1 , the device waits for a temporary suspend command from an external programmer via the telemetry interface. Upon receipt of such a command and a specified suspend interval from the external programmer, the device disables anti-tachyarrhythmia therapy and initializes a timer (e.g., a timer implemented in code executed by the controller) to the specified suspend interval at step A 2 . At step A 3 , the device waits for expiration of the suspend interval or receipt of a resume command from the external programmer. Upon occurrence of either of these events, the device re-enables anti-tachyarrhythmia therapy at step A 4 and returns to step A 1 . In other embodiments, the implantable device further includes a magnetic switch actuated by application of a magnetic field (illustrated as switch 250 in FIG. 2 ) so that delivery of anti-tachyarrhythmia therapy is re-enabled before expiration of the specified suspend interval by actuation of the magnetic switch and/or an activity sensor for measuring an activity level (illustrated as accelerometer 200 in FIG. 2 ) so that delivery of anti-tachyarrhythmia therapy is re-enabled before expiration of the specified suspend interval upon measurement of an activity level above a specified threshold value.
It may be desirable in certain circumstances, of course, to indefinitely disable anti-tachyarrhythmia therapy in an implantable device. Therefore, the controller may be programmed to disable the delivery of anti-tachyarrhythmia therapy indefinitely upon receipt of an indefinite suspend command from the external programmer via the telemetry interface and to re-enable the delivery of anti-tachyarrhythmia therapy upon receipt of a resume command. In order to eliminate the need for an external programmer in order to re-enable anti-tachyarrhythmia therapy, the implantable device may further include a magnetic switch actuated by application of a magnetic field so that the resume command is communicated to the implantable device by actuation of the magnetic switch and/or an activity sensor for measuring an activity level so that the resume command is generated upon measurement of an activity level above a specified threshold value.
As described above, disablement of anti-tachyarrhythmia therapy may be effected in one embodiment by disabling the sensing functions of the device. It should be appreciated that a temporary sensing channel disablement feature may be incorporated into a bradycardia pacemaker without the capability of delivering anti-tachyarrhythmia therapy. Disabling the sensing channels of such a device causes it to revert to an asynchronous pacing mode which may be desirable in situations where electromagnetic interference is expected to be present. Disabling and re-enabling the sensing channels of the device may be accomplished in different embodiments by any of the techniques for disabling and re-enabling anti-tachyarrhythmia therapy described above.
Although the invention has been described in conjunction with the foregoing specific embodiment, many alternatives, variations, and modifications will be apparent to those of ordinary skill in the art. Such alternatives, variations, and modifications are intended to fall within the scope of the following appended claims.
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An implantable cardiac rhythm management device for delivering anti-tachyarrhythmia therapy is provided with a temporary disablement feature so that the delivery of anti-tachyarrhythmia therapy may be conveniently disabled and re-enabled. The feature is particularly useful to patients who are undergoing imaging procedures or surgical procedures where electro-cauterizing instruments may cause inadvertent triggering of cardioversion/defibrillation shocks and/or anti-tachycardia pacing.
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TECHNICAL AREA
The invention concerns a wiper plate in accordance with the preamble of Patent Claim 1 .
STATE OF THE ART
Dust wiping devices with a wiper plate covered with a wiping cloth, for example made of a nonwoven fabric, are known. They represent an alternative to known wet wiping devices with a wiping cover and are, in particular, intended for quick intermediate cleaning, in particular, for the elimination of dusty and fibrous impurities. The surface of these wiping cloths is made in such a way that it is suitable to take up dust and smaller particles and fibrous impurities. In addition to dry wiping cloths, moist cloths are also frequently used, which are soaked with a special cleaning liquid or can be soaked by a suitable device. For use, the wiping cloths are clamped over the underside of the wiper plate, facing the surface to be cleaned, and fixed on it by means of suitable affixing agents. Upon passing over the surface to be cleaned, dust, smaller particles, and fibers are caught on the wiping cloth. Since the wiping cloths are very thin, in contrast to the thick and absorbing wet wiping covers, providing the wiper plate underside with a plastic foam covering for the improvement of the wiping behavior is known. This plastic foam covering improves the absorption of particulate dirt on the wiping cloth surface and thus reduces the danger of scratching during the wiping process.
Firmly adhering local soiling can be detached and absorbed with these wiping devices only with great force expenditure.
From FR 2 733 895, a sponge with a multifunction structure is known. The previously known sponge comprises on the side facing the surface to be cleaned sections made of the sponge material and sections with an abrasively acting surface. The surface of the abrasively acting sections is located staggered upwards, in comparison to the sponge sections, so that the abrasive sections do not come into contact with the surface to be cleaned if no pressure is exerted on the sponge. By exerting pressure on the sponge, the sponge sections are compressed and the abrasively acting sections engage with the surface to be cleaned.
The abrasive sections consist of a firm and rough material. The cleaning action of the sponge results from the detachment of soilings by the abrasive sections and the absorption of the detached dirt particles by the sponge sections. The functioning principle of the abrasive material consists of the scouring effect of the rough surface.
The functioning principle of the sponge described above is not suitable for use in connection with cleaning cloths, since, on the one hand, the cleaning cloths quickly wear out due to the scouring sections and, on the other hand, the abrasively acting, scouring layer is ineffective due to the cleaning cloths, since the abrasive surface does not engage with the surface to be cleaned. The sponge sections cannot absorb dirt particles when cleaning cloths are used, since they also do not directly touch the surface to be cleaned.
DESCRIPTION OF THE INVENTION
The goal of the invention is to further develop the wiper plate described in the beginning, so that firmly adhering soilings can also be detached and absorbed.
This goal was attained, in accordance with the invention, with a wiper plate with the features of Claim 1 .
The subordinate claims refer to advantageous developments.
To attain the goal, the foam body has at least one recess, in which at least one nonelastic punch connected to the carrier plate is located, which has a length that is equal to or smaller than the height of the foam body in an unused state, and the punch can be brought into contact at least with the side of the wiping cloth turned away from the wiping surface, by exerting pressure on the carrier plate and the compressed foam body.
The punches of the carrier plate do not exert a scouring action, but rather improve the wiping result with strong soiling only through a higher pressing force of the punch on the surface to be cleaned as a result of a smaller effective area. Therefore, it is not necessary to provide the abrasive area with a scouring surface, which would make the use of the wiper plate in connection with wiping cloths impossible. The wiping cloths need not be provided with a scouring surface either, for the aforementioned reason. The use of wiping cloths with a surface that scours at least in areas is not ruled out, however.
The punch can be 0 to 10 mm shorter than the height of the foam body in the unburdened state. With these distances, the use of the abrasively acting punch can be metered out with little force expenditure.
The ratio of the sum over all cross-sectional areas of the punches to the total area of the wiper plate can be between 1:10 and 1:100. With these area ratios, the effect of the punches is particularly good with a simultaneously large placement surface in the foam body in the unburdened state.
In an advantageous embodiment, the ratio can be 1:50. A ratio of 1:50 corresponds to the ratio of the sum of the cross-sectional areas of all bristles to the total cleaning area of a classic scrubber—that is, with the actuation of a structured functional surface, approximately the same pressing pressure is attained on the surface to be cleaned as with the use of a scrubber.
The punches can be uniform in material and connected in one piece with the carrier plate. The production of the wiping device is thus simple and low cost, since the number of manufacturing steps is reduced.
The punches can be connected to the carrier plate in a form- or material-locking manner. The configurations of the punches can be changed by the separate production of the punches and the carrier plate, without a change of the manufacturing mold for the wiper plate being required. During the manufacturing and later, it is possible to install various molds of punches.
In an advantageous embodiment of the invention, it is possible to design the punches as ribs, which extend in the longitudinal direction of the carrier plate. A linear pressing on the surface to be cleaned is attained by the ribs.
The ribs can extend over the entire width of the carrier plate. In this way, the entire longitudinal extension of the carrier plate can be used in an abrasively effective manner.
The ribs can extend over more than 50% of the longitudinal extension of the carrier plate. The abrasive effect by the greater pressing can be attained by a smaller effective area of the ribs.
The ribs can be situated at an angle, preferably approximately 45°, relative to the side edges of the wiper plate. In this way, a cleaning result can be attained, which is largely independent of the direction of movement of the wiper plate.
In another advantageous embodiment of the invention, the punches can be designed as rods which can be distributed uniformly over the entire underside or only partially in the area of the handle of the carrier plate. A point-like pressing on the surface to be cleaned is attained by the rod-like projections, which is advantageous on smaller surfaces, particularly with a great degree of soiling.
In an embodiment of the invention, the foam body can be made of a polymeric, organic material. Foams made of polymeric organic material do not absorb any moisture, whereby their characteristics remain the same with wet and dry cleaning.
The foam body can be formed by an open-pore foam. In this way, the foam body can store cleaning liquid, which can be released upon compressing the foam body on the wiping cloth.
The foam body can be provided with strips that protrude in an embossed manner, at least in a partial area of the surface of the foam facing the surface to be cleaned; these strips have areas with heights which differ from one another in the direction of their pattern. By means of the elevations, greater pressing forces are also produced, whereby the abrasive effect of the wiper plate is once more increased. By means of the elevations of the foam body, it is possible to implement a wiper plate with two zones with different magnitudes in their cleaning effects—on the one hand, the punches and, on the other hand, the elevations of the strips.
The surface of the wiper plate facing the surface to be cleaned can be curved in a convex manner. By means of the convex curvature, an absorption of the soiling is made possible over the entire area by the rolling of the wiper plate with a back and forth movement.
The carrier plate can be made of polymeric material. Elements of polymeric materials are simple to produce and polymeric materials are low-cost.
SHORT DESCRIPTION OF THE DRAWING
Some embodiment examples of the wiper plate, in accordance with the invention, are explained in more detail with the aid of the figures. In schematic representations, the figures show the following:
FIG. 1 , a wiper plate with riblike punches in cross-section;
FIG. 2 , a wiper plate, as a semi-sectional representation, in a side view, with rodlike punches;
FIG. 3 , a wiper plate as a partial sectional representation in a front view;
FIG. 4 , a wiper plate in a lower view;
FIG. 5 , a wiper plate with a structured wiping surface in a perspective representation;
FIG. 6 , a floor wiper with a wiper plate, in accordance with the invention, in a perspective representation.
EMBODIMENT OF THE INVENTION
FIG. 1 shows an embodiment example of the wiper plate 1 , in accordance with the invention. The wiper plate 1 comprises a carrier plate 3 with punches 6 , designed as one piece and uniform in material, constructed as ribs 7 in this embodiment example. A foam body 4 is affixed on the carrier plate 3 on the side facing the surface to be cleaned. The foam body 4 has recesses 5 into which the ribs 7 protrude. The ribs 7 are shorter in this embodiment than the height of the foam body 4 , so that the punches 6 do not touch the surface to be cleaned in the unburdened state of the foam body 4 . The ribs 7 extend over 90% of the width of the foam body 4 and are arranged in the area of the handle.
FIG. 2 shows a wiper plate 1 in which the carrier plate 3 and the foam body 4 have a convex curvature on the side facing the surface to be cleaned. The curvature extends, viewed in the direction of cleaning, between the back and the front edges of the carrier plate 3 . The punches 6 are designed as rods 8 in this embodiment example. The rods 8 are uniform in material and are connected in one piece to the carrier plate 3 . In the connecting area to the carrier plate 3 , the rods 8 are formed in cylindrical shape and taper in the shape of a cone on the side facing the surface to be cleaned.
FIG. 3 shows the wiper plate 1 in the embodiment according to FIG. 2 , in a front view. The punches 6 designed as rods 8 are placed in the area of the handle 12 , symmetrical to the middle line.
FIG. 4 shows the wiper plate 1 in the embodiment according to FIG. 2 in a bottom view. The punches 6 designed as rods 8 are placed around the center of the wiper surface 14 . In order to be able to attain an optimal cleaning result, the rods 8 are staggered. The ratio of the sum of the surfaces formed by the rods 8 and facing the surface to be wiped to the total surface of the wiping surface 14 is 1:20.
FIG. 5 shows a wiper plate 1 with a carrier plate 3 and a foam body 4 . The foam body consists of an open-pore foam 9 . The surface of the foam 9 , facing the surface to be cleaned is provided with strips 10 , which protrude, embossed, over the entire area and which have areas with heights which differ from one another. The punches 6 are designed as rods 8 in this embodiment, which are located in the area of the handle 12 .
FIG. 6 shows a floor wiper 11 with a handle 12 and a wiper plate 1 , in accordance with the invention, with a carrier plate 3 and a foam body 4 . The wiper plate 1 is covered with a wiping cloth 2 , which is fixed on the wiper plate 1 by means of soft clips 15 .
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A wiping plate ( 1 ) for accommodating a replaceable wiping cloth ( 2 ) is disclosed. The wiping plate ( 1 ) includes an essentially plate-shaped support plate ( 3 ) with an elastically resilient foam member ( 4 ) that can be fixed to the bottom face thereof. The foam member ( 4 ) is provided with at least one recess ( 5 ) inside which at least one non-elastic plug ( 6 ) is arranged. The at least one plug ( 6 ) is connected to the support plate ( 3 ) and has a length that is smaller than the height of the foam member ( 4 ) in the unstressed state. The plug ( 6 ) can at least be brought in contact with the side of the wiping cloth ( 2 ), which faces away from the wiping surface, by applying pressure to the support plate ( 3 ) and the compressed foam member ( 4 ).
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an air register having a built-in room humidifier. The invention further concerns a humidifying floor register having an air deflector.
[0003] 2. Description of the Prior Art
[0004] Room humidifiers have become a necessity in regions where significantly low relative humidity is prevalent, such as regions having extended winter periods. Excessive skin dryness and frequent static electricity shocks are undesirable consequences of such low humidity levels. Accordingly, room humidifiers have been developed to eliminate such concerns by providing a means for raising humidity levels to achieve optimum comfort.
[0005] Room humidifiers of varying complexity are known in the art. A sophisticated and costly humidification system can be installed for use with an existing forced-air heating system. This type of system requires an electrical feed, a control system, and a water line tap in order to operate, and will provide humidification for a number of rooms. Another form of humidifier is the portable electric device which includes a water-holding reservoir and an electric fan for circulating humidified air throughout a room. Another device for raising room humidity levels consists of a receptacle which contains a water-holding reservoir and a filter and is designed for placement over a floor heat register. The bottom of the filter maintains contact with the water and the remainder of the filter remains damp as a result of capillary attraction. Room humidity levels are raised as air discharges from the floor register and passes through the filter.
[0006] Devices of the prior art, however, have several notable drawbacks. The humidifier designed for use with an existing heating system can be very difficult to install. And significant ongoing maintenance is usually required. The portable room humidifier is typically noisy when in operation. Both the portable room humidifier and the floor register humidifying unit can be rather bulky in structure and thus present a somewhat unfavorable addition to the decor of a room. Further, such devices can present a safety hazard if placed in high traffic areas where occupants are likely to stumble over such devices. Finally, the floor register unit must be temporarily removed in order to adjust the damper to regulate the air flow through the register, which could be a strenuous endeavor if the water reservoir is completely full.
SUMMARY OF THE INVENTION
[0007] In accordance with an embodiment of the present invention, an air register with humidifier is provided. The air register comprises a body, a wick, and a rib. The body defines a flow passageway and includes a trough configured to hold a liquid. The wick includes a first portion projecting into the flow passageway and second portion extending at least partly into the trough. The rib contacts the wick in the trough to at least partly inhibit shifting of the wick in the trough.
[0008] In accordance with another embodiment of the present invention, an air register with humidifier for use with a floor vent is provided. The air register comprises a trough and a flow passageway. The trough extends at least partly below the surface of the floor and into the floor vent. The flow passageway allows for air charged to the floor vent to flow therethrough. The trough includes an outer wall spaced from the flow passageway and an inner wall proximate the floor passageway. The outer wall has an upper portion which converges towards the inner wall at a first angle of severity. The outer wall has a lower portion which converges towards the inner wall at a second angle of severity that is greater than the first angle of severity.
[0009] In accordance with a further embodiment of the present invention, a deflector couplable to an air register and operable to alter the flow direction of the air exiting the register is provided. The deflector comprises a deflection wall adapted to extend at least partly over the outlet of the air register. The deflection wall includes a lower terminal edge The deflector presents a generally planar bottom surface formed at least in part by the lower terminal edge. A tab is protrudes generally downward from the lower terminal edge of the deflection wall. A leg protrudes generally downward from the bottom surface. A foot is coupled to the leg and extends in a direction generally transverse to the direction from which the leg extends from the bottom surface. The tab, leg, and foot cooperate to couple the deflector to the air register.
[0010] In a still further embodiment of the present invention, an air register comprising a body, a wick, a grill, and a deflector is provided. The body defines a flow passageway and includes a trough configured to hold a liquid. The wick has a first portion extended at least partly into the flow passageway and a second portion extending at least partly into the trough. The grill is releasably coupled to the body and extends at least partly over the flow passageway and the trough. The deflector is coupled to the grill and operable to alter the direction of flow of the air exiting the grill.
[0011] In a yet further embodiment of the present invention, a method of humidifying a room having a floor vent is provided. The method includes positioning a room humidifying assembly so that it is supported on the floor surface and extends at least partly into the floor vent below the floor surface. The method further includes positioning a wick in a trough of the assembly so that the wick contacts a rib in the trough to thereby at least partly inhibit shifting of the wick in the trough.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A preferred embodiment of the present invention is described herein with reference to the following drawing figures:
[0013] [0013]FIG. 1 is an assembly view of an air register with humidifier and air deflector in accordance with a preferred embodiment of the present invention;
[0014] [0014]FIG. 2 is plan view of the air register with the air deflector being removed and certain sections of the grill being cut away to more clearly illustrate various features of the body of the register;
[0015] [0015]FIG. 3 is a cross sectional view taking a long line 3 - 3 of FIG. 3 which illustrates the air register with humidifier and air deflector being positioned in a floor vent; and
[0016] [0016]FIG. 4 is a cross sectional view taking along line 4 - 4 in FIG. 2 illustrating the coupling of the air deflector to the grill with portions being cutting away to better illustrate to the interface of the deflector and grill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Turning initially to FIG. 1, a room humidifying assembly 10 in accordance with an embodiment of the present invention is illustrated. Room humidifying assembly 10 is similar in design to the room humidifying assembly described in U.S. Pat. No. 5,922,248 issued Jul. 13, 1999, the entire disclosure of which is expressly incorporated herein by reference. Broadly, room humidifying assembly 10 includes a body 12 , a wick 14 , a grill 16 , and a deflector 18 .
[0018] Referring now to FIGS. 3 and 4, body 12 is preferably integrally formed of a synthetic resin material. Body 12 can generally be described in terms of an upper superstructure 20 and a lower substructure 22 . As best seen in FIG. 3, superstructure 20 is configured to be disposed above a floor surface 24 while substructure 22 is configured to be disposed below floor surface 24 .
[0019] Referring now to FIGS. 1 - 4 , superstructure 20 generally includes a flange 26 and a recess 28 . Flange 26 is generally rectangular in shape and continuously circumscribes recess 28 . Flange 26 includes a sloped wall 30 and top wall 32 . At the bottom of sloped wall 30 is and engagement edge 34 which engages floor surface 24 to thereby at least partly support room humidifying assembly 10 on floor surface 24 . Sloped wall 30 extends upwardly and inwardly from engagement edge 34 and joins with top wall 32 . A recess wall 36 extends generally downward from the inner edge of top wall 32 to thereby define the outer perimeter of generally rectangular recess 28 . Coupled to the bottom of recess wall 36 and extending inwardly therefrom is a recess ledge 38 . The outer perimeter of recess ledge 38 is defined by recess wall 36 . An inner perimeter 40 of recess ledge 38 defines a generally rectangular opening which provides access to sub-structure 22 .
[0020] As perhaps best seen in FIGS. 3 and 4, substructure 22 can generally be described in terms of a vent-side portion 42 and a trough-side portion 44 . Both vent-side portion 42 and trough-side 44 are coupled to and extend generally downwardly from the bottom of recess ledge 38 proximate inner perimeter 40 .
[0021] Trough-side portion 44 of substructure 22 generally includes a trough 46 which is capable of hold a liquid, preferably water. The top of trough 46 presents a generally rectangular upper opening which is bounded on three sides by inner perimeter 40 of recess ledge 38 . The upper opening in trough 46 is bounded on the fourth side by the top edge of an inner wall 48 of trough 46 . Inner wall 48 , an outer wall 50 , opposing end walls 52 and 54 , and a base 56 cooperate to form trough 46 . Inner wall 48 is located proximate vent-side portion 42 . Outer wall 50 is spaced from vent-side portion 42 . End walls 52 and 54 and outer wall 50 extend generally downward from respective portions of inner perimeter 40 of a recess ledge 48 . Inner wall 40 is coupled to and extends between end walls 52 and 54 on the side of trough 46 opposite outer wall 50 . Base 56 is sealingly coupled to the bottom edges of inner wall 48 , outer wall 50 , and opposing end walls 52 and 54 .
[0022] In accordance with an embodiment with the present invention, outer wall 50 includes an upper angled portion 58 and a lower angled portion 60 . Upper angled portion 58 converges toward inner wall 48 at a first angle of severity. Lower angled portion 60 converges towards inner wall 48 at a second angle of severity. The second angle of severity is greater than the first angle of severity. As used herein, the term “angle of severity” means an angle measure between a wall or surface of room humidifying assembly 10 and a line or plane extending perpendicular to floor surface 24 . As best seen in FIG. 3, the sloped configuration of outer wall 50 allows trough 46 to extend as far downward as possible into a vent shaft 62 , thereby maximizing the quantity of liquid which can be stored in trough 46 . If outer wall 50 of trough 46 were not configured as described herein, the quantity of liquid which could be stored in trough 46 would be dramatically reduced because the depth of trough 46 would need to be reduced in order to avoid interference with an outer duct wall 64 of ventilation shaft 62 . Although outer wall 50 of trough 46 is shown in the drawing figures as including a relatively flat upper angled portion 58 and a relatively flat lower angled portion 60 , it is contemplated by the present invention that outer wall 50 could be curved to provide a smooth transition between upper angled portion 58 and lower angle portion 60 . It is further contemplated by the present invention that a cross section of inner wall 48 , base 56 , and outer wall 50 (similar to that shown in FIG. 3) could be generally U-shaped to provide a smooth transition between inner wall 48 , base 56 , and outer wall 50 . Preferably, inner wall 48 is shaped so that it is substantially a mirror image of outer wall 50 , with a top angled portion 66 , a bottom angled portion 68 , and bottom angled portion 68 having a greater angle of severity than top angled portion 66 .
[0023] Referring again to FIGS. 1 - 4 , vent-side portion 42 of substructure 22 defines air passageways 70 which are adjacent trough 46 . Air passageways 70 are defined on three sides by a lip 72 which extends generally downward from the portion of inner perimeter 40 that does not define a portion of the upper opening of trough 46 . A plurality of support members 74 extend from inner wall 48 of trough 46 to lip 72 . Support members 74 are operable to at least partially support trough 46 relative to recess ledge 36 . Support members 74 are preferably generally triangular in shape and present a top surface 76 extending along a plane which is at least substantially perpendicular to the normal direction of air flow through air passageways 70 .
[0024] Referring now to FIGS. 1 and 3, wick 14 generally includes an upper portion 78 and a lower portion 80 . Upper portion 78 is configured to extend at least partially, preferably substantially, over air passageways 70 so that a substantial portion of the air passing through air passageways 70 must pass through upper portion 78 . Lower portion 80 is configured to extend generally downwardly into trough 46 . Preferably, the lower end of lower portion 80 is located proximate base 56 so that even when trough 46 contains only a minimal amount of liquid, lower portion 80 contacts the liquid. Wick 14 is operable to conduct a liquid stored in trough 46 from lower portion 80 to upper portion 78 by capillary attraction. Preferably, wick 14 is formed of lamented layers of expanded cellulose material.
[0025] It is preferred that wick 14 be well supported relative to body 12 so as to maintain wick 14 in a generally L-shaped configuration, with upper portion 78 extending substantially over air passageway 70 and lower portion 80 extending substantially downward into trough 46 . Referring now to FIGS. 1 - 3 , a wick-supporting structure including a plurality of pins 82 and plurality of ribs 84 operates to maintain wick 14 in its desired position relative to body 12 . Ribs 84 are fixedly coupled to base 56 of trough 46 and extend generally upward into trough 46 between outer wall 50 and inner wall 48 . Lower portion 80 of wick 14 can be placed against ribs 84 to restrain wick 14 from its natural tendency to flatten out from the desired L-shaped position. Pins 82 are configured to be inserted into upper portion 78 of wick 14 to restrain wick 14 from shifting relative to air passageways 70 .
[0026] Referring again to FIGS. 1 - 4 , grill 16 is configured to be removably received in recess 28 of body 12 and includes a plurality of openings therein to allow air to pass generally upwardly therethrough. Grill 16 includes a generally rectangular cover plate 86 bounded by a circumscribing lip 88 extending downwardly from the outer perimeter of cover plate 86 . The bottom edge of lip 88 contacts recess ledge 38 and supports grill 16 on recess ledge 38 when grill 16 is coupled to body 12 . Tabs 90 extend generally outwardly from one side of lip 88 and are configured to be releasably received in slots 92 of body 12 . An opposite side of cover plate 86 includes a projecting handle 94 which is configured to be received at least partly in a groove 96 in body 12 . As best seen in FIG. 3, catches 98 extend generally outward from the bottom of lip 88 on the same side of cover plate 86 as handle 94 and are configured to be releasably received in openings 100 in body 12 . Referring again to FIGS. 104 , grill 16 further includes a dampener 102 which is slidably coupled to the bottom of cover plate 86 . Dampener 102 includes openings which correspond to the openings in cover plate 86 so that when dampener 102 is shifted, via a knob 104 , into an open position, the slots in cover plate 86 and dampener 102 are generally aligned to allow air to flow therethrough. When dampener is shifted into a closed position, the corresponding openings in cover plate 86 and dampener 102 are misaligned so that dampener 102 at least partially covers the openings in cover plate 86 to thereby inhibit the flow of air through grill 16 . Grill 16 is preferably formed of a durable synthetic resin material.
[0027] In order to couple grill 16 to body 12 , tabs 90 are inserted into slots 92 and grill 16 is pivoted downward by handle 94 until catches 98 are received in openings 102 . To decouple grill 16 from body 12 , handle 94 can be grasped and raise to remove catches 98 from openings 100 . Grill 16 can then be pivoted upwards by handle 94 to a raised position. Once in the raised position, tabs 90 can be removed from slots 92 to decouple grill 16 from body 12 .
[0028] Deflector 18 generally comprises a deflection wall 106 and a pair of opposing sidewalls 108 and 110 coupled to respective ends 112 and 114 of deflection wall 106 and extending generally downward therefrom. Mounting flanges 116 are coupled to the bottom edge of respective sidewalls 110 and 112 and extend generally transverse to the plane along which sidewalls 108 and 110 extend. Deflection wall 106 is configured to cover a portion, preferably a substantial portion, of cover plate 86 . Deflection wall is operable to alter the direction of flow of air passing upwardly through the openings cover plate 86 . Deflection wall 106 preferably presents a curved inner deflection surface 116 for contacting the air exiting grill 16 . Deflection wall 116 presents a lower terminal edge 118 which is at least substantially co-planar with the bottom of mounting flange 116 . Projections 122 extend generally downwardly from lower terminal edge 118 and are configured to be received in apertures 124 of grill 16 . Protrusions 126 extend generally downward from the bottom of mounting flange 116 . Protrusions include a foot portion 128 which extends transversely to the direction in which protrusions 126 extend from mounting flange 116 . Foot portion 128 is configured to be snapped into openings 130 in grill 16 to thereby couple deflector 18 to grill 16 . Deflector 18 can be formed of any suitable synthetic resin material.
[0029] To assemble room humidifying assembly 110 , wick 14 is placed in body 12 so that lower portion 80 is received in trough 46 and rests against ribs 84 . Upper portion 78 of wick 14 is placed on top surfaces 76 of support members 74 with pins 82 being inserted at least partly into wick 14 to prevent wick 14 from pulling away from air passageways 70 . After wick 14 is placed in body 20 in a generally L-shaped configuration, grill 16 can be coupled to body 12 as described above. Once grill 16 is coupled to body 12 , a bottom surface of grill 16 contacts upper portion 78 of wick 14 to prevent upper portion 78 of wick 14 from raising out of contact with pins 82 . Thus, upper portion 78 of wick 14 is at least partially compressed between the bottom surface of grill 16 and top surface 76 of support members 74 when grill 16 is coupled to body 12 . Deflector 18 can then be coupled to grill 16 by inserting projections 122 into apertures 124 and extending feet 128 of protrusions 126 into openings 130 .
[0030] The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0031] The inventor hereby states his intent to rely on the doctrine of equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
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A floor vent register and room humidifier comprising a main body with a liquid trough located proximate an air passageway; a wick disposed at least partly in the trough and extending at least partly into the passageway and operable to draw water from the trough towards the passageway; a removable grill protecting the wick and providing access to the wick and trough; and a deflector coupled to the grill for altering the direction of flow of the air exiting the grill.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a mine door installation, and more particularly to a power-operated mine door system installed in a passageway in a mine.
[0002] The invention is especially concerned with a mine door system wherein doors for a passageway in a mine are adapted for powered opening and closing by means of hydraulic instrumentalities (specifically hydraulic cylinders).
SUMMARY OF THE INVENTION
[0003] Among the several objects of the invention may be noted the provision of a mine door system having a door-operating hydraulic instrumentality (such as a hydraulic cylinder) for a door thereof (or two such instrumentalities for a pair of doors) which is safely operable in a dangerous environment down in a mine (e.g. in a passageway where there may be explosive gas); the provision of a system such as described which eliminates the need for electrical empowerment (e.g. eliminates the need for an electric motor) and thus avoids arcing and sparking which might set off an explosion; the provision of such a system taking advantage of a power source in the mine for other purposes; and the provision of such a system which is relatively economical to install and reliable in operation.
[0004] The invention takes advantage of the compressed air system conventionally available in a mine, generally comprising the provision of an air motor for driving a pump for supplying hydraulic fluid under pressure to a hydraulic instrumentality for operating a door in the mine, and a compressed air circuit for supplying the air motor with compressed air from said compressed air system in the mine.
[0005] Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a top plan view of a double-door mine door arrangement having a hydraulic cylinder for operating each of the door components; and
[0007] [0007]FIG. 2 is a diagram showing hydraulic and air circuitry of the invention for operating the door components.
DETAILED DESCRIPTION
[0008] [0008]FIG. 1 shows a power mine door installation, generally designated 1 , for a doorway in a mine comprising a door frame generally indicated at 3 having a pair of door components 5 and 7 (each a generally rectangular door leaf) hinged on the frame as indicated at 9 and 11 at opposite sides of the doorway for swinging movement between open and closed positions. The door leafs are shown in open position in FIG. 1; in closed position they are generally coplanar. Leafs 5 and 7 are swingable between their open and closed positions by means of hydraulic instrumentalities. In one embodiment, these instrumentalities comprise hydraulic cylinders 15 (for leaf 5 ) and 17 (for leaf 7 ), each pivoted at its head end 19 on the frame 3 as indicated at 21 and having its piston rod 23 extending from its piston 25 (see FIG. 2) to a pin connection 27 with the respective leaf.
[0009] Now referring to FIG. 2, the power mine door installation 1 is shown to include a pumping unit 29 comprising a pneumatically driven pump 31 for supplying hydraulic fluid under pressure to the hydraulic cylinders 15 , 17 for operation thereof to operate the respective door leafs 5 , 7 via a four-way valve 33 which can be operated manually or by any other suitable means (e.g., solenoid, pilot, motor). Unit 29 further comprises an air motor 35 for driving pump 31 . At 37 is generally indicated a compressed air circuit for supplying air motor 35 with compressed air from a compressed air system 39 in the mine, said circuit including an on-off valve 41 therein. System 39 is preferably one conventionally available in a mine for supplying compressed air generally for mine-related purposes as will be readily understood. Alternatively, the system 39 could be a dedicated system provided for the sole purpose of supplying air under pressure to air motor 35 .
[0010] The pump 31 is adapted to receive hydraulic fluid via line 43 including a filter 45 from a supply at 47 and deliver it under pressure to the inlet of valve 33 via a line 49 , with a pressure relief line 51 extending from line 49 including a pressure relief valve 53 . At 55 is indicated in phantom an interconnection between valve 41 and valve 33 for synchronization of operation thereof such that the air valve 41 is opened to start the air motor 35 at substantially the same time as the valve 33 is actuated to either the “open door” or “close door” position. In a first setting of valve 33 , it is adapted to deliver hydraulic fluid under pressure via line 57 including a quick-connect coupler 59 and branch lines 61 and 63 including flow controls designated 65 and 66 , respectively, to the head ends of cylinders 15 , 17 and vents the rod ends of the cylinders via branch lines 67 and 69 , line 71 , quick-connect 73 and valve 33 to tank 74 . In a second setting of the valve 33 , it delivers hydraulic fluid under pressure via 71 , 67 , and 69 to the rod ends of the cylinders and vents the head ends of the cylinders via 61 , 63 , 59 , 57 and valve 33 to tank 74 . Lines 57 and 71 are connected to sumps 75 and 77 via lines 79 and 81 including release valves 83 and 85 , respectively. In the case of malfunction or a loss of power, these release valves may be opened manually to depressurize the system and allow the door components 5 , 7 to be operated (opened and/or closed) by hand.
[0011] It will be apparent from the above that with the pump 31 in operation and valve 33 in its first setting, the piston rods 27 will be extended to open the door components (leafs) 5 and 7 , and that with the pump 3 in operation and valve 33 in its second setting, the piston rods will be retracted to close the door components. The operation of the pump 31 by the air motor 35 , which is economically effected because the compressed air system 39 is already there in the mine, avoids the danger (such as may be caused by use of an electric motor and associated equipment) of explosion in the event of presence of explosive gas.
[0012] In one embodiment, each flow control 65 , 66 includes a check valve 65 CV, 66 CV and a fluid restricting (e.g., needle) valve 65 RV, 66 RV for restricting the flow of fluid. In the first setting of the valve 33 , the check valves 65 CV, 66 CV open to allow full flow of hydraulic fluid under pressure to the cylinders 15 , 17 to open the doors leafs. In the second setting of the valve 33 , the check valves 65 CV, 66 CV close and the hydraulic fluid flows through the restricting valves 65 RV, 66 RV to control the closing speed of the door leafs (i.e., to prevent door runaway). The restricting valves 65 RV, 66 RV can also be used to control the closing sequence of the door components 5 , 7 . For example, if one of the components is a door leaf carrying an astragal sealing flap, the restricting valves can be configured so that the door leaf with the flap closes last to ensure proper sealing of the flap against the other door leaf.
[0013] Means other than on-off valve 41 may be used to synchronize the operation of the air circuit 37 and the hydraulic fluid valve 33 . Indeed, this valve may be eliminated altogether, in which case the required synchronization can be effected simply by turning the air motor 35 on and off, for example.
[0014] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
[0015] As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.
[0016] When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
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A power mine door installation utilizing compressed air from the compressed air system available in the mine as the power source for a hydraulic door-operating mechanism.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates primarily to the field of replacement fittings or couplings for substantially rigid, plastic pipes such as polyvinylchloride (PVC) pipes whose ends are fixed relative to each other or otherwise cannot be easily moved relative to each other.
[0003] 2. Discussion of the Background
[0004] Replacing couplings or fittings between pipe ends that are fixed relative to each other or otherwise cannot be easily moved relative to each other presents special problems. Such pipes may have been initially coupled to each other in any number of easy and conventional manners (e.g., by a simple, open-ended socket coupler) when one or both of the pipes could be moved toward each other. However, once the coupled pipes are fixed in place (e.g., in the ground, in concrete, or to joists), replacing the coupling should it become broken or begin to leak becomes much more difficult. This is true because the pipes and their ends can no longer be moved (or at least not easily moved) relative to each other, particularly if the pipes are made of rigid material such as PVC. Consequently, in nearly all such cases, a replacement coupling must be used that will initially fit between the fixed ends of the pipes and then be outwardly adjustable or expandable to extend over the spaced-apart ends of the pipes.
[0005] Several replacement couplings or fittings exist which have telescoping members. In use, these couplings can be initially placed between the fixed ends of the pipes and then expanded or telescoped outwardly over the pipe ends. However, these couplings have a number of pieces or parts adding to both the cost and difficulty of using them. Further, these various pieces or parts are not initially linked or joined together and must be separately handled. Consequently, in use, it is first necessary for the installer to be sure he brings all of the necessary pieces and in the right sizes to the job site. Second, he must be careful at the job site not to drop or otherwise lose any of the separable pieces of the coupling. Such disadvantages can be critical. For example, the installer may find he does not have all of the necessary pieces (or in the right sizes) when he arrives at the job site. Additionally, in the usually tight quarters of the repair area, he may easily drop or lose one of the coupling pieces.
[0006] With this in mind, the replacement fitting of the present invention was developed. With it, all of the necessary pieces of the fitting are initially linked together into a single unit and cannot be inadvertently separated from one another. In use, the installer need only carry the single unit of linked pieces in one hand knowing all of the individual pieces of the fitting are there and are in the right sizes for each other. He also does not have to worry about dropping or otherwise losing any of the pieces on the way to the job site or at the site itself. Further, the repair can be accomplished with the fitting of the present invention by merely sliding individual sleeve members outwardly on a main body over the pipe ends.
SUMMARY OF THE INVENTION
[0007] The present invention involves replacement fittings for substantially rigid pipes. Each fitting preferably includes a main body with telescoping, sleeve members mounted on it. The sleeve members can be individually slid along the main body but cannot be removed from it. In this manner, the preferred fittings of the present invention can be handled as a single unit and all of the linked pieces will stay together and cannot be inadvertently left behind. They also cannot be accidentally lost or dropped on the way to the job site or during the repair operation. The various pieces of the fittings employ tapering surfaces that not only ensure the pieces will stay together while the fittings are being manipulated into position but also aid in creating the strongest bonds and seals with the pipes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 illustrates one of the most commonly used coupler arrangements for joining plastic pipes and in particular, plastic pipes made of rigid material such as PVC.
[0009] [0009]FIG. 2 shows how the prior art coupler and pipes of FIG. 1 are traditionally positioned when they are joined.
[0010] [0010]FIG. 3 illustrates the joined pipes of FIG. 2 as subsequently fixed in concrete. FIG. 3 also shows where the joined pipes would be conventionally cut should a break or leak develop and the coupling need to be replaced.
[0011] [0011]FIG. 4 shows the relative spacing of the pipes once the failed coupling of FIG. 3 is cut out. The newly cut ends of the rigid pipes as illustrated are fairly close to each other and are fixed in place relative to each other.
[0012] [0012]FIGS. 5 and 6 illustrate a common way of replacing a failed coupling if the pipes are fairly flexible and/or their ends can be moved relative to each other to accommodate a non-expanding coupler arrangement.
[0013] [0013]FIG. 7 illustrates a preferred embodiment of the present invention. In it, the slidable sleeve members are shown in solid lines in their outwardly extended positions on each end of the main body of the fitting. FIG. 7 also shows in dotted lines the left sleeve member moved as far as it can be moved to the right to abut the other sleeve member.
[0014] [0014]FIG. 8 shows the preferred embodiment of FIG. 7 with the sleeve members retracted and the fitting of the present invention positioned between the ends of the fixed, rigid pipes.
[0015] [0015]FIG. 9 illustrates the basic sealing structure of the present invention with the various pieces of the fitting in their preferred sealing positions.
[0016] [0016]FIG. 10 shows the basic sealing structure of the present invention adapted for use in a Teeshaped fitting.
[0017] [0017]FIG. 11 illustrates the basic sealing structure of the present invention adapted for use in an elbow fitting
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] [0018]FIG. 1 illustrates one of the most commonly used couplers 1 for joining the open ends 3 of cylindrical pipes such as 5 . As shown, the socket coupler 1 has a cylindrical outer surface 7 and two inwardly tapering surfaces 9 on each side. Consistent with ASTM (American Society For Testing And Materials) industry standards, each surface 9 tapers down from a diameter at 11 slightly greater than the outer diameter 13 of the pipe 5 to a diameter at 15 slightly less than the outer diameter 13 of the pipe 5 . For example, with an industry standard, schedule 40, three-fourths inch pipe 5 with an inner diameter 17 of 0.815 inches and an outer diameter 13 of 1.050 inches, each inner surface 9 of the socket coupler 1 would taper down from 1.058 inches at 11 to 1.046 inches at 15 . The industry standard taper is thus from a diameter at 11 of 0.008 inches larger than the outer diameter of the pipe 5 down to a diameter at 15 of 0.004 inches smaller than the outer diameter 13 of the pipe 5 . For larger pipes 5 (e.g., one inch pipe), the industry taper is greater (e.g., from a diameter at 11 of 0.010 inches larger than the outer diameter 13 of the pipe 5 down to 0.005 inches smaller at 15 ). Regardless of the size of pipe 5 , the industry taper is always desirable consistent with ASTM standards. It is noted at this time that all of the tapers in FIG. 1 and throughout the other drawings are greatly exaggerated in order to better illustrate the invention.
[0019] When the common socket 1 of FIG. 1 is used to join pipes such as 5 which can be freely moved relative to each other, the coupling process is fairly simple. That is, sealing solvent 19 is first applied about the outer surface portions 21 of the pipes 5 adjacent the open ends 3 and on the tapering, inner surfaces 9 of the coupler 1 . The pipes 5 can then be easily moved to the joined position of FIG. 2. Typically, the coupler 1 and/or pipes 5 are twisted about the axis 23 as this is done to ensure an even and complete smearing of the sealing solvent 19 on the various surfaces 21 and 9 . Additionally, where the sections 21 ′ of the surface portions 21 immediately adjacent the pipe ends 3 abut and are pinched down against surfaces 9 of the coupler 1 in FIG. 2, the sealing material 19 is preferably one that chemically reacts and fuses the sections 21 ′ of the pipe surfaces 21 to the coupler surfaces 9 .
[0020] In many common applications, the coupled pipes 5 of FIG. 2 are then fixed in place to joists, buried in the ground, or fixed in concrete 27 as illustrated in FIG. 3. Should the coupler 1 and/or pipe 5 begin to leak or become fractured (e.g., see crack 29 in FIG. 3) and need to be replaced, the coupler 1 and coupled pipes ends 3 are normally cut away at 31 creating new pipe ends 3 ′ (see FIG. 4). These new pipe ends 3 ′ as shown are spaced farther apart than the original ends 3 of FIG. 3.
[0021] If the pipes 5 of FIG. 4 were not fixed in place, it would be a simple matter to re-connect the new pipe ends 3 ′ in the manner of FIGS. 1 and 2, again using a common socket coupler 1 . Additionally, if the exposed segments of the pipes sticking out of the concrete 27 were longer (see segments 5 ′ in FIG. 5) and/or the pipe material were very flexible, it might also be possible to make the re-connection in the known manner of FIGS. 5 and 6. In this manner, the exposed pipe segments 5 ′ are flexed or arched to align the pipe ends 3 ′ with the respective couplers 1 on the extension pipe 5 ″. Subsequent movement of the members 1 , 3 ′, 5 ′, and 5 ″ downwardly to the position of FIG. 6 then serves to drive the pipe ends 3 ′ axially into the respective couplers 1 in the general manner of FIGS. 1 and 2. Other techniques also exist to re-connect pipes like 5 ′ in FIGS. 5 and 6 where the pipes 5 ′ and pipe ends 3 ′ can be flexed or otherwise moved relative to each other. However, where this is not possible as in FIG. 4 because the exposed pipe segments are too short or the material of the pipes 5 is too rigid and inflexible, it becomes necessary to use an expanding or telescoping coupler such as the fitting 2 of the present invention.
[0022] As best seen in FIG. 7, the preferred embodiment of the fitting 2 of the present invention includes a main body 4 with two sleeve members 6 and 6 ′ mounted thereabout. The main body 4 as shown extends along and about the axis 8 . The individual sleeve members 6 and 6 ′ in FIG. 7 are shown in solid lines in extreme positions extending outwardly beyond the respective open ends 12 of the main body 4 . In this regard, each sleeve member 6 and 6 ′ is mounted about the main body 4 for sliding movement relative to the main body 4 between at least first and second positions. However, the sleeve members 6 and 6 ′ cannot be removed from about the main body 4 .
[0023] More specifically, the sleeve member 6 in FIG. 7 can be slid on the main body 4 between the extreme positions of completely extended to the left (as shown in solid lines in FIG. 7) to the position shown on the right side in dotted lines in FIG. 7 abutting the extended sleeve member 6 ′. Sleeve member 6 ′ in turn can only be slid between similar extreme positions but cannot be removed from the main body 4 . In this manner, all of the pieces 4 , 6 , and 6 ′ of the fitting 2 are linked or joined together in one unit and cannot be separated. Consequently, the fitting 2 can be carried as a unit to the job site without fear of forgetting a piece or dropping a piece. Perhaps more importantly, the fitting 2 can be manipulated into place in the usually tight quarters of the job site also without fear of dropping or losing any of the pieces of the fitting 2 necessary to make the repair.
[0024] In this regard, each sleeve member 6 and 6 ′ is molded of plastic (e.g., PVC). While each sleeve member 6 and 6 ′ is still hot from the molding process (e.g., 200 degrees F.), the smaller ends 14 in FIG. 7 of the sleeve members 6 and 6 ′ are respectively popped over the larger ends 12 of the main body 4 . This can be done, for example, manually with a rubber mallet. The hot, plastic sleeve members 6 and 6 ′ at this point have only begun to contract and will even stretch somewhat to go over the larger ends 12 of the main body 4 . Once cooled, each sleeve member 6 and 6 ′ can be slid as discussed above along the main body 4 but cannot be removed from the main body 4 . Each sleeve member 6 and 6 ′ can actually be slid to a number of intermediate positions but is prevented from going beyond the extreme left and right positions as illustrated in FIG. 7 in solid and dotted lines in reference to sleeve member 6 . The sleeve members 6 and 6 ′ are therefore maintained at all times on the main body 4 and these linked pieces 4 , 6 , and 6 ′ of the fitting 2 cannot be separated from each other.
[0025] In use to couple the ends 3 ′ of the fixed-inplace pipes 5 of FIGS. 4 and 8, the extended sleeve members 6 and 6 ′ of FIG. 7 are first slid inwardly on the main body 4 to the retracted positions of FIG. 8. In these retracted positions, the abutting sleeve members 6 and 6 ′ are preferably dimensioned not to extend beyond the ends 12 of the main body 4 . In this way, the distance between the ends 12 of the main body 4 defines the minimum dimension not only of the main body 4 but also of the entire fitting 2 . This minimum dimension is then no greater than and can be less than the distance or spacing between the pipe ends 3 ′ in FIG. 8. If this distance is essentially the same as the pipe spacing, then the ends 12 of the fitting 2 will somewhat rub against the pipe ends 3 ′ as the fitting 2 is manually maneuvered into place. The fitting 2 with the sleeve members 6 and 6 ′ retracted as in FIG. 8 can thus be positioned as in FIG. 8 with the respective pipe ends 3 ′ and main body ends 12 adjacent and even slightly abutting one another. In this position, the pipe axes 23 and main body axis 8 are also aligned substantially in a co-linear manner. Thereafter, sealing solvent 19 is preferably applied to the outer, cylindrical surfaces 21 of the pipes S adjacent the ends 3 ′ as well as to the outwardly tapering surfaces 30 adjacent each end 12 of the main body 4 . The sleeve members 6 and 6 ′ in this regard are preferably dimensioned as in FIG. 8 so the sleeve members 6 and 6 ′ in the retracted positions of FIG. 8 leave the surfaces 30 exposed so the sealing solvent 19 can be easily applied to the surfaces 30 .
[0026] The respective sleeve members 6 and 6 ′ are thereafter moved to the extended positions of FIGS. 7 and 9 to form the seals (see in particular FIG. 9). This movement of the sleeve members 6 and 6 ′ can be done simultaneously or sequentially (e.g., first sleeve member 6 and then sleeve member 6 ′). Regardless, the sleeve members 6 and 6 ′ are preferably rotated or twisted during this movement to help smear the sealing solvent 19 over the surfaces 21 and 30 and on the covering surfaces 34 and 36 on each sleeve member 6 and 6 ′ (see FIG. 9 ). The sealing solvent 19 as shown is directly between the pair of surfaces 21 and 34 and pair of surfaces 30 and 36 .
[0027] Each outer surface 30 preferably tapers inwardly away from the respective main body end 12 (see FIG. 8). Conversely, the inner surface 36 on each sleeve member 6 and 6 ′ preferably tapers outwardly from adjacent the respective sleeve member end 14 toward the other sleeve member end 38 . In this manner as illustrated in reference to sleeve member 6 in FIG. 9, the surfaces 30 and 36 at least substantially abut and mate with the sealing solvent 19 positioned directly therebetween. Preferably, the surfaces 30 and 36 at area 40 actually do abut and are pinched wherein the sealing solvent 19 will chemically react and fuse the surfaces 30 and 36 of PVC together at area 40 for the strongest bond and seal. Prior to the application of the sealing solvent 19 , this abutting area 40 is also part of the structure that keeps the sleeve members 6 and 6 ′ from moving outwardly beyond the extended positions of FIG. 7. This in turn prevents the sleeve members 6 and 6 ′ from being removed from the main body 4 while the fitting 2 is being carried to the job site or manipulated between the pipe ends 3 ′ to be joined.
[0028] Referring again to FIG. 8, the inner surface 34 adjacent surface 36 on each sleeve member 6 and 6 ′ also preferably tapers inwardly from the respective sleeve member end 38 . The taper adjacent the sleeve member end 38 preferably begins at an inner diameter at 42 (see FIG. 7) that is greater than the outer diameter 13 of the pipe 5 of FIG. 8. Additionally, each surface 34 preferably tapers continuously downwardly to an inner diameter at step 44 in FIG. 7 that is less than the outer diameter 13 of the pipe 5 . Because the surface 34 in FIG. 9 tapers to an inner diameter at 44 less than the outer diameter 13 of the pipe 5 , the outer pipe surface 21 and sleeve surface 34 will preferably actually abut and pinch at area 46 in FIG. 9. As with surfaces 30 and 36 at 40 , the sealing solvent 19 directly between the surfaces 21 and 34 will then chemically react and fuse the surfaces 21 and 34 together at area 46 . The various surfaces do not have to abut and/or pinch to create an effective seal but preferably do so the sealing solvent can actually fuse the touching or crimped surface sections together for the strongest bond and seal.
[0029] For reference and with an industry standard, three-fourths inch pipe 5 with an outer diameter 13 of 1.050 inches, the taper of surface 34 is preferably continuous from 1.058 inches at end 38 in FIG. 7 down to 1.046 inches at step 44 . As previously noted, the tapers in the drawings are greatly exaggerated to better illustrate the invention.
[0030] The adjacent surfaces 34 and 36 of each sleeve member 6 and 6 ′ in FIGS. 7 - 9 are preferably offset from each other at the step 44 . In this manner, the surface 34 will not tend to scrape the applied sealing solvent 19 off the surface 30 of the main body 4 as the surface 34 passes by. That is, during the coupling operation, the sealing solvent 19 is initially applied to the surface 30 on each end 12 of the main body 4 in FIG. 8. Thereafter, each sleeve member 6 and 6 ′ is slid outwardly to the extended position of FIGS. 7 and 9. If the surfaces 34 and 36 were completely continuous without the step or offset 44 , the surface 34 might have a tendency to scrape some of the sealing solvent 19 off the surface 30 as the surface 34 passed by. With the various tapers, the surfaces 30 , 34 , and 36 are essentially frusto-conical shapes. It is again noted that all of the tapers of the drawings are greatly exaggerated. As for example as discussed above, the taper of surface 34 is essentially only from a diameter of 1.058 inches at 38 (for a three-fourths inch pipe 5 ) down to 1.046 inches at 44 over a distance of only about an inch. Surface 34 then steps down at 44 about 0.019 inches to a diameter on surface 36 of 1.008 inches. Surface 36 subsequently tapers down over a distance of less than an inch to a diameter of 0.978 inches adjacent sleeve member end 14 . The surface 34 is thus actually very close to the surface 30 as surface 34 passes by. Consequently, the increased spacing (even if only thousandths of an inch) created by the step or offset 44 offers a significant advantage to reducing the possibility that sealing solvent 19 will be scraped off surface 30 by surface 34 .
[0031] Further, this offset at 44 allows the outer maximum diameter 48 of each end 12 of the main body 4 (see FIG. 8) to be less than the outer diameter 13 of the pipe 5 . Stated another way, the smaller outer diameter 48 of the ends 12 (e.g., one inch versus the 1.050 inches of pipe diameter 13 for a three-fourths inch pipe 5 ) permits the tapered surfaces 34 to preferably abut and pinch or crimp the pipe at area 46 in FIG. 9 so the sealing solvent 19 can react and fuse the surfaces 21 and 34 together at area 46 . The incline or taper of the surfaces 34 and 36 could be continuous but the offset at 44 allows for a more abrupt transition so that the tapered surface at 36 will receive and preferably abut the pipe end 3 ′ in a shorter distance. The pipe ends 3 ′ and main body ends 12 can then be positioned as closely as possible and preferably actually abut. This close spacing in turn helps keep a laminar flow through the pipes 5 and fitting 2 . The ends 12 of the main body 4 in this regard are preferably even radiused to further help maintain a laminar flow with as little turbulence (friction) as possible. The offset 44 also allows the inclines of the surfaces 34 and 36 to be different degrees or slopes relative to the axis 8 . The slopes could be uniform if desired but in the preferred embodiment of FIG. 9, the slope of surface 36 is, for example, actually greater to better follow the sloping surface 30 .
[0032] The embodiment of FIGS. 7 - 9 is illustrated as having sleeve members 6 and 6 ′ on each end 12 of the main body 4 . However, the basic sealing structure on each end 12 of the main body 4 could be used alone as essentially illustrated in FIG. 9. If used alone or with, for example, a coupler like 1 of FIG. 1 on the other end of main body 4 , the basic sealing structure of the present invention would still have at least a main body like 4 and at least one sleeve member such as 6 in FIG. 9. The main body 4 would still have a first, preferably cylindrical portion 4 ′ (see FIG. 9) and an integral, second portion 4 ″ with the sleeve member 6 positioned about at least a part of the main body 4 . Additionally, the outer surface at 30 would still taper outwardly from portion 4 ′ toward the end 12 . The tapering surface 36 of the sleeve member 6 in turn would also at least substantially abut and mate with the surface 30 with the sealing solvent 19 positioned directly between the surfaces 30 and 36 . Preferably, the surfaces 30 and 36 would actually abut and pinch at area 40 as discussed above to be fused together at area 40 by the reaction of the sealing solvent 19 .
[0033] As illustrated in FIGS. 10 and 11, the basic sealing structure of the present invention can be easily adapted for use in Tee-shaped fittings such as 2 ′ of FIG. 10 and elbow fittings like 2 ″ of FIG. 11. Tee-fitting 2 ′ is essentially fitting 2 of FIGS. 7 - 9 with a third leg extending along an axis 8 ′ perpendicular to axis 8 . In the elbow fitting 2 ″ of FIG. 11, the parts 4 ′ of the main body extend along intersecting axes 8 and 8 ′ that are substantially perpendicular to each other. With all of the fittings 2 , 2 ′, and 2 ″, it is preferred but not necessary to have the basic, expandable, sealing structure of the preferred embodiment on each end of the parts of the main body 4 . Nevertheless, for the fittings to still be expandable to join fixed-in-place pipes, it is only necessary that at least one end (in the cases of inline fitting 2 and elbow fitting 21 ″) and at least two ends in the case of the Tee-shaped fitting 2 ′ have the expandable structure of the present invention. Also, because of the expanding or telescoping nature of the fittings of the present invention, effective seals can still be achieved even though the pipes 5 and fittings are not exactly cut and dimensioned to create the abutting and pinched or crimped areas 21 ′ and 40 of FIG. 9. For example as illustrated in FIG. 10, the sleeve member 6 ended up only abutting the pipe 5 at the circular contact 46 . Consequently, the sealing solvent 19 would then only fuse the pipe 6 and sleeve member 6 together about the contact 46 . In FIG. 11, the sleeve member 6 ended up not actually abutting the pipe 5 so in that case, the seal between therebetween is achieved by the sealing solvent 19 alone. In this regard and although the preferred seal is achieved in the proper cutting and dimensioning of the pipe 5 and fitting as in FIG. 9, effective seals can still be obtained with the structure of the present invention in the less precise relationships illustrated in FIGS. 10 and 11.
[0034] While several embodiments of the present invention have been shown and described in detail, it is to be understood that various changes and modifications could be made without departing from the scope of the invention.
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Replacement fittings for substantially rigid pipes. Each fitting preferably includes a main body with telescoping, sleeve members mounted on it. The sleeve members can be individually slid along the main body but cannot be removed from it. In this manner, the preferred fittings of the present invention can be handled as a single unit and all of the linked pieces will stay together and cannot be inadvertently left behind. They also cannot be accidentally lost or dropped on the way to the job site or during the repair operation. The various pieces of the fittings employ tapering surfaces that not only ensure the pieces will stay together while the fittings are being manipulated into position but also aid in creating the strongest bonds and seals with the pipes.
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BACKGROUND
[0001] This disclosure relates in general to data communications and, but not by way of limitation, to communication using a compliant medium.
[0002] Electronic communication takes place wirelessly using radio frequencies, optically using light and with wires using electron flow. Often these communication mechanisms are not practical in certain applications. For example, wires are difficult to string along pipelines and down a bore hole. Equipment needs to communicate information despite limitations on available communications medium.
[0003] There are systems for down hole communication using pressure in a hydraulic line. The pressure in the hydraulic line is modulated by the pump with data to communicate with sub-surface devices that have no other communication medium available. Over time, the pressure can be increased and decreased to send information. These systems only communicate away from the pump.
[0004] Other systems use acoustic waves to communicate. An acoustic wave is produced and a gate may be inserted and removed to modulate the reflection of the acoustic wave. These systems require a generally direct path from the acoustic source back to the sensor registering the reflection. Heavily damped systems are not appropriate candidates for these systems.
[0005] On occasion, drillstrings can become snagged somewhere down hole. To determine the location of the snag, tension is put on the drillstring. A point of the drillstring is marked. Tension is increased and the distance the mark moves is measured. The distance and the differential in tension can be used to determine how far down the drillstring the snag occurs.
SUMMARY
[0006] In one embodiment, the present disclosure provides a communication system for communicating information with a compliant medium is disclosed. The communication device includes a constrained fluid, a valve, a modulator, a sensor and a demodulator. The constrained is fluid distributed along a length. The valve is configured to operatively engage a second point relative to the length. The modulator configured to actuate the valve according to information. The sensor configured to measure pressure at a first point relative to the length, where the first point is distant from the second point. The demodulator is coupled to the sensor to recover the information.
[0007] In another embodiment, the present disclosure provides a communication system for communicating information with a compliant medium. In one step, a compliant medium has a first point and a second point, where the first point is distant from the second point. A compliance damper is configured to operatively engage the second point. A modulator is configured to actuate the compliance damper according to information. A sensor configured to measure compliance of the compliant medium at the first point. A demodulator is configured to operatively engage the first point to recover the information.
[0008] In yet another embodiment, the present disclosure provides a communication system for communicating information with a compliant medium. In one step, a compliant medium includes a first point and a second point, where the first point is distant from the second point. A compliance damper is configured to operatively engage the second point. A modulator is configured to actuate the compliance damper according to information. A sensor configured to measure compliance of the compliant medium at the first point. The demodulator configured to operatively engage the first point to recover the information.
[0009] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present disclosure is described in conjunction with the appended figures:
[0011] FIGS. 1A through 1E depict block diagrams of embodiments of a compliant communication system;
[0012] FIG. 2 depicts a chart of an example of pressure measured at a point of a compliant medium;
[0013] FIG. 3 depicts a chart of an example of a rate of pressure change over time;
[0014] FIG. 4 depicts a chart of an example of an absolute value of the rate of pressure change over time;
[0015] FIG. 5 illustrates a flowchart of an embodiment of a process for transmitting data using a compliant medium; and
[0016] FIGS. 6 and 7 depict a block diagram of an embodiment a compliant communication system that uses a deployment wire as the compliant medium.
[0017] In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
DETAILED DESCRIPTION
[0018] The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
[0019] In one embodiment, a compliant communication system has sensors that are distributed along a compliant medium (e.g., a tank, a pipe, a hydraulic line, or a wire). Sparse data is transmitted at low power levels for applications such as telemetry. Above-ground equipment continuously applies a displacement to one part of the compliant medium to provide a bias (e.g., pumping or extracting fluid for the hydraulics, or pulling or releasing tension for the wire), and measures the rate of change of force (e.g., pressure or tension) as flow rate or displacement. Pinching (e.g., valves or grippers) along the compliant medium can actively isolate or connect the section of line below the sensor from the section above. The rate of change of force is inversely proportional to the compliance of the system above the pinching mechanism. By modulating the isolation and reconnection of the line above and below the sensor, data may be communicated from a sub-surface to a surface receiver by continuously measuring the observed compliance at the surface. In one embodiment, modulation of the bias communicates information to the sub-surface devices coupled to the compliant medium.
[0020] Data from downhole production gauges and sensors may be desired over the lifetime of a well, but only using a very low data rate to communicate information. Hourly, daily or even weekly data may be all that is required to monitor the performance of a well, for example. In some embodiments, there may be a limited amount of stored energy available downhole, without such limits above ground. When fluid is added to (or withdrawn from) the hydraulic line the pressure will rise (respectively fall). For a uniform line, the rate of rise (respectively fall) is inversely proportional to the length of line, so signals can be transmitted by varying the length of the line using valves.
[0021] The power required for to transmit data can be very low, especially if valve operations only take place when the hydraulic line pressure is at one preset value as is the case in one embodiment. The compliant system can be used to communicate with a device at the end of a hydraulic line by deploying a hydraulic reservoir beyond the device—effectively lengthening the line.
[0022] The data rate can be variable between embodiments or for one embodiment. Viscous effects of the compliant media define a characteristic time for the system. In one embodiment, the time taken to transmit one bit is a multiple of the characteristic time. Multiple transmitters may use the same compliant medium by use of time division, different data rates, etc.
[0023] Referring first to FIG. 1A , a block diagram of an embodiment of a compliant communication system 100 - 1 is shown. A compliant medium 124 or hydraulic line in this embodiment is connected to a reservoir 104 of hydraulic fluid. In one embodiment, the reservoir 104 might be at the surface of an oil well, the line 124 being used to operate a flow-valve deep underground. The reservoir 104 would therefore also be underground. A pump 108 can pump at a measured rate both into and out of the hydraulic line 124 . There is a pressure sensor 112 , measuring the pressure inside the hydraulic line 124 .
[0024] Below surface there are one or more data devices 128 from which data is to be sent with a sub-surface transmitter 122 . Each of sub-surface transmitter 122 is connected to a mechanism for intermittently blocking the hydraulic line 124 , for example, a valve 116 . The sub-surface transmitter 122 sends information from the data device 128 to the surface receiver. By opening and closing the valve 116 , the sub-surface transmitter modulates the pressure on the hydraulic line 124 . The pressure is read by the pressure sensor 112 and fed to the surface receiver 134 for decoding back into the information.
[0025] The pump 108 pumps hydraulic fluid in and out of the line 124 . By biasing the fluid in the line 124 , the constrained fluid is enhanced as a complaint medium. In one embodiment, the pump 108 would normally cycle between pumping a fixed volume in and then out again. The pumping is periodic. The data that the sub-surface transmitter sends is encoded into bits. A 2-level, 4-level, 8-level, etc. modulation scheme could be used. For example, in a 2-level modulation scheme zero or closed is used for one level and one or open is used for the other. For more than two modulation levels, the valve could be partially opened or closed. Positive or negative logic could be used along with an optional error correction scheme. More complicated modulation schemes such as NRZ (non-return zero) could be used in other embodiments.
[0026] With reference to FIG. 1B , a block diagram of another embodiment of a compliant communication system 100 - 2 is shown. This embodiment has three different data devices 128 , each with its own sub-surface transmitter 122 to modulate a different valve 116 . At any given moment only one of the sub-surface transmitters 122 is modulating the compliant medium or line 124 . For example, the first and third valves 116 - 1 , 116 - 3 could be open, while the second valve 116 - 2 opens and closes to encode information onto the compliant medium 124 .
[0027] Various schemes could be used to allow all the data devices 128 to use the compliant medium 124 for data transfer. For example, time-division could be used in one embodiment. The downhole equipment 122 , 128 may either have a way to measure the line pressure to avoid transmissions from others or may be able to synchronize to the pump period. In the present embodiment, each data device tracks time and only transmits in a particular time slot. Another embodiment avoids time synchronization and randomly transmits information in the hope of avoiding overlap enough of the time to send an adequate amount of data for a given application.
[0028] Referring next to FIG. 1C , a block diagram of yet another embodiment of a compliant communication system 100 - 3 is shown. This embodiment allows bi-directional communication. The pump 108 modulates the volume inserted or removed from the line 124 . Each sub-surface transceiver 120 has a pressure sensor 112 to detect these changes in pressure. After decoding, that information is passed to the data device 128 . The surface transceiver 132 can send information on the compliant medium 124 to set up time slots, poll the data devices 128 , configure the data device and/or sub-surface transceiver, etc.
[0029] In order to transmit information from a data device 128 , the valve 116 is opened and shut under the control of the sub-surface transceiver 120 . In one embodiment, the opening and closing is synchronized with the pump 108 . The pressure sensor 112 coupled to the sub-surface transceiver 120 allows actuating the valve 116 when there is generally the same volume of fluid in the line 124 .
[0030] This embodiment includes a second reservoir 104 - 2 at the end of the line 124 proximate to the last sub-surface transceiver 120 . For a data device 128 - 2 at the end of the line 124 , the second reservoir 104 - 2 is used to enhance the difference in compliance between the valve 116 - 2 opening and closing.
[0031] With reference to FIG. 1D , a block diagram of still another embodiment of a compliant communication system 100 - 4 is shown. This embodiment has three different data devices 128 where each has a pressure sensor 112 to enable bi-directional communication and/or time slot determination. The terminal data device 128 in this embodiment is not close to the end of the line 124 such that a second reservoir may not used as the terminal end of the line 124 provides a reservoir for the fluid.
[0032] This embodiment allows peer communication between the sub-surface transceivers 120 . Each data device 128 could be addressed such that singlecast or multicast messaging could be done. A surface transceiver 132 could be used in other embodiments and still allow peer communication between the sub-surface transceivers 120 .
[0033] Referring next to FIG. 1E , a block diagram of another embodiment of a compliant communication system 100 - 5 is shown. This embodiment includes a second reservoir 104 - 2 at the terminal end of the line 124 to enhance compliance of the line for a valve 116 close to the terminal end of the line 124 .
[0034] With reference to FIG. 2 , a chart of an example 200 of pressure measured at a point of a compliant medium is shown. This figure shows the pressure measured at the sensor 112 over approximately one hundred minutes of operation. The pump cycle lasts for about twelve minutes in this example. If there were no fluid viscosity, the pressure would either rise or fall linearly with time, giving a triangular saw-tooth pattern. The viscous pressure, which is proportional to flow rate, results in an asymmetric shape to the teeth in the curve. The valve 116 is closed initially, then opening after two cycles, next shutting again after two cycles, opening again for the sixth cycle, and closing for the final two cycles. In a two-level modulation scheme this would be transmitting the binary digits 11001011.
[0035] Referring next to FIG. 3 , a chart of an example 300 of a rate of pressure change over time is shown. In this example, there is a transient at each change in flow rate, but this is short compared to the bit length. The transient is longer when the valve is open (and hence the hydraulic line is longer). The characteristic time, T, of the system is given by the following formula:
[0000]
T
=
(
L
r
)
2
η
κ
[0000] Where L is the length of the line, r is the radius, η is the viscosity, and κ is the bulk modulus of the hydraulic fluid possibly corrected for the compliance of the line wall. Typically, the characteristic time is from 10 s of seconds to minutes.
[0036] With reference to FIG. 4 , a chart of an example 400 of an absolute value of the rate of pressure change over time is shown. This figure shows the same data as FIG. 3 , now normalized by the direction of flow, and with the time divided into bit times. The level changes can clearly be seen. If the bits are transmitted over at least one cycle (as shown), then instead of level being measured by rate of pressure change, it can be measured by using peak (or trough) pressures. Bits can be transmitted over less than one cycle, or asynchronously with the flow cycles, but has greater transients each time a valve opens or shuts, as the pressure may not be the same on each side of the valve. Some embodiments may filter the signal in the figure to remove the spikes.
[0037] Referring next to FIG. 5 , a flowchart of an embodiment of a process 500 for transmitting data using a compliant medium 124 is shown. The depicted portion of the process begins in step 504 where the tube or line has fluid pumped into it. This pumping happens continuously to bias the compliant medium 124 . The data device 128 is gathering information in block 508 . In block 512 , a determination is made as to whether a time slot is available for sending information.
[0038] When a time slot is available, information is modulated in step 516 . By actuating the valve 116 according to the data being sent in step 520 the complaint medium is given the information. The receiver 134 is coupled to a pressure sensor 112 that measures the pressure in step 512 . With the pressure curve, the data is demodulated according to FIGS. 2-4 in step 528 to recover the data.
[0039] Referring next to FIGS. 6 and 7 , another embodiment of a compliant communication system 700 is shown that uses a deployment wire 604 as the compliant medium. In this embodiment, a downhole tool 616 is installed in a borehole and connected to the surface by the deployment wire 604 . The compliance of the system 700 is modified by the downhole tool 616 .
[0040] The deployment wire 604 is attached to the downhole tool 616 . A gripping arrangement is used to pinch the deployment wire 604 , for instance hydraulic grippers 612 are used in this embodiment. The compliant medium or deployment wire 604 is biased with a spring 608 in this embodiment. When the grippers 612 are closed, the compliance of the wire 604 is defined by the compliance of the length of wire above the grippers 612 . When the grippers 612 are opened, the additional compliance of the spring 608 is in series with the wire compliance, thus when the same force is applied to the deployment wire 604 , a larger displacement is seen. The data device 128 uses a sub-surface transmitter 122 to modulate the grippers 612 to communicate information to the surface.
[0041] The downhole tool 616 is firmly attached to the borehole walls 708 by a mechanism such as a wireline-deployed packer 704 . The deployment wire 604 joins the tool 616 to a surface winch and reel (not shown), via a pulley wheel 712 and a carrier mechanism 716 for pulling and releasing the deployment wire 604 , within which the force-displacement characteristics of the wire deployment system can be measured and demodulated back into information by the surface receiver 134 . The range of displacement of the carrier mechanism 716 is chosen so that the spring 608 will not be extended beyond the grippers 612 .
[0042] The carrier mechanism 716 rhythmically or periodically pulls and releases the deployment wire 604 , and measures the force versus displacement, i.e., the system compliance. In order to transmit data from the downhole tool 616 to surface, the grippers 612 are engaged and dis-engaged by the sub-surface transmitter 122 in order to modulate the compliance according to information produced by the data device 128 . Other embodiments could have multiple downhole tools that use the same deployment wire to send information to the surface. Although this embodiment only sends information in one direction, other embodiments could use the carrier mechanism to send information to the downhole tool, allowing bidirectional communication.
[0043] A number of variations and modifications of the disclosed embodiments can also be used. For example, some of the above embodiments describe an application where there are portions of the system above ground and other portions below ground. In other embodiments, all the components could be above or below ground or underwater. Some of the above embodiments discuss the complaint medium being a hydraulic line, but other embodiments could be a tank of fluid, a pipeline, or a wire.
[0044] Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0045] Implementation of the techniques, blocks, steps and means described above may be done in various ways. For example, these techniques, blocks, steps and means may be implemented in hardware, software, or a combination thereof. For a hardware implementation, the processing units may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described above, and/or a combination thereof.
[0046] Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
[0047] While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.
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A communication system for communicating information with a compliant medium is disclosed, the communication device includes a constrained fluid, a valve, a modulator, a sensor and a demodulator. The constrained is fluid distributed along a length. The valve is configured to operatively engage a second point relative to the length. The modulator configured to actuate the valve according to information. The sensor configured to measure pressure at a first point relative to the length, where the first point is distant from the second point. The demodulator is coupled to the sensor to recover the information.
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This application is a divisional of application Ser. No. 08/277,724, filed Jul. 20, 1994, now abandoned, which is a continuation-in-part of Ser. No. 08/169,285, filed Dec. 20, 1993, now abandoned, which is a continuation of application Ser. No. 07/763,762, filed Sep. 25, 1991, now Pat. No. 5,281,571, which is a continuation-in-part of application Ser. No. 07/600,031, filed Oct. 18, 1990, now abandoned.
FIELD OF THE INVENTION
The present invention relates to novel benzoyl derivatives and their methods of manufacture. These compounds are useful for the preparation of agricultural chemicals and medicines and particularly, as intermediates for an active class of arylhaloalkylpyrazole and aryl alkylsulfonylpyrazole herbicides.
BACKGROUND OF THE INVENTION
In recent years it has been found that one class of active herbicides are the substituted phenylpyrazoles, the phenyl and pyrazole moieties of which contain a variety of substituents.
Methods of manufacturing these phenylpyrazoles commonly involve chemical conversions of one or more radicals substituted on the phenyl and/or pyrazole moieties, e.g., by halogenation, esterification, etc. It is also known to prepare these compounds from substituted acetophenones by interaction with various compounds, including various esters which contribute the desired substituent radical to the 5-position of the pyrazole radical via cyclization of an intermediate phenyl diketone. For example, various halo- and/or alkyl-substituted acetophenones have been reacted with (halo) acetic acid esters to produce the corresponding phenyl diketone which is cyclized with hydrazine to yield phenylpyrazoles substituted in the 5-position of the pyrazole radical with (halo) alkyl groups.
It has recently been disclosed that certain 3-substituted aryl-5-substituted pyrazoies are particularly useful for broadspectrum control of a variety of weeds at very low application rates in a number of agronomically important crops. The aryl group is typically the phenyl radical substituted with halogen, alkyl, alkoxy and ester groups, substituents which are also commonly found on the pyrazole moiety. Particularly effective within this class of compounds are esters of 2-chloro-5-(4-halo-1-methyl-5-(trifluoromethyl)-1H-pyrazol-3-yl)-4-fluorobenzoic acid. These particular compounds are most readily available from 2-fluoro-5-alkylacetophenones and their derivatives. The literature, however, does not provide methods of preparation of these intermediates or related compounds that could provide the desired pyrazolylbenzoic acid esters. Thus, there is a need in the art for the discovery of novel intermediates and for efficient methods for the preparation of these substituted arylpyrazole compounds.
The present invention describes intermediates useful for production of compounds within this new class of herbicides.
SUMMARY OF THE INVENTION
The present invention relates to a class of benzoyl derivatives of Formula I and synthesis methods therefor: ##STR1## wherein X 1 and X 2 are H or a halogen atom, R 1 is a C 1-6 alkyl group optionally substituted with halogen or alkoxy or alkoxyalkyl having up to 6 carbon atoms; and R 2 is C 1-6 alkyl or C 1-6 haloalkyl, H or --CH 2 COR 3 ; wherein R 3 is a C 1-6 haloalkyl group.
A preferred subgenus of the benzoyl compounds in this invention are those according to Formula I wherein:
X 1 is fluorine;
X 2 is Cl or Br;
R 1 is methyl;
R 2 is H, halogen, methyl or --CH 2 COR 3 and
R 3 is CF 3 , CF 2 Cl, CF 2 H or C 2 F 5 .
The most preferred species herein are those according to Formula I wherein X 1 is fluoro, X 2 is chloro, R 1 is CH 3 and R 2 is --CH 2 COCF 3 .
As readily apparent to those skilled in the art, when R 2 in Formula I is hydrogen, the resulting compound (Formula IA below) is a substituted benzaldehyde; when R 2 is methyl (Formula IB below), the compound is a substituted acetophenone and when R 2 is the --CH 2 COR 3 radical, the resulting compound is a substituted phenyldiketone (Formula IC below). All of these compounds have the substituted benzoyl radical as a common structural feature, hence, for simplicity and convenience herein all of these compounds will be referred to collectively as benzoyl derivatives.
To applicants' knowledge all of the substituted benzoyl derivatives herein are novel compounds.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of Formula I wherein R 1 is a methyl group, X 1 is fluoro, X 2 is H or a halogen and R 2 is H (Formula IA) or methyl (Formula IB) are prepared from 2-substituted-4-fluoroanisoles of Formula II, which are known in the art, according to the following equation ##STR2##
Typically, 2,4-dihalo-5-alkoxybenzaldehydes of Formula IA are prepared by alkylation of 2,4-dihaloanisoles of Formula II with a 1,1-dihaloalkylalkylether in the presence of an acid catalyst at a temperature in the range of -100° C. to 100° C., preferably -78°C. to 50°C. An alkylating agent such as 1,1-dichloromethyl methyl ether is preferred and can be employed in a range of one molar equivalent to an excess. The acid catalyst may be a Lewis acid such as TiCl 4 , SnCl 4 , FeCl 3 or a Bronstead acid such as H 2 SO 4 . The amount of catalyst can be from less than 0.1 mole % to excesses greater than 100 mole % relative to the 2,4-dihaloanisole. Any inert solvent may be used in this reaction that does not markedly hinder the reaction from proceeding or the reaction can be carried out neat. Preferred solvents include, but are not limited to, dichloromethane, dichloroethanes, nitrobenzene or hydrocarbons. Products are isolated by treatment of the reaction mixture with water and isolation of the product by standard methods. Yields of the desired materials can be favorably improved by treatment of the crude product with mineral acid, such as conc. H2SO4 or HCl to convert any geminal dichlorides to aldehydes. Isolation can then be caried out in the usual manner.
Acetophenones and alkyl aryl ketones of Formula I wherein R 2 is a lower alkyl group can be prepared from the above obtained benzaldehydes by a sequence of known reaction types. The benzaldehyde is treated with an organometallic reagent such as an alkyl lithium or alkyl Grignard reagent to give an intermediate benzyl alcohol. Methyl lithium and methyl Grignard are preferred for preparation of the acetophenones. The reactions can be carried out in any suitable anhydrous solvent such as THF, diethyl ether, toluene. Oxidation of the benzyl alcohol with any suitable oxidizing agent gives the desired aryl alkyl ketone of Formula I. Preferred oxidants include, but are not limited to, chromium oxide, chromium oxide in sulfuric acid, potassium permanganate, potassium dichromate, etc. Reaction temperature is in the range of -78° C. to the boiling point of the inert solvent, preferably 0° C. to 100° C. The reaction period may be chosen from the range of a few minutes to several weeks depending on the amounts of reagents, reaction temperature, etc.
Compounds of Formula IC are prepared from compounds of Formula IB by reaction with R 3 COZ wherein Z is a C 1- 6 alkoxy or C 6-8 aryloxy group or a halogen atom or by reaction with anhydride (R 3 CO) 2 O, where in both formulae R 3 is C 1-6 haloalkyl. ##STR3##
Thus, diketones of Formula IC can be prepared by treatment of 2-fluoro-4-(H or halogen)-5-alkylacetophenones with an ester, an anhydride or an acid halide in the presence of a base. Any suitable solvent or mixture of solvents can be employed; the preferred solvents are anhydrous ether, alcohols, dimethylsulfoxide, toluene, benzene, etc. The reaction is carried out in the presence of a base such as an alkali alkoxide, alkali amide or alkali hydride with the alkali alkoxides such as sodium methoxide being preferred. Reaction temperature is in the range of -100° C. to 200° C., preferably -78° C. to the reflux temperature of the solvent. The reaction period may be chosen from the range of a few minutes to several weeks depending on the amounts of reagents, reaction temperature, etc.
Compounds of Formula IC are meant to include all possible tautomers, such as enols and all possible salts wherein the cation is an alkali metal or other suitable organic or inorganic cationic species.
The compounds of Formula IC can be converted to pyrazolylbenzoyl esters useful as synthetic herbicides by the following reactions. ##STR4##
In the above formulae, R 1 , R 3 , X 1 and X 2 are as previously defined for Formula I, X 3 is halogen and R is an alkyl or substituted alkyl group.
The following Examples 1-9 describe specific working embodiments for the preparation of representative compounds according to this invention.
EXAMPLE 1
Preparation of 4-Chloro-2 -fluoro-5-methoxy-benzaldehyde
To a nitrogen purged 3 L round bottom flask equipped with a mechanical stirrer and a gas scrubber was added 114 g of titanium(IV) chloride followed by 48 g of 2-chloro-4-fluoroanisole. The stirred mixture was cooled in an ice water bath and treated dropwise with of 68.4 g of α, α-dichloromethyl methyl ether. After stirring for 90 minutes, the resultant slurry was treated with 200 mL of methylene chloride and the reaction allowed to reach room temperature. The mixture was treated with an additional 500 mL of methylene chloride, added dropwise to ice water in a 4 L beaker and the resultant mixture extracted three times with methylene chloride. The combined organic extracts were washed with water, 10% Na 2 CO 3 , dried and concd to give a crude oily solid. Trituration with hexanes yielded 42 g (74%) of 4-chloro-2-fluoro-5-methoxybenzaldehyde as a white solid. An analytical sample was obtained by bulb-to-bulb distillation to give a white, crystalline solid: mp 120.0-122.0° C.; 1 H NMR (CDCl 3 ) δ 3.93 (s,3H), 7.25 (d, lH, J=9.4 Hz), 7.34 (d, lH, 5.9 Hz), 10.28 (s, lH).
Anal. Calcd for C C 8 H 6 o 2 CL 1 F 1 :
C, 50.95; H, 3.21; Cl, 18.80.
Found: C, 50.83; H, 3.24; Cl, 18.90.
EXAMPLE 2
Preparation of 1-(4-Chloro-2-fluoro-5methoxyphenyl) ethanone
A stirred solution of 10.4 g of 4-chloro-2-fluoro-5-methoxybenzaldehyde in 150 mL of anhydrous THF was cooled in a dry ice-acetone bath and treated with 35 mL of a 3M solution of methyl magnesium chloride in THF over a period of one minute. The ice bath was removed and the mixture allowed to warm to room temperature. After warming, the solution was slowly poured into ice water. The water slurry was extracted three times with diethyl ether, the ether extracts dried and concd to afford a crude oil. Crystallization from hexanes yielded 10.8 g (95.6%) of 4-chloro-2-fluoro-5-methoxy-α-methyl-benzenemethanol: mp 68.5°-69.5° C. This benzenemethanol intermediate was dissolved in 100 mL of acetone, cooled in an ice water bath and treated dropwise with 50 mL of freshly prepared Jones'reagent (prepared from 6.7 g of CrO 3 , 6 mL of H 2 SO 4 and 50 mL of water), keeping the temperature below 10° C. After stirring for 2 hrs., the solution was diluted with water and extracted three times with methylene chloride. The organic extracts were dried and concd to give a crude product. Recrystallization from methanol yielded 9.66 g (90.3%) of 1-(4-chloro-2-fluoro-5-methoxyphenyl) ethanone as a white solid: mp 96.5-98.5 ° C.; 1 HNMR (CDCl 3 ) δ 2.50 (d, 3H, 5.4 Hz), 3.80 (s, 3H), 7.10 (d, 1H, 10.1 Hz), 7.30 (d, 1H, 6.3 Hz).
Anal. calcd for C C 9 H 8 O 2 Cl 1 F 1 : C
C, 53.55; H, 3.98.
Found: C, 53.45; H, 3.96.
EXAMPLE 3
Preparation of 1-(4-Chloro-2-fluoro-5-methoxyphenyl)-4,4,4-trifluoro-l,4-butanedione
A solution of 21.8 g of 1-(4-chloro-2-fluoro-5-methoxyphenyl) ethanone in 100 ml of anhydrous diethyl ether was cooled in an ice bath. The stirred mixture was treated all at once with 28.1 g of ethyl trifluoroacetate. After stirring for a few minutes, 50 mL of 25% sodium methoxide in methanol (0.20 mol) was added and the solution was allowed to stir overnight. The mixture was quenched with 150 ml of water and 100 ml conc. HCL. The reaction mixture was extracted three times with diethyl ether and the combined organic layers separated, dried, and concd to afford a tan solid. The crude solid was recrystalized from methanol to give 23.5 g (73.2%) of 1- (4-chloro-2-fluoro-5-methoxyphenyl)-4,4,4-trifluoro-1,4-butanedione as a yellow solid: mp 122-123° C.; 1 HNMR (CDCl 3 ) δ3.80 (d, 3H, 2 Hz), 6.60 (d, 1H, 2 Hz), 7.10 (dd, 1H, 11 Hz, 2 Hz), 7.40 (dd, 1H, 4 Hz, 2 Hz).
Anal. Calcd for C C 11 H 6 O 3 Cl 1 F 4 : C, 44.39; H, 2.03. Found: C, 44.23; H, 2.36.
Examples 4-6 were prepared by alkylation of the corresponding anisole in a manner analogous to the process of Example 1.
Example 7 was prepared according to the two-step addition-oxidation sequence in a manner analogous to the process of Example 2.
Examples 8 and 9 were prepared according to the process analogous to that in Example 3.
Physical properties for the compounds of Examples 4-9 are shown in the table below.
TABLE______________________________________PHYSICAL DATA FOR 2,4-DIHALO-5-METHOXY-BENZALDEHYDES AND THEIR DERIVATIVES ##STR5##EXAMPLE X.sub.1 X.sub.2 R.sub.2 mp/refractive index______________________________________4 Cl F H 102.0° C.-104.0° C.5 F F H 85° C.-86° C.6 Cl Cl H 113° C.-115° C.7 F Cl Et 82° C.8 F Cl CH.sub.2 COCF.sub.2 CF.sub.3 114.0° C.9 F Cl CH.sub.2 COCF.sub.2 Cl 112.0° C.______________________________________
The novel 2,4-dihalo-5-alkoxybenzaldehydes, 2,4-dihalo-5-alkoxyacetophenones and benzoyl derivatives of the present invention are useful as intermediates for the preparation or manufacture of agricultural chemicals and medicines, particularly the substituted phenylpyrazole type herbicides. These intermediates allow direct introduction of a 5'-alkoxy substituent on the phenyl ring of the phenylpyrazole which can be converted to 5'-substituted oxyphenyl pyrazoles such as 5'-propargyloxyphenylpyrazoles or pyrazolylphenoxyacetic acids or esters.
As will be appreciated by those skilled in the art, various modifications of the invention described herein may be made without departing from the spirit and scope thereof.
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The present invention relates to novel 4-halo-2-fluoro-5-alkoxybenzoyl compounds and their methods of manufacture. These compounds are useful for the preparation of agricultural chemicals and medicines, particularly as intermediates for an active class of arylhaloalkylpyrazole and aryl alkylsulfonylpyrazole herbicides.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to packages and more specifically to packages and packaging methods in which a product supported in a tray is wrapped with a film which is selectively affixed to the tray using a heat activated adhesive.
2. Description of the Prior Art
In a typical prior art package and packaging technique the product is placed in a tray and covered with a plastic film such that the film totally encloses the tray and the product. Heat is applied to the bottom of the package. Portions of the film which overlap such that contact is established therebetween adhere to form a seal.
Such packaging techniques are widely used in the food industry to package food products which include moisture. Since the plastic film adheres to itself, a relatively leak-proof seal is formed in areas where the film overlaps without wrinkles or excessive overlaping layers. Wrinkles and excessive overlaping layers adversely effect the sealing characteristics of the film resulting in an increase in the number of packages which develop leaks.
Areas forming a good seal are usually concentrated in the central portion of the package. Areas near or adjacent the ends usually include excessive overlaping layers and wrinkles. Wrinkles and excessive overlaping layers change the sealing characteristics as a result of the formation of regions where no contact is established between overlaping layers of the film. Passages are formed along the wrinkles and between excessive overlaping layers which may extend from the interior of the package to the exterior of the package.
The inside surface of the film is typically treated to prevent the formation of water droplets. Condensation forming on the inside surface of the film tends to flow along this surface and through the passageways, discussed above. As a result, the package leaks and must be removed from the shelf before it is sold. Such leaks are particularly troublesome when food products such as fresh meats, poultry and seafood are to be packaged due to the high moisture content of these products.
SUMMARY OF THE INVENTION
In one embodiment of the invention a strip of double sided adhesive tape is affixed to the bottom surface of the tray adjacent the edges thereof using a conventional pressure sensitive adhesive. The exposed surface of the tape includes a layer of a heat activated adhesive. The product to be packaged is placed in the tray and the film is folded around the sides, around the ends and underneath the tray to totally enclose the tray. Folding the film underneath the tray in this manner tends to form areas of multiple layer film and wrinkles. These multiple layers of film and wrinkles tend to be concentrated in regions of the bottom adjacent to or near the ends of the tray.
After the sides and ends of the film have been folded underneath the package heat is applied to its under surface causing the film to adhere to itself where it overlaps and to the tape as the adhesive is activated. Along the central portion of the bottom of the package the film seals to itself and forms a relatively leak proof seal in a conventional fashion. Other portions of the film are sealed to the tray by the heat activated adhesive. Areas where the film overlies the heat activated adhesive and areas where the film overlaps are collectively referred to as the sealing zone.
In a second embodiment of the invention, the product to be packaged is placed in a tray and the entire bottom surface of the tray is coated with a heat-activated adhesive. A film is placed over the product and folded underneath the tray to totally enclose the tray. Wrinkles and excessive overlapping layers are formed, as discussed above. Heat is applied causing the film to seal to the package along substantially the entire sealing zone as the adhesive is activated, thereby forming an essentially leak proof package.
In all embodiments of the invention, the film tends to be attracted by the adhesive when in the activated state. Additionally, the adhesive tends to flow, changing the contour of the adhesive layer to fill, at least a portion of, any space between the film and the tray. This significantly reduces the number of passageways and forms a highly leak-resistant package.
In practicing the invention, the product may be placed in the tray, wrapped with film and heated to produce the seal using currently available equipment and materials. For example, the film may be polyvinylchloride. The adhesive tape and the adhesive layer may be applied to the bottom of the tray using any convenient technique.
OBJECTS OF THE INVENTION
It is the principal objective of the invention to provide an improved leak-resistant package.
It is another object of the invention to provide a leak-resistant package using currently available materials.
It is another object of the invention to provide a packaging technique using a film to cover the product in which the number of passageways from the interior to the exterior of the package are reduced.
It is another object of the invention to provide a film packaging technique in which a heat-activated adhesive is used to reduce the number of passageways along wrinkles and between excessive layers of the film.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing partially in cross section illustrating a first embodiment of the invention.
FIG. 2 is a bottom view of the embodiment illustrated in FIG. 1.
FIG. 3 is partial cross-sectional view of a portion of the package.
FIG. 4 is a drawing illustrating the adhesive tape used in the invention.
FIG. 5 is a drawing in partial cross-section illustrating a second embodiment of the invention.
DETAILED DESCRIPTION
Referring now to FIG. 1, which is a drawing illustrating a product packaged in accordance with the invention, a conventional polyurethane tray 10 of the type frequently used to package fresh meats, poultry and seafood, is used to support a product 12. The tray includes a substantially flat bottom member and a perimetrical side wall surrounding and joined to the bottom member. Two strips of heat-activated adhesive tape 14 and 16 are affixed to the bottom surface of the tray 10 in areas adjacent opposed ends of the tray 10. A thin transparent plastic film 18 extends over the top surface of the product 12 and around the edges of the tray 10. The film is folded underneath to totally enclose the product 12 and the tray 10.
As the film 18 is folded underneath the tray 10, it extends over the bottom of the tray 12 and overlaps making relatively wrinkle-free contact with itself and the bottom of the tray in the central portion of the tray, identified by the letter "A" in FIG. 2. This region also tends to be relatively free of excessive overlapping regions, i.e. regions of more than two overlapping layers. However, as the ends of the film 18 are folded underneath the tray 10, multi-layers, wrinkles and excessive overlapping regions develop, which are typically concentrated near the opposed ends of the tray 10 as generally indicated at reference numerals 22 and 24 of FIG. 2.
After the film 18 has been folded underneath the tray, along both its sides and ends, heat is applied to the bottom of the package causing the film 18 to adhere to itself, forming a relatively leak-proof seal along the central portion A of the package. Adjacent the ends of the package, portions of the film 18 in contact with itself seal together. Additionally portions of the film 18 in contact with the heat-activated adhesive on the outer surface of the adhesive tape strips 14 and 16 are sealed to the tape forming a relatively leak-proof package. The surface of the adhesive tends to change contour to conform to the space between the film 18 and the surface of the adhesive tape reducing the number of passageways between the interior and the exterior of the package, further improving the seal. In summary, a highly leak-resistant seal is formed over the entire sealing zone.
In FIG. 2, the wrinkling of the film along the end portions is clearly illustrated. Additionally, the heat-activated adhesive tends to change in contour and fill in the irregular spaces between the film and the tape 14, as previously described and generally illustrated at reference numeral 26. The thermally activated adhesive may be BOSTIC THERMOGRIP #6370, for example.
The heat-activated adhesive tape 14 is illustrated in FIG. 4. Heat-activated adhesive tape strip 14 is also representative of the second strip of heat-activated adhesive tape 16. The tape 14 includes a suitable base member 30, which may be of paper or suitable plastic. The upper surface of the base 30 is coated with a layer of pressure sensitive adhesive 32. A temporary peel off protective layer of paper or other suitable material 34 is attached to the upper surface. A suitable heat-activated adhesive layer 36 is formed on the lower surface of the tape stock 30. A suitable tape can be made using currently available materials.
In practicing the invention, the product 12 is placed in the tray 10 using conventional packaging techniques. The upper protective layer 34 is removed from two pieces of heat-activated adhesive tape to expose the pressure sensitive adhesive. The two strips of heat-activated adhesive tape 14 and 16 are then positioned in the proper relationship of the package 10 and suitable pressure is applied between the tapes 14 and 16 causing them to adhere to package 10. The plastic film 18 is then positioned around the product and sealed as previously described.
A second embodiment of the invention is illustrated in FIG. 5. In this embodiment, the product 40 to be packaged is placed in a tray 42. The bottom surface of the tray 42 is coated with a heat activated adhesive. A suitable plastic film 44 is positioned over the product 40 and folded underneath the package as previously discussed with respect to the embodiment illustrated in FIG. 1. Heat is applied to the bottom surface of the package causing the heat-activated adhesive to seal the film 44 to substantially all of the bottom surface of the tray 42, thereby forming a leak-resistant package. Sealing is further improved as the contour of the adhesive layer changes and tends to conform to the space between the film 44 and the tray 10. This results in a highly leak-resistant seal being formed across the entire sealing zone.
The package and packaging technique which is the subject of this invention may be implemented using a variety of commercially available components. If food products are to be packaged, it is obvious that all f the materials must be approved for use in food packaging and storage. Additionally, the heat-activated adhesive must have an activation temperature compatible with the film and the tray. More specifically, the activation temperature of the heat-activated adhesive must be so selected that the film and tray are not damaged in the sealing process.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
From the foregoing, it is readily apparent that I have invented an improved leak-resistant package, particularly for a food product, using currently available materials; as well as a packaging technique using a film to cover the product in which the number of passageways from the interior to the exterior of the package are reduced, and in which a heat-activated adhesive is used to reduce the number of passageways along wrinkles and between excessive layers of the film.
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The invention provides an improved package and packaging method for products that contain moisture. In the preferred embodiment, the product to be packaged is placed in a tray and the product and the tray are wrapped with a transparent film. The film is selectively affixed to at least a portion of the bottom of the tray using a heat-activated adhesive to form a leak-resistant package.
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TECHNICAL FIELD
[0001] The invention relates generally to gas turbine engines, and more particularly, to an improved method and apparatus for detecting the rotational speed of a gas turbine engine.
BACKGROUND OF THE ART
[0002] The rotational speed of a gas turbine engine, particularly the rotational speed of the high pressure spool shaft of the engine (sometimes referred to as the N2 speed), is a primary input variable necessary for the control logic of a gas turbine engine. In the prior art, engine speed is detected by way of a sensor positioned adjacent to a phonic wheel which is usually incorporated at a suitable location along a rotor of the engine, such as the high pressure spool shaft. A phonic wheel typically defines a number of slots extending therethrough and is mounted on a rotor shaft. A medium such as a beam of light, a magnetic field, etc. is employed such that the sensor receives the medium affected by the slots of the phonic wheel when rotating, thereby enabling it to provide data regarding the rotational speed of the rotor shaft. The phonic wheel and the associated sensor are conventionally buried within the engine, which makes access thereto for maintenance and repair very difficult. Furthermore, the conventional location of the phonic wheel and associated sensor of a gas turbine engine is in a high temperature environment inside of the engine and this can cause a high differential thermal expansion mismatch between the sensor and the tips of the phonic wheel.
[0003] Accordingly, there is a need to provide an improved method and apparatus for detecting the rotational speed of gas turbine engines.
SUMMARY OF THE INVENTION
[0004] It is therefore an object of this invention to provide a method and apparatus for detecting a rotational speed of a rotor shaft of a gas turbine engine, overcoming the shortcomings of the prior art.
[0005] In one aspect, the present invention provides gas turbine engine having at least one rotor shaft operatively connecting a compressor apparatus and a turbine apparatus. The gas turbine engine further comprises an auxiliary gear box and a phonic wheel apparatus. The auxiliary gear box is drivingly connected to the rotor shaft, and the phonic wheel apparatus includes a toothed gear of the auxiliary gear box and a sensor for sensing a rotational speed of the toothed gear
[0006] In another aspect, the present invention provides an auxiliary gear box of a gas turbine engine which is drivingly connected to a rotor shaft of the engine. The auxiliary gear box comprises at least one pair of gears thereof to rotate in a fixed ratio with respect to a rotational speed of the rotor shaft, and a sensor adjacent to one of the gears for determining a rotational speed of the rotor shaft.
[0007] In another aspect, the present invention provides method for detecting a rotational speed of a rotor shaft of a gas turbine engine, which operatively connects a compressor apparatus and a turbine apparatus, and drivingly connects an auxiliary gear box. The method comprises detecting a rotational speed of one toothed gear associated with the auxiliary gear box as the toothed gear rotates in a fixed ratio with respect to the rotational speed of the rotor shaft and determining the rotational speed of the rotor shaft based on the detected rotational speed of the toothed gear and the fixed ratio.
[0008] Further details of these and other aspects of the present invention will be apparent from the detailed description and drawings included below.
DESCRIPTION OF THE DRAWINGS
[0009] Reference is now made to the accompanying drawings depicting aspects of the present invention, in which:
[0010] FIG. 1 is a schematic cross-sectional view of a turbofan gas turbine engine as an example illustrating an application of the present invention; and
[0011] FIG. 2 is schematic cross-sectional view of an oil gear pump affixed to an auxiliary gearbox of the engine of FIG. 1 , incorporating an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring to FIG. 1 , a turbofan gas turbine engine incorporating an embodiment of the present invention is presented as an example of the application of the present invention, and includes a engine case 10 , a core casing 13 , a low pressure spool assembly seen generally at 12 which includes a fan assembly 14 and a low pressure turbine assembly 18 , and a high pressure spool assembly seen generally at 20 which includes a compressor assembly 22 and a high pressure turbine assembly 24 . The core casing 13 surrounds the low and high pressure spool assemblies 12 and 20 in order to define a main fluid path (not indicated) therethrough. An auxiliary gear box (AGB) 26 attached to the engine case 10 of the engine is drivingly connected by a tower shaft 28 to the shaft (not indicated) of the high pressure spool assembly 20 such that the speed reduction gears of the AGB 26 rotate at a fixed ratio with respect to the rotational speed of the shaft of the high pressure spool assembly 20 . The AGB 26 further includes a plurality of accessories such as an oil gear pump 30 , a generator, etc. which are affixed to the AGB 26 and are driven by the AGB 26 such that these accessories also rotate in a fixed ratio with respect to the rotational speed of the shaft of the high pressure spool assembly 20 . A starter (not shown) is also conventionally affixed to the gearbox and is drivingly connected to the shaft of the high pressure spool assembly 20 through the tower shaft 28 .
[0013] Therefore, in accordance with the present invention, it is preferred to determine the rotational speed of the shaft of a high pressure spool assembly 20 based on the rotational speed of one of the gears associated with the AGB 26 , such as the oil gear pump 30 , and the fixed rotation ratio of the gear with respect to the rotational speed of the shaft of the high pressure spool assembly 20 .
[0014] Referring to FIGS. 1 and 2 , one embodiment of the present invention includes the oil gear pump 30 which is an AGB scavenge gear pump used in a lubricating system (not shown) of the gas turbine engine. The oil gear pump 30 is affixed to and driven by the AGB 26 . The oil gear pump 30 preferably includes a body or housing 32 defining a cavity 34 therein with an inlet 36 and outlet 38 in fluid communication with the cavity 34 , thereby allowing oil to flow through the housing 32 via the inlet 36 , the cavity 34 and the outlet 38 . A pair of preferably identical toothed gears 40 , 42 in a gearing relationship, are operatively mounted to the housing 32 within the cavity 34 of the oil gear pump 30 .
[0015] The cavity 34 has a profile such that the gears 40 , 42 can rotate in a gearing relationship without interfering with the surfaces of the cavity 34 , but will substantially block the oil flow passing through the cavity between the inlet 36 and the outlet 38 when the gears 40 and 42 are not rotating. One of the gears 40 , 42 is driven to rotate by the AGB 26 and the other is a free gear which rotates together with but in the opposite rotational direction of the gear driven by the AGB 26 . When the gears 40 , 42 rotate, oil contained in slots defined by adjacent teeth of the respective gears 40 , 42 is forced to move within the cavity 34 from the inlet side to the outlet side or vice versa, depending on the rotational direction of the gears 40 , 42 .
[0016] The housing 32 of the oil gear pump 30 further preferably defines a hole 44 extending thereinto and intersecting the cavity 34 , for receiving therein a sensor 46 such as a N2 speed probe of a magnetic type, such as a magnetic speed pick-up. The sensor 46 received in the hole 44 in the pump housing 32 , is adjacent to the gear 40 , preferably extending radially toward thereto with a predetermined clearance therebetween. Flanges 48 , 50 of the sensor 46 ensure the predetermined clearance between the sensor 46 and the tips (not indicated) of the gear 40 such that the sensor 46 is enabled to detect variations in a magnetic field disturbed by the teeth and slots of the gear 40 passing thereby when the gear 40 rotates. The rotational speed of the gear 40 is calibrated from the detected variations in the magnetic field. Thus, the gear 40 and the sensor 46 in combination form a phonic wheel apparatus although the primary function of the gear 40 is one of the rotors of the oil gear pump for pressurizing an oil flow.
[0017] The environment of the phonic wheel is wet, as the gear and sensor are subject to oil flow in the area. An O-ring seal 52 is preferably provided between the hole 44 and the sensor 46 to prevent oil leakage from the cavity 34 .
[0018] The sensor 46 is in electrical contact with the electrical engine control (EEC) (not shown) of the gas turbine engine. Thus, data regarding the rotational speed of gear 40 is provided to the EEC.
[0019] As described, the AGB 26 is drivingly connected through the tower shaft 28 to the shaft of the high pressure spool assembly 20 and the pair of gears 40 , 42 are driven to rotate by the AGB 26 , therefore the rotational speed of gear 40 is in a fixed ratio with respect to the rotational speed of the shaft of high pressure spool assembly 20 . This fixed ratio is known when the engine is designed and manufactured. Therefore, the instant rotational speed of the shaft of the high pressure spool assembly 20 (N2 speed) can be determined based on a calculation of the detected instant rotational speed of the gear 40 and the known fixed ratio. This is computed from time to time by the EEC and, as an output result, the instant N2 speed other than the rotational speed of gear 40 is displayed and is used as a primary input variable necessary for the control logic of the gas turbine engine.
[0020] The oil pump-mounted solution of the present invention is novel and has several advantages, including a novel location within the AGB which results in, among other things, a reduced tolerance stack-up and a low differential thermal expansion mismatch between the sensor 46 and the gear tips.
[0021] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departure from the scope of the invention disclosed. For example, the present invention can be applied to various types of gas turbine engines other than a turbofan gas engine which is used as an example to illustrate the application of the present invention. The oil gear pump incorporating a phonic wheel apparatus can be affixed to an AGB either outside or inside of the AGB. The sensor can be selected from any suitable types, although a magnetic speed probe is used in the embodiment of this invention. The sensor can be mounted by any suitable support structure other than the body of the oil gear pump, depending on the location of the AGB gear being selected to function as a phonic wheel. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.
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A gas turbine engine having at least a rotor shaft operatively connecting a compressor apparatus and a turbine apparatus, comprises an auxiliary gear box and a phonic wheel apparatus. The auxiliary gear box is drivingly connected to the rotor shaft and the phonic wheel apparatus includes an oil pump having toothed gear and a sensor mounted to the oil pump for sensing a rotational speed of the toothed gear.
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This is a continuation, of application Ser. No. 26,157 filed Apr. 2, 1979, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates in general to vehicles such as tractors and the like, and in particular to a tractor for agriculture having at least one engine-driven wheel axle for propelling the tractor, which is selectively connected to the engine by either a hydraulic stepless speed change mechanism or an alternate transmission mechanism employed when trouble occurs in the operation of the hydraulic stepless speed change mechanism.
A prior known tractor includes the power transmission system shown in FIG. 8. Namely, a transmission change mechanism (0C) is disposed between an intermediate portion of an input shaft assembly (011) from an engine (01) to a hydraulic stepless speed change mechanism (02) and an intermediate portion of a transmission shaft assembly (0Y) from the hydraulic stepless speed change mechanism (02) to an output shaft (012), to by-pass the hydraulic stepless speed change mechanism (02), said transmission change mechanism (0C) being connectable and disconnectable of power transmission from the output shaft (012) to a running device (0X) and capable of power transmission from the intermediate portion of the input shaft assembly (011) to the running device (0X). According to this construction, when the hydraulic stepless speed change mechanism (02) is in trouble, it is possible to take emergency measures for continuing running of the tractor by transmitting a power from the intermediate portion of the input shaft assembly (011) to the running device (0X) by operating the transmission change mechanism (0C).
However, this known tractor includes a large and complex transmission case for housing the transmission change mechanism (0C) which greatly increases the cost of the tractor, even though this known emergency running mechanism is only used infrequently, when the hydraulic stepless speed change mechanism is in trouble.
SUMMARY OF THE INVENTION
In view of the above circumstances, it would be highly desirable to provide a tractor having a hydraulic stepless speed change mechanism, and a simple, compact, emergency running mechanism for use when trouble occurs in the hydraulic stepless speed change mechanism which can be constructed inexpensively.
A tractor for agriculture according to the present invention comprises an engine, a hydraulic stepless speed change mechanism having an output shaft, an input shaft connecting the engine with the hydraulic stepless speed change mechanism and having an extended portion, a PTO shaft connected in association with the extended portion, a running device, a transmission shaft assembly connected in association with the output shaft, and a transmission change mechanism disposed at an intermediate portion of the transmission shaft assembly, said transmission change mechanism being connectable and disconnectable of power transmission from the output shaft to the running device and capable of power transmission from the extended portion to the running device when said power transmission from the output shaft to the running device is cut.
Thus, the input shaft from the engine to the hydraulic stepless speed change mechanism is extended and the extended portion is connected in association with the PTO shaft and the intermediate portion of the transmission shaft assembly is used as the mounting portion for the transmission change mechanism.
Therefore, as compared with the prior known construction in which this type of transmission change mechanism is arranged to go around the hydraulic stepless speed change mechanism, the whole construction of the present invention including a transmission case may be constituted more simply and compactly.
The main object of the present invention is to provide a tractor for agriculture which is not only simple and compact in construction, but also capable of continuing running thereof when a hydraulic stepless speed change mechanism is in trouble.
Another object of the present invention is to provide a tractor for agriculture may be more simple in construction by utilizing a transmission line from a hydraulic stepless speed change mechanism to a running device as much as possible.
Other objects and advantages will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show a tractor for agriculture with respect to embodiments of the present invention in which:
FIG. 1 is a simplified side view of the whole tractor,
FIG. 2 is a sectional side view of a main part of the tractor,
FIG. 3 is a sectional view taken lines III--III in FIG. 2,
FIG. 4 is a sectional view taken lies IV--IV in FIG. 2,
FIG. 5 is a schematic diagram of the hydraulic stepless speed change mechanism,
FIG. 6 is a block diagram of the tractor transmission system,
FIG. 7 is a sectional side view of the main part showing another embodiment, and
FIG. 8 is a block diagram of a known tractor transmission system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a four wheel drive tractor, particularly to a wheel drive apparatus for the tractor in which an output shaft which is extended from a hydraulic stepless speed change mechanism having an input shaft connected to an engine, is operatively connected to a transmission mechanism for a wheel system in a gear transmission case connected to the rearward end of the hydraulic stepless speed change mechanism and afront wheel drive shaft is extended forwardly from the transmission mechanism for a wheel system. An object of the present invention is not only to construct the whole of the wheel drive apparatus simply and compactly, but also to easily carry out assembly thereof.
A wheel drive apparatus in the prior art is so constructed that said front wheel drive shaft may be extended forwardly from a transmission mechanism for a wheel along with the lateral side of a hydraulic stepless speed change mechanism or under thereof. Therefore, many parts such as blakets, and bearings for supporting the front wheel drive shaft are necessary and the system becomes complex and large in construction. Further, it is troublesome to assemble the system.
The present invention has solved the above mentioned disadvantageous problems by effectively using a hydraulic stepless speed change mechanism and accordingly comprises a wheel drive apparatus for a tractor characterized in that an output shaft which is extended from a hydraulic stepless speed change mechanism having an input shaft connected to an engine, is operatively connected to a transmission mechanism for a wheel system in a gear transmission case connected to the rearward end of the hydraulic stepless speed change mechanism, and a front wheel drive shaft is extended forwardly from the transmission mechanism for a wheel system through said hydraulic stepless speed change mechanism.
Namely, the front wheel drive shaft of the present invention is extended forwardly through the hydraulic stepless speed change mechanism and not extended forwardly along with the lateral side of the hydraulic stepless speed change mechanism or under thereof as is in the prior art. Therefore, necessary parts for forwardly extending the front wheel drive shaft, such as blackets and bearings which support transmission gears for transmitting a power from the transmission for a wheel system to the front wheel drive shaft and which bear the front wheel drive shaft, are omitted by using a part of the hydraulic stepless speed change mechanism and thereby a large number of parts may be reduced. Thus, it is obtained not only to compactly construct the whole of the wheel drive apparatus, but also to make a simple assembly thereof.
An embodiment of this invention will be described below with reference to the accompanying drawings.
FIG. 1 shows an agricultural tractor comprising, as arranged from front to rear, an engine (1), a housing (3) accommodating a clutch, a hydraulic stepless speed change mechanism (2) for giving a steplessly variable running speed including a slanting plate whose angle is altered to produce an altered output of working oil for steplessly varying the running speed, and a transmission case (7) housing a transmission mechanism (4) for a wheel system and another transmission mechanism (6) for a power take-off shaft (5) (hereinafter referred to a PTO shaft) for driving an attachment. Provided above the hydraulic stepless speed change mechanism (2) and the transmission case (7) are a steering wheel (8), a driver's seat (9) and a lift arm (10) for raising and lowering the attachment.
As shown in FIG. 5, the hydraulic stepless speed change mechanism (2) comprises a pump (2A) of the axial plunger type and a charge pump (2B) which are coupled to an input shaft (11) from the engine (1), and a motor (2C) of the axial plunger type to be driven by a pump (2A). A speed change lever (2D) extending upward from the pump (2A), when pivotally operated, alters the angle of the slanting plate of the pump (2A) to thereby steplessly vary the number of revolutions of the motor (2C) rotating in either a forward or reverse direction, thus giving a steplessly variable forward or reverse running speed.
FIGS. 2 to 4 show the wheel transmission mechanism (4) in greater detail. An output shaft (12) of the motor (2C) of the hydraulic stepless speed change mechanism (2) extends into the transmission case (7) and carries a gear (12a) meshable with a gear (13a) mounted on a front end of a first drive shaft (13) for the wheel system. Mounted on the rear end of the first drive shaft (13) is a gear (27a), which comprises a part of a change mechanism (C) described hereinafter. A second transmission shaft (14) has a gear (14a) meshable with the gear (27a). A third transmission shaft (17) has a bevel gear (17a) meshable with a differential gear (16) for rear wheels (15). The first drive shaft (13) is in alignment with the third transmission shaft (17). A splined portion of the third transmission shaft (17) is provided with a slidable shift gear (17b) including gear portions (17b1) and (17b2) integral therewith and meshable with large and small gears (14b) and (14c) respectively which are mounted on the second transmission shaft (14). As shown in FIG. 3, a gear (17c) on a rear portion of the third transmission shaft (17) is meshable with a gear (18a) which is slidably mounted on a splined portion of a front wheel drive shaft 18. The front wheel drive shaft (18) extends through, and projects forward from, the hydraulic stepless speed change mechanism (2). The front wheel drive shaft (18) is coupled by a universal joint (22) to a front wheel transmission shaft (21) extending rearwardly upward from a gear case (20) for the front wheels (19).
The shift gear (17b) on the third transmission shaft (17) is slidable axially thereof to selectively provide a first state in which the gear (17b) meshes with the large gear (14b) on the first transmission shaft (14) or a second state in which the gear (17b) meshes with the small gear (14c), thus giving a low or high running speed in a changeover fashion.
The gear (18a) on the front wheel drive shaft (18) is shiftable to provide a first state in which it meshes with the gear (17c) on the third transmission shaft (17) or alternatively a second state in which it is out of engagement with the gear (17c). These two gears (18a) and (17c) constitute a clutch (23). When the tractor is adapted for four-wheel drive or rear-wheel drive selectively, the tractor is usable as a tractor of the four-wheel drive type when running in a paddy field or on soft ground.
Alternatively a clutch may be provided at an intermediate portion of the front wheel transmission shaft (21).
The front wheel drive shaft (18) may comprise two separate segments, one extending through the hydraulic stepless speed change mechanism (2) and the other positioned within the transmission case (7), with a coupling (18') connecting these two segments together.
A transmission line from the gears (17c) on the third transmission shaft (17) to the rear wheels (15) and to the front wheels (19) is called a running device (X) herein. A transmission shaft assembly (Y) is constituted by the first transmission shaft (13), the second transmission shaft (14) and the third transmission shaft (17). Further, a coupling mechanism (A) is constituted by the above mentioned gears, the transmission shaft assembly (Y) and other elements in connection therewith.
The PTO transmission mechanism (6) has the following construction. A tubular PTO input shaft (24) loosely mounted on the first drive shaft (13) of the wheel transmission mechanism (4) has a gear (24a) meshable with a gear (11a) on an extended portion (11') of the input shaft (11) extending from the hydraulic stepless speed change mechanism (2) into the transmission case (7). The PTO shaft (5) carriers a gear (5a) meshable with a gear (25a) on a transmission shaft (25) which is provided with a clutch (26) at its intermediate portion. A shift gear (25b) mounted on a splined portion of the transmission shaft (25) is axially slidable thereof and includes gear portions (25b1) and (25b2) respectively meshable with large and small gears (24b) and (24c) formed on the tubular shaft (24). The shift gear (25b) is shiftable to a first state in which it meshes with the large gear (24b) of the tubular shaft (24) or alternatively to a second state in which it meshes with the small gear (24c) to drive the PTO shaft (5) at a high or low speed selectively.
A further coupling mechanism (B) is constituted by the tubular shaft (24), the gear (25b), the transmission shaft (25), the gears (25a), (5a) and other elements in connection therewith, which are arranged for transmitting power from the extended portion (11') to the PTO shaft (5).
According to the present invention, the hydraulic stepless speed change mechanism (2) is fixed to the rear wall of the transmission (7), in which the extended portion (11'), the output shaft (12) and both the coupling mechanisms (A), (B) are housed. A transmission change mechanism (C) is provided at an intermediate portion of the transmission shaft assembly (Y) from the output shaft (12) to the running device (X), or at a rear end portion of the first transmission shaft (13). The transmission change mechanism (C) is constituted by a shift gear (27) having a gear portion (27a) meshed with the gear (14a) on the second transmission shaft (14) and a further gear portion (27b) meshed with an inner gear (24d) formed with the tubular shaft (24). The shift gear (27) is axially shiftable along the first transmission shaft 13 to provide a first state in which a splined inner surface of the rear gear portion (27a) is meshed with a corresponding splined portion of the first transmission shaft (13) and rotatable therewith (Thereby, the transmission mechanism (4) is operated as described hereinafter and the speed of the running device (X) is steplessly changed by a hydraulic power.), and a second state in which the front gear portion (27b) is meshed with the inner gear (24d) formed at the rear end of the tubular shaft (24).
In the second state, coupling between the first transmission shaft (13) and the second transmission shaft (14) is released since the shift gear (27) departs from the splined portion of the first transmission shaft (13). Namely, the hydraulic drive is cut. Further, the rotational power of the extended portion (11') is mechanically transmitted to the second transmission shaft (14) via the tubular shaft (24), the gear portion (27b), the gear portion (27a), and the gear (14a). Power is transmitted from the second transmission shaft (14) to the rear wheels (14) and to the front wheels (19) in the same manner as described hereinbefore. Accordingly, when the hydraulic stepless speed change mechanism (2) is in trouble, as an emergency measure, it is possible to continue running of the tractor by operating the transmission change mechanism (C) into the second state. FIG. 2 also shows a needle bearing (28) disposed between the first transmission shaft (13) and the shift gear (27), and a hydraulic cylinder (30) for the lift arm (10).
The construction as mentioned above may be shown in block diagram form in FIG. 6 with relation to FIG. 8 showing the prior art.
The transmission change mechanism (C) may be disposed on the second transmission shaft (14). Namely, as shown in FIG. 7, the second transmission shaft (14) is extended forward and the extended end is rotatably supported (in a disconnected state) by the rear end of the extended portion (11'). A shift gear (29) having a gear portion (29a) meshable with the gear (13b) (This corresponds to the gear portion (27b) as mentioned above.) formed at the rear end of the first transmission shaft (13) and another gear portion (29b) meshable with the gear (24b) on the tubular shaft (24), is in spline engagement with the second transmission shaft (14). By shifting the shift gear (29), there is provided a first state in which the rear gear portion (29a) is meshed with the gear (13b) (Thereby, the speed of the running device (X) is steplessly changed by a hydraulic power.) and a second state in which the front gear portion (29b) is meshed with the gear (24b) and the gear portion (29a) is disconnected with the gear (13b).
In the second state, the hydraulic power is cut and the running device (X) is mechanically driven by the extended portion (11').
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A tractor for agriculture comprising an engine, a hydraulic stepless speed change mechanism having an output shaft, an input shaft connecting the engine with the hydraulic stepless speed change mechanism and having an extended portion, a PTO shaft connected in association with the extended portion, a running device, a transmission shaft connected in association with the output shaft, and a transmission change mechanism disposed at an intermediate portion of the transmission shaft, said transmission change mechanism being connectable and disconnectable of power transmission from the output shaft to the running device and capable of power transmission from the extended portion to the running device when said power transmission from the output shaft to the running device is cut. The tractor may be running even if the hydraulic stepless speed change mechanism is in trouble.
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This is a continuation of copending application Ser. No. 08/799,240 filed Feb. 14, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure relates to the non-invasive application of ultrasonic energy to enhance and/or accelerate the process of wound healing, and more particular, to the healing of wounds including ulcers, such as venous ulcers.
2. Description of the Related Art
Venous ulcers on human legs have proven difficult to treat, for example, because of the lack of vascularization in and around the wound.
The term "wound" for the purposes of "wound healing", as used throughout the present disclosure, includes ulcers such as venous ulcers as well as burns, ulcerated wounds due to, for example, diabetes, surgical incisions or other surgical cuttings including stitched surgical cuttings, skin grafts, hair transplants, re-vascularization, bed sores, tissue dehiscence, and ligament and tendon repair and reconstruction. In general, as used throughout the present disclosure, the term "wound healing" encompasses addressing damage to, repair of, or restoration of soft tissue.
U.S. Pat. No. 4,530,360 to Duarte (hereafter "Duarte"), describes a basic therapeutic technique and apparatus for applying ultrasonic pulses from an ultrasonic applicator placed on the skin at a location adjacent a bone injury. Duarte gives a range of radio frequency (RF) signals for creating the ultrasound, ultrasonic power density levels, a range of duration of each ultrasonic pulse, and a range of ultrasonic pulse frequencies. The length of daily treatment is also described in Duarte. The Duarte patent is incorporated herein by reference.
U.S. Pat. Nos. 5,003,965 and 5,186,162, both to Talish and Lifshey (hereafter "Talish '965" and "Talish '162", respectively) describe an ultrasonic delivery system in which the RF generator and transducer are both part of a modular applicator unit which is placed at the skin location. The signals controlling the duration of ultrasonic pulses and the pulse repetition frequency are generated apart from the applicator unit. Talish '965 and Talish '162 also describe fixture apparatus for attaching the applicator unit so that the operative surface is adjacent to the skin location. In one application described in Talish '965 and Talish '162, the skin is surrounded by a cast.
5,211,160 to Talish and Lifshey (hereafter "Talish '160") also describes a fixture apparatus which is mounted on uncovered body parts; i.e. without a cast or other medical wrapping. Talish '160 also describes various improvements to the applicator unit. Each of Talish '965, Talish '162, and Talish '160 is incorporated herein by reference.
U.S. patent application Ser. No. 08/388,971 entitled Locator Method and Apparatus and 5,626,554 to Ryaby, Talish and McCabe (hereafter "Ryaby '554"), 5,556,372 to Talish, Ryaby, Scowen and Urgovitch (hereafter "Talish '372"), and 5,520,612 to Winder, Talish and Ryaby (hereafter "Winder '612"), entitled Gel Containment Structure, Apparatus for Ultrasonic Bone Treatment, and Acoustic System for Bone-fracture Therapy, respectively, provides ultrasonic apparatus and methods which are applicable to wound healing. U.S. patent application Ser. No. 08/388,971 and Ryaby '554, Talish '372, and Winder '612 are incorporated herein by reference.
In general, an ultrasound carrier frequency between 20 kHz and 10 MHz coupled with a relatively low-frequency modulating signal, such as 5 Hz to 10 kHz, and a spatial peak temporal average acoustic intensity, such as an intensity less than about 100 milliwatts/cm 2 , should aid in and should be effective in wound healing.
Heretofore, such techniques have not been applied to heal wounds by internal application of ultrasound, such as using reflection of ultrasonic waves by reflection from internal tissue such as bone.
SUMMARY
It is herein recognized that both longitudinally propagating ultrasound and shear waves generated by a transducer mechanism and/or by such longitudinally propagating ultrasound provide effective healing of wounds.
A portable therapeutic device and method of use thereof for healing a wound includes a transducer having an operative surface, with the transducer, disposed substantially adjacent to the wound to emit ultrasound to propagate in the direction of the wound for the healing thereof. Reflections of the ultrasound by bone tissue and by skin layers propagate toward the wound as longitudinal waves for the healing thereof, and shear waves are generated by the longitudinal waves and/or the reflected longitudinal waves for the healing of the wound.
The transducer may include an axis and a focusing element for focusing the propagation of the ultrasound at a predetermined angle with respect to the axis, with the focused ultrasound propagating toward the wound for the healing thereof.
Alternative configurations of the operative surface of the transducer include an annularly shaped operative surface for emitting the ultrasound therefrom, with the wound encircled by the operative surface for receiving the ultrasound and/or reflected ultrasound.
A housing may be provided for positioning the transducer substantially adjacent to a portion of the skin substantially adjacent to the wound, and for causing the portion of the skin to form a cavity, with the operative surface of the transducer disposed in the cavity to emit the ultrasound to an internal surface of the wound for the healing thereof.
Reflective media may be internally disposed within the body having the wound for reflecting the ultrasound from the transducer to propagate toward the wound for the healing thereof. Fixture structures, extending about a portion of the body having the wound, may also be provided for positioning the transducer substantially adjacent to the skin substantially adjacent to the wound. The fixture structure may include an adjustable strap.
In other embodiments, the transducer may be a rod-shaped operative surface having an axis for emitting the ultrasound radially toward the wound for the healing thereof.
Using the disclosed therapeutic devices, wounds are safely and simply treated, with such wounds as venous ulcers responsive to therapeutic ultrasound to be healed effectively. Such therapeutic devices and methods of use provide for wound treatment by modest adaption of existing devices for delivering ultrasound in therapeutic settings.
In one embodiment, a device is provided for delivering an ultra-high-frequency carrier signal for low power excitation of an acoustic transducer which is acoustically coupled to a limb or other part of a living body. The transducer is positioned adjacent an external skin location in the vicinity of the external border of the wound on the skin to provide a surgical, non-invasive transcutaneous delivery of at least part of its acoustic energy directed from the external skin location toward a portion of a bone located within the body in the vicinity of the boundary of the wound internal to the body. The boundary of the wound internal to the body is also referred to herein as the internal or interior surface of the wound.
Once the acoustic energy enters the body, it passes into internal body tissue and/or fluids. The acoustic energy, in the form of ultrasonic pulses, is reflected off the surface of underlying bone or other ultrasound reflective material, and the reflected ultrasound travels toward at least part of the internal surface or underside of the wound. Healing of the wound at the internal surface by the generation of epithelial cells is enhanced via the acoustic stimulation.
Preferably, a low frequency signal which is present as a modulation of the carrier frequency is transmitted from the ultrasonic transducer, through interposed soft tissue, and onto the surface of the bone. The carrier wave incident on the bone surface, or other reflection surfaces in the body, is reflected toward the internal surface of the wound. When the carrier wave impinges the internal surface of the wound, at least a portion of the carrier wave is converted into therapeutically beneficial shear waves of acoustic energy, flooding a region of the internal surface of the wound. The shear waves increase vascularization at the internal surface of the wound, thus enhancing growth of epithelial cells. The epithelial cell growth represents healing of the wound. The technique thus promotes healing of the wound from the internal surface of the wound.
The number, position, and size of ultrasonic applicators used at the external skin location are chosen based on the size and position of the wound, and the relative position and proximity of the bone from which the ultrasonic waves are reflected. One or more ultrasonic therapy treatments per day, each having a duration of approximately 20 minutes, is suitable.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the disclosed therapeutic ultrasound apparatus and method will become more readily apparent and may be better understood by referring to the following detailed description of an illustrative embodiment of the present invention, taken in conjunction with the accompanying drawings, where:
FIG. 1 is a cut-away perspective view showing a device and method of use thereof for wound healing;
FIG. 2 is a side view of an embodiment of an ultrasound transducer;
FIG. 3 is a side cross-sectional view of the device using a focusing attachment;
FIG. 3A is a cut-away perspective view of an alternative embodiment of the transducer configured to have an annular shape and a woven fabric covering;
FIG. 4 is a frontal view of a typical wound disposed on a torso;
FIG. 5 is a cut-away perspective view of the wound healing device disposed near the wound in the torso;
FIG. 6 is a cut-away perspective view of the wound healing device applied to a wound in conjunction with a gel bladder;
FIG. 7 is a cut-away perspective view of the wound healing device causing an indentation of the torso to orient the transducer for healing the wound;
FIG. 8 is a cut-away perspective view of the wound healing device operating in conjunction with an internally disposed reflecting medium;
FIG. 9 is a cut-away perspective view of an alternative configuration of the wound healing device having an annular configuration and a woven fabric covering and operating in conjunction with an internally disposed reflecting medium;
FIG. 10 is a cut-away perspective view of an alternative configuration of the wound healing device having a rod-like configuration;
FIG. 11 is a cut-away perspective view of an alternative configuration of the wound healing device having an annular configuration without a woven fabric covering; and
FIG. 12 is a perspective view of an alternative configuration of the wound healing device attachable to a thigh for healing a wound thereupon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in specific detail to the drawings, with like reference numerals identifying similar or identical elements, as shown in FIG. 1, the present disclosure describes an apparatus 10 and method of use thereof for wound healing, which includes an ultrasonic generator 12 and one or more ultrasonic applicators 14, which include ultrasonic transducers 16 known in the art, for applying ultrasonic waves 18, 20 to a wound 22, such as an ulcer. More than one applicator 14 or transducer 16 may be used to stimulate larger wounds, as needed. The spatial peak temporal average acoustic intensity of the applicators 14 is between about 5 mW/cm 2 and about 100 mW/cm 2 . The carrier frequency and intensity of the ultrasonic treatment is selected by taking into account such factors as: (1) the amount of soft tissue interposed between the external skin location, where the ultrasonic applicator 14 is positioned, (2) the position and cross-section of the bone site 24 from which the ultrasonic waves 18 are reflected, (3) the amount of soft tissue interposed between the bone 26 and the internal surface 28 of the wound 20, and (4) the size, topography and medical characteristics of the internal surface 28 of the wound 20, and, consequently, shear waves or surface acoustic waves (SAW) and longitudinal waves to be generated at the site.
The carrier wave is modulated with an audio signal approximately between 5 Hz and 10 Khz. Low level ultrasound delivers a primary wave called the longitudinal wave 30, which is emitted by the transducer 16 of the applicator 14 as shown in FIG. 1. There are also shear waves or SAW 32 generated by the ultrasound from the transducer 16 which radiate outward along the skin surface. The primary longitudinal wave 30 is partially incident on a bone 26 in the body, and so is partially reflected at a reflection site 24 to generate a reflected portion 34, with the reflected portion 34 directed toward the internal surface 28 of the wound 22. The primary longitudinal wave 30 may also be reflected by other surfaces. For example, as shown in FIG. 1, the internal layer 36 of skin on the opposite side of a limb to the transducer 16 may provide a reflective surface to thus generate additional reflected longitudinal waves 38 directed from the opposite internal skin layer 36 to the wound 22.
When the reflected longitudinal waves 34, 38 impinge on the internal surface 28 of the wound 22, such reflected longitudinal waves 34, 38 are at least partially converted to shear waves or SAW 32 in and around the internal surface 28 of the wound 22, which enhance wound healing at the internal surface 28 by stimulating cell production by the mesenchymal line, thus promoting vascularization and epithelialization.
As shown in the illustrative embodiment in FIG. 1, the ultrasonic applicator 14, including the transducer 16 configured as a modular unit, is placed adjacent an external skin location 40 in the vicinity of the external border of the wound 22. A gel bladder 42, or alternatively a loose conducting gel or other ultrasound conducting media, is positioned between the transducer 16 and the external skin location 40. As shown in FIG. 1, the ultrasound which is transmitted into the soft tissue medium in the form of longitudinal waves 30 diverges as it moves toward the bone 26 or other surfaces such as the skin layer 36 providing reflection. The reflected ultrasound, in the form of longitudinal waves 34, 38, continues to diverge as it approaches the internal surface 28 of the wound 22, so that the ultrasonic treatment delivered to the general site of the wound 22 covers a relatively large region of the internal surface 28 of the wound 22.
Alternatively, as shown in FIG. 2, the transducer 16 may have an attachment, typically positioned between the operative surface 46 of the transducer 16 and the gel bladder 42, which acts as a focusing element to focus the ultrasound emitted from the operative surface 46 into the soft tissue. In another embodiment, the transducer 16 may be configured to have the focusing element integrally formed with the transducer 16. FIG. 3 shows a side view of the transducer housing of FIG. 2 showing the transducer 16 including the focusing element, illustratively embodied as the attachment 44. Thus, the ultrasound emitted from the transducer 16 in the form of a primary longitudinal wave 30 may be directed at an angle 48 with respect to an axis 50 associated with the transducer and thence toward the bone 26 or other reflective surfaces when the ultrasound enters the soft tissue. The reflected waves 34, 38 also remain relatively focused.
The reflected longitudinal waves 34, 38 may generate respective sets of shear waves or SAW for providing a combined therapeutic treatment to the wound 22. As shown in FIG. 3, the reflected longitudinal wave 34 created by reflection of the primary longitudinal wave 30 off the bone 26 is incident on a portion of the internal surface 28 of the wound 22, thus creating a first set of shear waves 52. The reflected longitudinal wave 38 created by the reflection of the primary longitudinal wave 30 off the opposite side layer 36 of tissue is incident on a separate portion of the wound 22, thus creating a second set of shear waves 54. In addition to this technique, the angle 48 of the ultrasonic emission may be swept and/or modified, either physically or electronically, so that different regions of the internal wound surface 28 may be treated.
In either technique, two or more transducers may be used, as determined by the size, length, etc. of the wound 22. Generally, multiple transducers may be provided at a number of external skin locations around the wound 22 in order to increase the effectiveness of the ultrasonic therapy reflected to the internal surface 28 of the wound 22.
In the illustrative embodiments of FIGS. 1-3, the ultrasonic head module of the ultrasonic applicator 14 includes the transducer 16 of an ultrasonic treatment apparatus. For clarity, the fixture structure which holds the head module adjacent the external skin location 40 is omitted. Also omitted are the electronics and other features which ultimately provide the excitation signals for the transducer 16. These are described in further detail in the above-referenced patents and patent applications, which have been incorporated by reference.
Alternatively, or in conjunction, the at least one ultrasonic applicator 14 may be moved, or may be configured to be movable, to a different external skin location adjacent the wound 22 in order to provide treatment to various portions of the wound 22. Varying the position of the at least one ultrasonic applicator, including moving the transducer 16 circularly or linearly along the skin, also provides treatment of varying intensity at portions of the wound 22.
The transducer 16 itself may also be configured to vibrate with respect to a given external skin location, so that the longitudinal waves 30 generated therefrom and transmitted through the soft tissue are more uniform, thus providing more uniform treatment, including more uniform shear waves, at the internal wound surface 28 where the reflected longitudinal waves 34, 38 impinge. The transducer 16 may be made to vibrate with respect to a housing (not shown in FIGS. 1-3 for clarity) which holds the transducer 16 adjacent an external skin location to accomplish such uniformity of longitudinal waves 30.
The focusing of ultrasonic waves described with respect to FIGS. 2-3 above is illustratively shown with a substantially planar operative surface 46 and a substantially conical attachment 44. In alternative embodiments, the focusing of ultrasonic waves may be provided by configuring the transducer 16 with non-planar surfaces such as non-planar operative surfaces or non-planar segments to generate and emit ultrasound with different propagation characteristics in order to allow differing patterns and intensities of ultrasonic waves to be transmitted toward the internal surface 28 of the wound 22. This provides a variety of therapeutic ultrasonic stimulation and treatment at the internal surface 28.
For example, the transducer segments may be pie shaped, annular rings, or other configurations, which may be activated separately or in unison. Alternatively, or in conjunction, the transducer 16 may be provided with a modal converter or transducer lens, which may also change the pattern of the ultrasound emitted from the transducer 16.
The carrier frequency and/or the modulating frequency may also be varied or swept through a range of frequencies in order to provide a variety of treatments to the internal wound surface 28. The frequencies may be varied either in a continuous manner, or discrete changes may be made in the applied frequency. Varying the carrier and/or modulating frequency is especially useful in applying ultrasonic treatment to promote a variety of stages of cell regeneration in approximately the same region during the same therapy session.
In an alternative embodiment, FIG. 3A illustrates treatment of a wound 22 such as a venous ulcer as in FIGS. 1-3, but utilizing an annular-shaped transducer 56 having a curved operative surface 58 (shown in a cut-away perspective view in FIG. 3A) composed of a composite piezoelectric material attached by a connector 60 to an ultrasonic generator (not shown in FIG. 3A), in which the composite piezoelectric material disposed in a woven fabric 62 or a semi-permeable member provides ultrasonic conductivity between the transducer 56 and the skin of the patient. The woven fabric 60 may have either a hard or a pliable construction, and may be composed of material conductive of ultrasound. Alternatively, the woven fabric 60 may be porous for retaining and releasing ultrasound conductive gel.
The transducer 56 is cut or constructed to surround the external surface of the wound 22. When the appropriate RF signals are applied, the composite piezoelectric material of the transducer 56 emits ultrasonic waves having the therapeutic parameters previously described. Primary longitudinal waves 64, 66 are emitted from the composite piezoelectric material into the body, as shown in FIG. 3A, and reflected from the surface of the bone 26 or from other reflective interfaces, to generate reflected longitudinal waves 68, 70, respectively, which are directed onto the internal surface 28 of the wound 22, thus creating therapeutic shear waves 72, 74, respectively. It is understood that the composite piezoelectric material may completely surround the wound 22; thus, the primary longitudinal waves 64, 66 are emitted from around the entire wound, reflected from the reflecting material, and incident on the internal surface 28 of the wound 22, thereby flooding the internal surface 28 of the wound 22 with the induced shear waves 72, 74.
While the embodiments of the present invention described above refer to the reflection of a primary longitudinal wave from a bone to an internal surface of a wound, the present invention also encompasses delivery of ultrasound to the internal surface of the wound where there is no bone or other reflecting surface in the vicinity of the wound, as described below in further detail with reference to FIGS. 4-11.
FIG. 4 illustrates the front of a male torso 76 having a wound 78 on the stomach. The views illustrated in FIGS. 5-11 are cross-sectional views of FIG. 4 taken across lines 5--5. As shown in FIG. 5, a transducer 80 is positioned in a transducer housing 82 disposed upon the external skin of the torso 76 adjacent to the external border of the wound 78, and a longitudinal wave 84 emitted from the transducer 80 penetrates far into the body before it is reflected off a surface internal to the torso 76 such as the spine or any internal organs such as the lungs, stomach, or intestines, which may contain gases such as air, with reflected longitudinal waves then directed onto the internal surface 86 of the wound 78. This is especially true when the person is overweight, or when the cross-section of available reflecting surfaces is small and/or uneven. The longitudinal wave 84 may provide some therapeutic healing of the wound 78, but the intensity of the reflected wave incident on the internal surface 86 of the wound 78 may be too attenuated to provide the necessary therapeutic treatment.
FIG. 6 shows an alternative method and embodiment of treating such wounds of the torso 76, in which a gel bladder 88 is interposed between the external surface of the wound 78 and the operative surface of the transducer 80. The longitudinal wave 84 emitted from the transducer 80 travels directly through the gel bladder 88 and into the wound 78, thus creating a shear wave 90 when the longitudinal wave 84 is incident on the internal surface of the wound 78. The gel bladder 88 is to be sterile, especially if the wound 78 is open, and may be impregnated with medication, such as an antibacterial ointment, which flows into the wound 78 and/or its surface during the ultrasonic treatment.
FIG. 7 illustrates another method and device for treating the wound 78 of a torso 76, in which the transducer 80 is pressed against the external surface of the lower torso, such as approximately adjacent the stomach, to be positioned near the wound 78. By pressing the transducer housing 82 against the external region of the stomach, a local indentation 92 is created. The transducer housing 82 may be turned as it is pressed inward, so that the operative surface 94 of the transducer 80 is directed in the general direction toward the internal surface 96 of the wound 78 within the indentation 92. As shown, the longitudinal wave 98 emitted is incident directly on at least a portion of the internal surface 96 of the wound 78, thus inducing therapeutic shear waves 100. If a specially configured transducer, or alternatively a transducer attachment 102, is used, such as shown in FIG. 3, for focusing the ultrasound in a specific direction, the longitudinal wave 98 may be emitted off of a center axis 104 of the transducer 80, for example, in a direction toward the internal surface 96 of the wound 78, without the need for turning the transducer housing 82 as it is pressed against the skin.
FIG. 8 illustrates another method and device for treating a wound 78, in which a reflecting medium 106 is inserted into the body in the proximity of the internal surface 96 of the wound 78. The properties of the reflecting medium 106 provide for the reflection of the longitudinal wave 108 toward the internal surface 96 of the wound 96, as if a bone were present, such as described above with reference to FIGS. 1-3A. The reflecting medium 106 may be composed of a variety of materials, and may be fixed in the body or inserted temporarily. For example, the reflecting medium 106 may be a metallic plate, a gas filled pouch, or other quasi-permanent inserts. The reflecting medium 106 may be also be, for example, a contrast agent composed of, for example, bubbles in a gelatin, which is injected intravenously prior to the treatment. In one embodiment, the contrast agent may be absorbable by the body in a relatively short period, thus the contrast agent acts as a temporarily inserted reflecting medium.
An inserted reflecting medium 106, as described with respect to FIG. 8 above, performs particularly well in conjunction with a piezoelectric ultrasonic material or device. As shown in FIG. 9, the piezoelectric ultrasonic device 110 may be embodied as the device 56 described above with respect to FIG. 3A. The piezoelectric ultrasonic device 110 may be configured to surround the exterior boundary of the wound 78. As shown in FIG. 9, illustrative examples of the longitudinal waves 112, 114 generated from the piezoelectric ultrasonic device 110 surrounding the wound 78 are reflected off of an internally disposed medium 116 and onto the internal surface 96 of the wound 78, thereby generating therapeutic shear waves (not shown in FIG. 9) at the internal surface 96 of the wound 78. It is understood that the piezoelectric ultrasonic device 110 completely surrounds the wound 78; thus, longitudinal waves not limited to the illustrative examples of longitudinal waves 112, 114 are emitted around the entire wound 78, reflected from the reflecting material 116, and incident on the internal surface 96 of the wound 78, to flood the internal surface 96 of the wound 78 with induced shear waves.
In an alternative embodiment shown in FIG. 10, an ultrasonic transmitting rod 118 is provided which emits at least one longitudinal wave 120 radially from the axis of the ultrasonic transmitting rod 118. The rod 118 may be composed of, for example, a composite piezoelectric material, and the rod 118 is secured to the patient by a harness apparatus 122, 124 such that the rod 118 is pressed against the skin adjacent the wound 10, and a portion of the longitudinal wave 120 is incident on the internal surface 96 of the wound 78, thus inducing therapeutic shear waves (not shown in FIG. 10).
In another alternative embodiment shown in FIG. 11, an ultrasonic transmitting ring 126 is provided which emits longitudinal waves 128, 130 radially from the surface of the ring 126. The ring may be composed of, for example, a composite piezoelectric material, and may be configured in a manner similar to the piezoelectric ultrasonic devices 56 and 110 in FIGS. 3A and 9, respectively, without the woven fabric to act as an ultrasonic conductor. Accordingly, ultrasonic conductive gel may be used with the ring 126 of FIG. 11. With the ring pressed against the skin surrounding the wound 78, a portion of the longitudinal waves 128, 130 emitted from the ring 126 is incident on the internal surface 96 of the wound 78, thus inducing therapeutic shear waves 132, 134. It is understood that the ring 126 may be configured to completely surrounds the wound 78; thus, longitudinal waves including the illustrative longitudinal waves 128, 130 are emitted from around the entire wound 78 and incident on the internal surface 96 of the wound 78, to flood the internal surface 96 of the wound 78 with induced shear waves 132, 134.
In an alternative configuration shown in FIG. 12, the wound healing device 136 includes a transducer 138 positioned in a housing 140 which is secured by an adjustable securing structure 142 to a thigh for healing a wound 78 thereupon, with the transducer 138 emitting longitudinal ultrasonic waves 144 which generate shear waves (not shown in FIG. 12) upon contact with the internal surface of the wound 78. In an illustrative embodiment, the adjustable securing structure 142 shown in FIG. 12 includes an adjustable strap 146 having a first portion 148 engaging a second portion 150 using hook and link fasteners. Alternatively, a belt with a buckle and notches may be used, or a sterile adhesive strip for adhering to the thigh.
As noted above, the term "wound" as used herein, has a broad meaning, generally encompassing addressing damage to, repair of, or restoration of soft tissue. The present invention may be used, for example, to prevent surgical adhesions, by stimulating the proper repair of surgical incisions. It may also prevent or arrest wound dehiscence, by promoting vascularization at the surfaces adjacent surgical incisions. It may also be used in cosmetic surgery, for example, by enhancing the healing of hair transplants, or by directly stimulating regeneration of cells.
Accordingly, modifications such as those suggested above, but not limited thereto, are to be considered within the scope of the invention.
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A portable therapeutic device and method of use generate longitudinally propagating ultrasound and shear waves generated by such longitudinally propagating ultrasound to provide effective healing of wounds. A transducer having an operative surface is disposed substantially adjacent to the wound to emit ultrasound to propagate in the direction of the wound to promote healing. Reflections of the ultrasound by bone tissue, by skin layers, or by internally disposed reflective media propagate toward the wound as longitudinal waves, with shear waves generated by the longitudinal waves for the healing of the wound. A focusing element is used for focusing the propagation of the ultrasound at a predetermined angle toward the wound. The operative surface of the transducer may be annularly shaped to encircle the wound to convey the ultrasound and/or reflected ultrasound thereto. A housing may be provided for positioning the transducer near a portion of the skin near the wound, and for indenting the skin to form a cavity, with the transducer disposed in the cavity to emit the ultrasound toward an internal surface of the wound. Fixture structures, such as adjustable straps, may extend about a portion of the body to position the transducer near the wound.
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The invention described herein arose in the course of, or under, Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California.
BACKGROUND OF THE INVENTION
In the construction and operation of certain optical systems such as, for example, laser beam optical transport systems, it is often required that the mirror systems employed in such systems be rapidly adjustable to permit active compensation for beam position jitter due to mechanical system vibration, ground motion, or laser system jitter.
Various provisions have been previously made for the adjustment of mirrors used in optical systems. Shull U.S. Pat. No. 3,953,113 teaches a laser mirror mounting device which provides for the exchangeability of sets of mirrors associated with various wavelengths of operation. The mirror mounting device is positioned within a housing which includes an adjustable internal reference surface for adjustment relative to an external reference surface included with the mirror mounting device. The device also includes support means for supporting a mirror relative to a laser and an adjustment means for adjusting the angular relationship of the mirror relative to the external reference surface.
Thompson U.S. Pat. No. 4,401,288 discloses an optical mirror mount in an upright position on a horizontal surface and which is adjustable in pitch and yaw. The mount includes a bracket having a horizontal leg and a vertical leg. Yaw adjustments are made by loosening mounting screws holding the bracket on a supporting surface and rotating the bracket about the mounting screw extending into the circular mounting hole in the horizontal leg. Pitch adjustments are made by turning an adjusting screw in a flexure spring until the vertical leg of the bracket is at the desired position in pitch.
Horton U.S. Pat. No. 4,293,112 describes apparatus for mounting and aligning an optical element on a support structure which comprises pivot means for mounting the element so that it can rotate about axes in two orthogonal directions and a pair of alignment means, each comprising a plunger and inclined guide groove. Adjustment means such as threaded screws, are provided for urging the plunger along the inclined grooves.
Reeder et al. U.S. Pat. No. 4,442,524 discloses a four-bar alignment adjustment mechanism with elastic hinges to enable the mirrors of a gas laser to be very finely tuned.
Koseki U.S. Pat. No. 4,672,626 describes the adjustment of the rear or output mirror of a laser oscillator by pivoting a laser mirror holder about three pivot points connecting the laser mirror holder and a support bracket. The first and third pivot points form an X-axis about which the holder may be rotated and the second and third pivot points form a Y-axis about which the holder may be rotated. The first and second pivot points are mounted so as to displace the holder in a direction parallel to the central longitudinal axis of the holder. Two control motors are disposed with their actuating shafts transverse to the central longitudinal of the laser mirror holder, at opposite sides of the holder and act against the first and second pivot points to adjust the angular alignment of the laser mirrors.
Koop U.S. Pat. No. 4,796,275 discloses a floating mirror mount in which a resiliently biased spring plate biases the mirror against a peripheral flange of a keeper while permitting the mirror to be lifted off the flange of the keeper when the front surface of the mirror is engaged by mirror positioning structure of a laser in the course of installing the mirror mount in a laser.
Great Britain Patent 2,059,143 describes a deformable support structure for supporting a controllable mirror for a laser. The support structure comprises a rim and a center post joined together by two spaced apart flexible membranes. Piezo-electric ceramic wafers are coupled to the support to provide adjustment of the mirror.
Russian Patent Abstract SU-901-968 describes the use of moving and stationary radially displaced discs interconnected by a screw thread in a gas laser optical system adjustment mechanism.
Tarabocchia et al., in an article entitled "Intracavity Tip and Tilt Adaptive Control Experiments" published in the Proceedings of the Society of Photo-Optical Instrumentation Engineers, Vol. 141 (1978), pp. 20-25, describe the use of a 2-axis tip and tilt dynamic mirror mount developed at Stanford Research Institute.
However, there remains a need for an adjustable mirror system capable of rapid adjustment with very little force so that an increased frequency of mirror compensation can be applied for beam jitter. There also remains a need for an adjustable mirror system wherein adjustment in either the X or Y axes may be made with a minimum of crosstalk between the axes.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an adjustable mirror mount system for a mirror comprising a mirror support having a planar surface thereon, a mirror frame containing a mirror and having a planar surface behind the mirror facing the planar surface of the mirror support and parallel to the reflecting surface of the mirror and mounted pivotally to the mirror support at a point central to the frame, a first adjustment means between the mirror support and the mirror frame spaced from the central pivot mount for adjusting the movement of the mirror along one axis lying in the plane of the planar surface of the mirror frame; and a second adjustment means between the mirror support and the mirror frame spaced from the central pivot mount for adjusting the movement of the mirror along a second axis lying in the plane of the planar surface of the mirror frame and perpendicular to the first axis.
It is another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the central pivot mount comprises a sphere partially received in a central conical opening in the planar surface of the end wall of the mirror frame, the conical opening having a smaller diameter than the sphere and having its center axis coaxial to the center axis of the mirror frame; and the mirror support also has a conical opening therein of smaller diameter than the sphere and which also partially receives the sphere.
It is still another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the first adjustment means comprise first yieldable means coupled between the mirror frame and the mirror support for biasing the mirror frame toward the mirror support, and first adjustable driver means mounted to the mirror support and in contact with the mirror frame to resist the bias of the first yieldable bias means; and the second adjustment means comprise second yieldable means coupled between the mirror frame and the mirror support for biasing the mirror frame toward the mirror support and second adjustable driver means mounted to the mirror support and in contact with the mirror frame to resist the bias of the second yieldable bias means; to thereby provide adjustment of the mirror in both the X and Y axes of the plane of the reflective surface.
It is still a further object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the center of the sphere comprising the central pivot mount, and the contact point between the first adjustable driver means and the mirror frame lie in a first plane perpendicular to the plane of the reflecting surface of the mirror; and the center of the sphere comprising the central pivot mount, and the contact point between the second adjustable driver means and the mirror frame lie in a second plane also perpendicular to the plane of the reflecting surface of the mirror and perpendicular to the first plane.
It is another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the attachment point of the first yieldable means to the mirror frame, the contact point between the first adjustable driver means and the mirror frame, and the center of the sphere comprising the central pivot mount all lie in a first plane perpendicular to the plane of the reflecting surface of the mirror; and the attachment point of the second yieldable means to the mirror frame, the contact point between the second adjustable driver means and the mirror frame, and the center of the sphere lie in a second plane also perpendicular to the plane of the reflecting surface of the mirror and perpendicular to the first plane.
It is yet a further object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the first adjustable driver means is provided with a hemispherical end portion in contact with the planar surface of the mirror frame; and the radius of the hemispherical end portion is equal to the radius of the sphere comprising the central pivot mount less the distance which the sphere extends into the conical bore, whereby the center of the hemispherical end portion of said first adjustable driver means and the center of the sphere will lie in a plane parallel to the plane of the reflective surface of the mirror.
It is another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the second adjustable driver means is also provided with a hemispherical end portion and the second hemispherical end portion is received in a groove formed in the planar surface of the mirror frame, whereby rotation of the mirror frame in the plane of the reflective surface of the mirror is inhibited.
It is still another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein the radius of the second hemispherical end portion less the distance which the hemispherical end portion extends into the groove is equal to the radius of the sphere comprising the central pivot mount less the distance which the sphere extends into the conical bore in the planar surface of the mirror frame; whereby the center of the hemispherical end portion of the second adjustable driver means and the center of the sphere will also lie in a plane parallel to the plane of the reflective surface of the mirror.
It is yet another object of the invention to provide an adjustable mirror mount apparatus similar to that described, but wherein first transducer means are operationally connected to the first adjustable driver means to adjust the mirror in one axis of the plane of the reflective surface of the mirror; and second transducer means are operationally connected to the second adjustable driver means to adjust the mirror in the other axis of the plane of the reflective surface of the mirror.
These and other objects of the invention will be apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is vertical cross-sectional view of the adjustable mirror mounting apparatus showing the vertical mirror adjusting means.
FIG. 2 is a sectioned view looking down from the top of the apparatus showing the horizontal mirror adjusting means.
FIG. 3 is a vertical view of the rear of the mirror frame, showing a groove formed to receive a portion of the horizontal mirror adjusting means to inhibit rotation of the mirror and mirror frame.
FIG. 3A is a fragmentary side section view of a portion of FIG. 3 taken at lines 3A--3A to show the fit of the hemispherical head in the v-shaped groove.
FIG. 4 is a front view of the mirror illustrating the respective alignment, along the vertical and horizontal axes of the mirror, of the vertical and horizontal adjustment means with the center of the mirror.
FIG. 5 is a fragmentary view of a portion of the adjustable mirror mounting apparatus illustrating the parallel alignment of a vertical centerline through the center of the pivot ball and the center of the hemispherical vertical adjustment contact with the vertical axis of the mirror.
FIG. 6 is a fragmentary view of a portion of the adjustable mirror mounting apparatus illustrating the parallel alignment of a horizontal centerline through the center of the pivot ball and the center of the hemispherical horizontal adjustment contact with the horizontal axis of the mirror.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, the adjustable mirror mounting apparatus of the invention is generally indicated at 2 comprising a mirror mounting base 10 on which is pivotally mounted, via a pivot ball 30, a cylindrical mirror frame 100 containing a mirror 120. Mirror frame 100 and mirror 120 are pivotally secured to base 10 via biasing means 40 and 50, vertical adjustable driver means 60, and horizontal adjustable driver means 80.
Base 10 of adjustable mirror mounting apparatus 2 comprises a horizontal portion 12 and an upright portion 14. Mounted to one face or surface 16 on upright portion 14 is a mirror frame 100 containing a mirror 120. Mirror frame 100 comprises a side wall 102, which surrounds the sides of mirror 120, and a rear wall 104 having a planar surface 106 thereon which is parallel to the reflective surface of mirror 120 and which faces surface 16 of base 10.
Mirror 120, mirror frame 100, and sidewall 102 may comprise any geometrical shape, provided there is a central point therein which can be used as a central pivot point as will be described below. However, by way of illustration, and not of limitation, mirror 120 and mirror frame 100 will hereinafter be described as circular or cylindrical in shape.
Centrally positioned in planar surface 106 is a conically shaped bore 108. By "centrally positioned" is meant that the axis of the cone of conically shaped bore 108 is coincident with the center axis of cylindrical mirror frame 100, as shown by dotted line 114 in FIG. 1. Preferably, the sides of conically shaped bore 108 are 45° with respect to planar surface 106, so that viewed in cross-section, bore 108 appears to be a 90° v-shaped groove.
Received in conical bore 108 is spherical pivot ball 30 having a diameter larger than the diameter of conical bore 108, i.e., larger than the base defined by conical bore 108 at planar surface 106.
Surface 16 of upright portion 14 of base 10 is similarly provided with a conical bore 18 which may have identical dimensions to conical bore 108 whereby, as shown in FIGS. 1 and 2, surface 16 of base 10 will be spaced from planar surface 106 of mirror frame 100 by spherical ball 30 to thereby permit mirror frame 100 to pivot in either the X or Y axis with respect to base 10.
As previously mentioned, mirror frame 100 and mirror 120 are pivotally secured to base 10 via biasing means 40 and 50, vertical adjustable driver means 60, and horizontal adjustable driver means 80. As shown in FIG. 1, biasing means 40 is illustrated as comprising a metal spring which is received in a horizontal bore 20 in upright portion 14 of base 10, as shown in FIG. 1. Biasing means 40 is secured, at one end 42, to upright portion 14 of base 10 by any convenient securement means such as, for example, pin 44, which is longer than the diameter of bore 20, and therefore may be passed through the looped end 42 of biasing means 40 to facilitate easy disassembly and removal of mirror frame 100 from base 10. Biasing means 40 is secured to planar surface 106 of mirror frame 100 at its opposite end 46 by any convenient securement means such as a screw 48 received in rear wall 104 of mirror frame 100.
Referring to FIG. 2, biasing means 50 is also illustrated as a metal spring which is similarly received in a horizontal bore 22 in upright portion 16 of base 10 and may be secured therein at one end 52 by a pin 54, in similar fashion to the securement of biasing means 40 by pin 44. Biasing means 50 may be secured at its opposite end 56 to planar surface 106 of mirror frame 100 by a screw 58 received in rear wall 104 of mirror frame 100.
It should be noted that while biasing means 40 (and 50) are herein illustrated as comprising metal springs, they may comprise any convenient biasing means such as elastomeric members, e.g., rubber grommets, or dashpots. When a metal spring is used as either biasing means 40 or 50, the stiffness of the spring must be selected, or otherwise adjusted, so that the spring is not too loose, since this may cause the mirror frame to bounce on the adjustment means or adjustable driver means 60 and/or 80. Similar precautions will need to be taken with any other type of biasing means as well.
It is also important that the biasing means (40 or 50) be carefully selected with respect to the resonant frequency of the biasing means (40 or 50) relative to the frequency of operation of the mirror adjustment means. It is preferable to select components such as the biasing means (40 or 50) with a resonant frequency of about 10 times the desired operating frequency. Thus, when the mirror adjustment means will be operated in a moderate band frequency of about 100-500 Hz, the resonant frequency of the biasing means (40 or 50), e.g., the springs should be about 10 times this, or from about 1000-5000 Hz.
A vertical adjustable driver means 60, as shown in FIG. 1, is received in a horizontal bore 24 and reduced diameter counterbore 25 in upright portion 16 of base 10. Vertical adjustment means 60 comprises a rod or piston 62 which is received in counter bore 25 and which is provided with a hemispherical head 64 thereon which makes point contact, at 70, with planar surface 106 of end wall 104 of mirror frame 100. Vertical adjustable driver means 60 operates in cooperation with spring 40 which acts to urge or bias planar surface 106 against hemispherical head 64.
Piston 62 of vertical adjustable driver means 60 is operationally coupled to means for horizontally moving piston toward and away from planar surface 106 such as, for example, a transducer or driver 66 received in bore 24, and which may be connected to a tunable power supply (not shown) which can be operated at a frequency selected to move mirror 120 in its Y axis an exact amount to counter the Y axis jitter in the optical signal being reflected by mirror 120. Transducer 66 may comprise any means capable of imparting physical motion to piston 62 in response to a signal, such as, for example, a voice coil, a piezoelectric device, or a magnetostrictive device.
Piston 62 may be threadedly received in transducer 66 to thereby provide initial gross adjustment of piston 62 against planar surface 106 relative to the spring bias of biasing means 40 so that planar surface 106 is initially aligned, along the Y axis with surface 16 of base 10. Such an initial alignment function could, of course, be automated, for example by motorizing the rotation of threaded piston 62 to initialize the alignment.
Referring now again to FIG. 2, a horizontal adjustable driver means 80, generally similar to vertical adjustable driver means 60, may be mounted in horizontal bore 26 and counterbore 27 in upright portion 14 of base 10. Horizontal adjustment means 80 comprises a piston 82 which fits into counterbore 27 and is provided with a hemispherical head 84 thereon. However, in this instance, hemispherical head 84 does not make point contact with the planar surface 106, but is rather received in a horizontal 90° v-shaped groove 110 formed in rear wall 104 of mirror frame 100 adjacent the edge thereof, as seen in FIGS. 2, 3, and 3A.
The purpose of horizontal groove 110 is to inhibit the rotation of mirror frame 100 and mirror 120 in the Z axis as adjustments are made in the X and Y axes. Since hemispherical head 84 is partially received in horizontal v-shaped groove 110, head 84 is preferably formed having a larger radius than hemispherical head 64, as will be explained below.
As in the case of vertical adjustable driver means 60, horizontal adjustable driver means 80 further comprise means, such as transducer 86, received in bore 26 for moving piston 82 toward and away from planar surface 106 in cooperation with the spring bias of biasing means 50.
Similarly, as previously described with respect to transducer 66, transducer 86 may be connected to a tunable power supply (not shown) which can be operated at a frequency selected to move mirror 120 in its X axis an exact amount to counter the X axis jitter in the optical signal being reflected by mirror 120. As previously described with respect to transducer 66, transducer 86 may comprise any means capable of imparting physical motion to piston 82 in response to a signal.
Piston 82 may be threadedly received in transducer 86 to thereby provide initial gross adjustment of piston 82 against planar surface 106, relative to the spring bias of biasing means 50, so that planar surface 106 is initially aligned along the X axis with surface 16 of base 10. As previously mentioned, such an initial alignment function may be automated, for example, by motorizing the rotation of threaded piston 82.
Turning now to FIG. 4, it is necessary for proper alignment that the center 32 of spherical pivot ball 30 and the contact point 70 of hemispherical head 64 lie in a plane which is perpendicular to the X axis of mirror 120, and similarly that the center 32 of spherical pivot ball 30 and the contact point 90 of hemispherical head 84 lie in a plane perpendicular to the Y axis of mirror 120. Preferably, however, as shown in FIG. 4, it is desirable if the respective contact points of biasing means 40 and 50 also lie in the respective planes just described.
Therefore, as shown in FIG. 4, in a preferred embodiment, contact point 70 of hemispherical head 64, contact point 41 of biasing means 40, and center 32 of spherical ball 30 all lie in a plane which is perpendicular to the plane of planar surface 106, and therefore, perpendicular to the reflective surface of mirror 120, i.e., in the Y-Z plane.
Similarly, in a preferred embodiment the equivalent contact point 90 (equivalent because hemispherical head 84 is received in v-shaped groove 110 and does not, therefore, make a single point contact with end wall 106), contact point 51 of biasing means 50, and center 32 of spherical pivot ball 30 all lie in a second plane (the X-Z plane) which is also perpendicular to the X-Y plane of planar surface 106, as well as perpendicular to the first plane (the Y-Z plane).
Such alignment of the respective contact points of hemispherical heads 64 and 84 of pistons 62 and 82 with the center point 32 of spherical pivot ball 30 and the respective attachment point 41 and 51 of biasing means 40 and 50 reduce the cross-talk between the X and Y axes as respective adjustments are made to each to compensate for the movement of the optical signal being reflected.
Referring now to FIGS. 5 and 6, in a preferred embodiment, cross talk between the X and Y axes is further reduced by parallel alignment, with the plane of planar surface 106, of the centerlines passing respectively through center 32 of spherical pivot ball 30 and the centers of hemispherical heads 64 and 84.
Thus, as shown in FIG. 5, vertical centerline 74 passes through center 32 of spherical pivot ball 30 and through center 65 of hemispherical head 64 is shown as parallel to the Y axis of planar surface 106. This alignment may be accomplished by selecting a radius for hemispherical head 64 equal to the distance from center 32 of spherical pivot ball 30 to the plane of planar surface 106. That is, the radius of hemispherical head 64 must be selected to be smaller than the radius of spherical pivot ball 30 by the amount that spherical pivot ball 30 protrudes into planar surface 106 via conical bore 108, as can be seen in FIG. 5.
However, as shown in FIG. 6, parallel alignment of the X axis of planar surface 106 to horizontal centerline 94, which passes through center 32 of spherical pivot ball 30 and center 85 of hemispherical head 84, is more easily accomplished since hemispherical head 84 protrudes into rear wall 104 of mirror frame 100 similarly to spherical pivot ball 30. Such alignment can then be accomplished by using the same radius for hemispherical head 84 as the radius of spherical pivot ball 30 and then making the depth and slope of v-shaped groove 110 equal to the depth and slope of conical bore 108, e.g., by making both groove 110 and conical bore 108 v-shaped at 90° in cross-section.
While various materials could be used, respectively for base 10, mirror frame 100, spherical pivot ball 30 and hemispherical-headed pistons 62, and 82, it is preferable that all of these components be constructed of low wear materials, preferably a hardened steel material or equivalent.
The adjustable mirror mount apparatus of the invention may be successfully employed with mirrors up to about 3 inches in diameter and used to control mechanical vibrations and other mechanically or electrically generated beam position jitter at frequencies up to about 500 Hz, being capable, without further mechanical adjustment, of providing variations in mirror position of up to about 600 micro radians peak to peak via operation of the transducers.
While a specific embodiment of the adjustable mirror mount apparatus of the invention has been illustrated and described, modifications and changes of the apparatus, parameters, materials, etc. will become apparent to those skilled in the art, and it is intended to cover in the appended claims all such modifications and changes which come within the scope of the invention.
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An adjustable mirror mount system for a mirror is disclosed comprising a mirror support having a planar surface thereon, a mirror frame containing a mirror and having a planar surface behind the mirror facing the planar surface of the mirror support and parallel to the reflecting surface of the mirror and mounted pivotally to the mirror support at a point central to the frame, a first adjustment means between the mirror support and the mirror frame spaced from the central pivot mount for adjusting the movement of the mirror along one axis lying in the plane of the planar surface of the mirror frame; and a second adjustment means between the mirror support and the mirror frame spaced from the central pivot mount for adjusting the movement of the mirror along a second axis lying in the plane of the planar surface of the mirror frame and perpendicular to the first axis.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotatable supporting structure and more particularly to a ceramic supporting structure having portions adapted to engage dental bridgework made of porcelain which must be baked or fired during the production thereof. The supporting structure facilitates rotation of the workpiece without the necessity of removing or displacing it from its position within the furnace or oven utilized for curing the workpiece.
2. Description of the Prior Art
There are various types of supporting means which have been used in the past to support porcelain dental bridges or the like during the production thereof, while the porcelain is in its raw or pastelike state. The prior art support means are adpated with appendages which are adapted to engage the base metal supporting structure of the dental bridge and hold same keeping the porcelain in its paste form from engaging surfaces of the oven or the supporting means. Such prior art supporting structures are designed and adapted to hold the workpiece in one position only and it was necessary to move the entire supporting structure to move or rotate the workpiece in any manner. During the firing or curing of porcelain, in connection with the production of dental bridges, it is necessary to view or visually scrutinize the porcelain to determine the proper time for its removal from the oven or furnace.
It must be noted that during the heating of procelain in connection with the manufacture of bridgework, as each unit or workpiece is unique being made each individually, it is impossible to predetermine the exact amount of time which the procelain should be subjected to heat within a porcelain furnace or oven. The only way to accurately ascertain whether the proper amount of heat has been absorbed by the porcelain is by viewing the porcelain itself, which serves as a visual hardening indicator. When the porcelain is in its paste or soft state it is somewhat colorless, whereas as it absorbs heat it gains a whiteish tint. It is important during the curing of the porcelain that all portions thereof be heated to the proper degree during this initial curing, which is generally referred to in the art as the bisque bake. If parts of the porcelain have a modeled appearance it is an indication that it has not been cured to the proper degree. Generally, porcelain is applied to a base metal structure of the dental bridgework in varying depths, shapes and configurations. Therefore, portions of the procelain may be "cured" whereas other portions are not, a condition which must be avoided in order to produce a suitable product.
As is well known in the porcelain art, overbaking or curing subjects the porcelain to conditions which are undesirable structurally, and accordingly prompt removal of the porcelain at the point in time when all exposed surfaces visually indicate that the proper hardening has occurred, is required. In the past, as prior art supporting means held the bridgework in a stationary position, it was necessary to interrupt the curing or heating process by opening the furnace door, and completely removing the supporting structure with the workpiece disposed thereon, to the oven door or other open surface. To accomplish such a removal, suitable prongs or tweezers are required to hold the supporting means or move it into various positions so that one could look at all sides or 360° of the workpiece. The removal of the workpiece from the oven, in order to properly view all angles of the bridgework, presented severe disadvantages as the heat loss associated with removing the workpiece from the oven is generally in the area of 400°-600° F. Such a severe reduction in temperature causes the porcelain to acquire glass build-up due to the silicon present in most porcelain materials. In the past, heating and reheating was required in order to allow for the inspection of the workpiece, and normally it was necessary to reheat two or three times in order to find the correct amount of curing. Accordingly, cracking of the porcelain, due to glass build-up was common which necessitated the discarding of the workpiece. As is appreciated in the art, glass build-up due to reheating greatly increases the likelihood of a defective finished product and greatly increases the cost of production.
It is, of course, possible to merely open the door of the heating oven or furnace in order to view the workpiece without moving it, which results in a heat loss of only 50°-70° F., but it is then impossible to view all sides of the porcelain. If the workpiece is removed too early, it is then necessary to re-introduce the workpiece as described above, which shocks the porcelain introducing glass build-up, which severely weakens the structure as well as causing surface deformities and large structural cracks. If the workpiece is left to remain in the oven too long, glass build-up is also promoted.
Also required for the preparation of porcelain bridgework is a glaze bake coating which is applied to the porcelain or a subsequent glaze bake. After the second coating or glaze bake the workpiece must then be fired at a temperature most often times higher than that at which it was cured and again, the glaze bake must be visually viewed in order to determine the proper point at which to remove the workpiece. Generally, during the two firing procedures discussed, it is common to remove the workpiece from ten or fifteen times in order to determine the proper time at which the various curing or firing steps have been completed.
During the bisque bake as well as the glaze bake it should be noted that a temperature drop in the area of 50°-70° F., which occurs when the oven door is opened only, does not affect the porcelain or the glaze coating and accordingly the oven door may be opened an unlimited number of times without causing any damage to the workpiece. However, heat loss in the area of 400°-600° F. which occurs when the workpiece is moved out of the oven for inspection does cause severe problems and structural and physical damage to the workpiece, and in some instances damage beyond the point where the product can be used.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the prior art supporting means by providing a rotatable supporting means which may be easily rotated within conventional porcelain ovens or furnaces, which furnaces due to the high temperature and intense heat required normally are three inches wide, five inches high, and approximately five inches deep. Accordingly, being able to rotate the workpiece without removing it from the oven completely eliminates heat losses in excess of 50°-70° F., and allows for proper direct viewing of the visual indications of the porcelain during all curing and firing steps required in making porcelain dental bridgework.
The structure of the present invention features a base having substantially planar upper surface, and having a pin located on the upper surface extending upwardly therefrom. There is provided an upper member having an opening at the center thereof which opening is of a diameter slightly larger than that of the pin. There are movable supporting means located on the upper surface of the upper member which are adapted to hold porcelain workpieces away from the supporting structure and the surfaces of the oven so that the wet or pastelike porcelain can be subjected to heat as evenly as possible. The upper member may be rotatably disposed on the base which remains stationary throughout the entire firing operation whereby the upper member may be readily, easily and smoothly rotated so that all sides of the workpiece may be viewed without having to remove same from the oven.
It is an object of the present invention to provide a supporting structure which can be readily rotated within conventional porcelain furnaces and ovens and which can withstand the intense heat and repeated heatings.
Furthermore, it is an object of the present invention to provide a supporting means which will enable the workpiece to be rotated within conventional ovens for viewing. Furthermore, as at the rear of conventional ovens the heat is the greatest, rotating the workpiece allows for even heating of all surfaces without having to laterally displace the supporting means.
Another object of the present invention is to provide a supporting structure made of a ceramic material that facilities its easy removal from the oven due to its configuration and which may be smoothly and readily rotated without the supporting structure tending to displace.
It is a further object of the present invention to provide a movable supporting means on the upper portion of the upper member so that a large variety of differently shaped workpieces may be readily accommodated. The supporting means are preferably movable such that the distance between supporting structures is readily changeable.
Still further objects and features of the present supporting means reside in the provision of a two piece rotatable structure whereby the base frictionally engages the base of the ceramic furnace to resist being displaced, whereas the upper member disposed thereon is readily rotatable.
These, together with the various ancillary objects and features of the invention which will become apparent as the following description proceeds, are attained by this rotatable supporting structure, preferred embodiments of which are shown in the accompanying drawing, by way of example only, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of a rotatable supporting structure made in accordance with the present invention including several dowels disposed thereon to facilitate the supporting of a workpiece;
FIG. 2 is a side elevational view of the base thereof;
FIG. 3 is a partial vertical cross-sectional view taken along the plane 3--3 in FIG. 2;
FIG. 4 is a top plan view of the base;
FIG. 5 is a bottom plan view of the base;
FIG. 6 is a top plan view of the upper member;
FIG. 7 is a top plan view of an alternate embodiment of the upper member;
FIG. 8 is a perspective view of a preferred embodiment of a supporting dowel, and
FIG. 9 is a side elevational view of the supporting structure shown with a workpiece disposed thereon.
DETAILED DESCRIPTION OF THE INVENTION
With continuing reference to the accompanying drawing wherein like reference numerals designate similar parts throughout the various views, reference 20 is used to generally designate a rotatable supporting structure constructed in accordance with the concepts of the present invention. The supporting structure 20 includes a base 22 and an upper member 24 which has an opening 26 therein, which upper member is disposed upon the base whereby it is rotatably supported thereon. The base 22 includes a pin 28 which is at least partially disposed within the opening 26 when the upper member 24 is mounted on said base 22.
The upper member 24 includes, in the preferred embodiment, a plurality of elongated slots 30, into which a plurality of supporting dowels 32 may be disposed and displaced laterally with respect to one another such that the spacing between dowels 32 may be readily and easily changed. It is noted that either one or more dowels 32 may be utilized as required to accommodate and support various workpieces of various shapes.
All components of the rotatable supporting structure may be manufactured of a suitable ceramic material such that it will withstand temperatures in the area of 2500° F. and above. Generally, any ceramic material which can be cast, machined, or pressed into the desired structural shape as set forth herein, and which can withstand temperatures in the area of 2500° F. are suitable in connection with the present invention, materials such as Cordierite, Dichorite, or Iolite (4(Mg.Fe)0.4Al 2 O 3 10SiO 2 H 2 O). A ceramic material such as Cordierite manufactured by Corning Glass Company has been found to provide a suitable material with which to construct the base, upper member and dowels of the present invention.
By way of explanation, it should be understood that the present invention may be utilized for supporting workpieces of a variety of types and kinds which are to be subjected to intense heating, such as dental bridgework comprised of porcelain applied to a supporting base metal. However, the present invention is useful and intended for use in connection with a wide variety of products which require heating during the production thereof. It is in connection with the baking or firing of the porcelain with which the rotatable supporting structure provides distinct advantages over prior art methods and apparatus of supporting procelain or other structures during heating, by enabling one to rotate the workpiece without having to laterally displace same or remove it from the heating furnace.
As discussed previously herein, providing a means for rotating a porcelain workpiece during the various heating or baking steps thereof while it is retained in the oven provides distinct advantages and eliminates severe disadvantages present in prior art methods and apparatus used in connection with porcelain products. The present invention is particularly suited for manufacturing dental products comprised at least partially of porcelain as it is desirable to view all surfaces of the irregular and unique hand-made items prior to removing same from the furance.
As noted above, most conventional ceramic materials are suitable for manufacturing the components of this rotatable supporting means, if said ceramics can withstand temperatures up to 2500° F. However, it is preferable that the ceramic contain as little air as possible as prolonged and frequent heating and cooling may cause the ceramic to crack or undergo catastrophic failure after many reheatings.
In the manufacture of porcelain products the present invention has been found particularly useful in connection with most conventional heating furnaces such as known in the industry as a Ney-Barkmeyer furnace manufactured by J.M. Ney Company or ceramic furnaces as manufactured by New York Dental Manufacturing Company. Most conventional furnaces for use in the preparation of dental bridges maintain a sub-atmospheric pressure during heating temperatures from room temperature to 1700° F. Thereafter, atmospheric pressure is maintained and it is possible to open the doors of the furnace during the heating, and it is during the heating process over and above 1700° F. that it is normally necessary to visually view the workpiece being produced.
As may be easily seen in FIG. 2, the base 22 of the supporting means includes a plurality of legs 34, (and as shown in FIG. 5 which is a bottom plan view of the base) the legs 34 are somewhat evenly spaced across the bottom surface of member 22. As the base 22 is intended to remain stationary while the upper member 24 rotates thereon the legs 34 facilitate supporting the base on the bottom of the furance floor, or the like, and further serve to grip or form a frictional engagement with the surface of the heating furnace whereby manual rotation of the upper surface will not cause movement or rotation of the base 22.
There is also provided at the lower surface of the base at the outer edges thereof a plurality of depressions 36 which extend from the outer periphery of the base inwardly therefrom. The depressions 36 serve to reduce the thickness of the base at its outer edge such that conventional gripping means, such as tongs or tweezers can easily engage and grip the base. It must be appreciated that when the upper member is disposed on the base, in order to easily pick up or displace the supporting means after it has been exposed to intense heat for some period of time, that tweezers or tongs or the like are required and that as the base 22 and member 24 are movable with respect to one another, it is desirable to grip the base only during handling with tweezers, or the like. The depressions 36 reduce the thickness or the distance between the upper surface of the upper member 24 and the general lower surface of the base such that at the perimeter of the supporting means, at the location of the depressions 36, the distance between the upper surface 42 and the lower surface of the base 37 at the location of the depressions is reduced to readily receive the prongs of a tweezer.
A pin 28 is located at substantially the geographic center of the base 22 and surrounding the pin is a raised portion or bearing surface 40 which serves to facilitate rotation of the upper member without movement of the base. As may be readily seen in FIG. 4, in the preferred embodiment, the bearing surface 40 completely surrounds the pin 28 and extends radially outwardly therefrom.
The raised portion, traveling away from the pin 28 towards the edge of the base, tapers off gradually into the substantially planar upper surface of the base. The bearing surface 40 is raised only a slight distance above the level of the generally planar upper surface 42 of the base, but it is intended to engage the lower surface of the upper member which surrounds the opening 26 therein such that the upper member is substantially solely supported thereby. Generally, the raised portion extends from the pin to a point where it engages the planar upper surface of base 22 a distance approximately one tenth of the radius of the base 22. However, the raised portion 40 may be of any desired shape and configuration deemed desirable in connection with the complementary surface of the upper member which it engages (surrounding opening 26). The bearing surface 40 need only raise the substantially planar lower surface of the upper member 24 a small distance above surface 42 such that there is not coextensive engagement between the lower surface of the upper member 24 and the upper surface 42 of the base during rotation. It must be understood that the upper member 24 will rotatably or movably engage the stationary pin during use about the exterior side surface of pin 28 at raised portion 40 and, possibly at the upper surface 42 of base 22 at the outer edge of the upper member at only a smally portion there of if there is sufficient weight on the upper surface to cause the upper surface to tilt and bear on surface 42 during rotation. However, a large area of coextensive engagement is eliminated between member 22 and 24 during use.
As may be seen in FIG. 9, the workpiece 100 may be supported by the rotatable supporting means 20 via the supporting dowels 32 which engage any suitable portion or area of the workpiece 100 such that the porcelain surfaces thereof will not engage the base or the walls of the firing furnace. With the upper member 24 engaging the bearing surface 40 there is created a slight space 50 between the facing surface of the base and the upper member. The limited area of engagement between the two members (at surface 40) of the supporting means reduces the frictional engagement therebetween and facilitates rotation of the upper member while the lower member remains stationary. Even if the weight of the workpiece 100 should be off-center and cause the center of gravity of its weight to be located on a portion which is not over the bearing surface 40, the base 22 and the upper member 24 will only be tilted or displaced a very slight distance whereby members 22 and 24 would engage at only one point at the perimeter thereof and not create a large additional area of mutual engagement which would defeat ready rotation of the upper member.
The upper member 24, as may be readily seen in FIG. 6, preferably has a scalloped or irregular outer shape which facilitates engaging the upper member with a tweezer, or the like, to effect rotation as well as providing areas of reduces radial size 60 which, when placed directly above a depression 36 will allow one to engage the base 22 with a tweezer without having to grip the upper member. It must be understood that the upper member 24 may have any desirable shape such as conventional geometric shapes (triangular, square or rectangular or the like) as well as being circular and of a diameter equal to, greater than or less than the diameter of the base 22. Preferably, the upper member 24 includes at least one portion of reduced radial size 60 whose radius is less than that of the base above the depression 36 so that a portion of the base is easily accessible to tweezers.
To facilitate supporting the workpiece the upper member 24 has a plurality of holes therein 52 which there may be placed the supporting dowels 32. As seen in FIG. 6, there is provided a plurality of holes 52 such that it is possible to create various spacings between the supporting dowels 32 when there are two or more of such dowels utilized, so that it is possible to engage all types and shapes of workpieces. However, it must be understood that various arrangements of holes 52, and various other types of supporting means may be utilized in connection with the rotatable supporting structure. As seen in FIG. 7, there may be provided a plurality of slots 54 such that the supporting dowels or the like may be disposed therein and readily moved laterally along the slots that the spacing between dowels 32 may be easily changed, and provides for a wide range of spacings to be created between the dowels 32.
As may be seen in FIG. 8, the supporting dowel 32 may include a conical upper portion 61 and a lower cylindrical rod portion 63. The dowel also may include an outwardly extending lip 65 of a diameter greater than the diameter of holes 52 or greater than the transverse size of the slots 54. The lip 65 may be of any desired shape such as square, rectangular or the like, but the disc-like or circular configuration is preferred. As may be readily understood, one or more dowels 32 may be disposed in one or more slots 54, or disposed in several holes 52 in the upper member 24.
A latitude of modification, substitution and change is intended in the foregoing disclosure, and in some instances, some features of the present invention may be employed without a corresponding use of other features.
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A rotatable supporting structure adapted to withstand substantial intense heat and provide for the rotation of a workpiece without lateral displacement thereof during the heating of the workpiece within a furnace, including a base having a substantially planar upper surface, and a pin located on the upper surface of the base extending upwardly therefrom. The supporting structure also includes an upper member having an opening at substantially the center thereof, and of a diameter slightly larger than that of the cross sectional size of the pin. The upper member is provided with a plurality of holes or slots into which a plurality of supporting dowels may be disposed, in a variety of positions, thereby varying the space therebetween so as to support a workpiece without engaging the upper surface of the upper member and provide for the rotation thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method of manufacturing a chip type piezoelectric resonator for use in a piezoelectric filter, an oscillator or the like.
2. Description of the Prior Art
There has been proposed a chip type piezoelectric resonator constructed as in FIG. 3 and a method of manufacturing the same effectively.
In FIG. 3, 1 shows a piezoelectric resonator which comprises a piezoelectric device 5A which includes a piezoelectric substrate 2 provided on both of its sides with a plurality of vibrating electrodes 3 and input/output electrodes 4, respectively. Layers each comprising a first sealing substrate 6 are placed over and adhered to both sides (top and bottom) of the piezoelectric device 5A followed by forming a pair of outside electrodes 7 each electrically communicating with the input/output electrodes 4. Further a second sealing substrate 8 is adhered to both exposed lateral side surfaces (front and back) of the piezoelectric device 5A thereby sealing both of its lateral sides.
The vibrating electrodes 3 are located in a vibration cavity 9 to prevent vibration from being damped, and the vibration cavity 9 is sealed at both ends by an adhesive 10. Each vibration cavity 9 is a gap which is defined between the piezoelectric substrate 2 and the first sealing substrate 6. The gap's height is equal to the thickness of the coated adhesive 10.
The method of manufacturing the above piezoelectric resonator 1 will be detailed with reference to FIGS. 1A, 4A and 4B.
A piezoelectric device 5A constituting a principal portion of the piezoelectric resonator 1 is made, as shown in FIG. 4A, by providing the piezoelectric substrate 2 made of piezoelectric ceramics or the like on both its sides with the electrodes 3 and 4 by sputtering, vacuum deposition, or printing and baking of conductive paste, or the like. A plurality of piezoelectric devices 5A (see FIG. 1A) are comprised in the piezoelectric device substrate 5. The opposing (overlapping) portions of the electrodes in the piezoelectric devices 5A at the top and bottom sides of the piezoelectric device substrate 5 (as seen in the figures) form the vibrating electrodes 3, and the remaining end parts of the piezoelectric devices 5A which are not overlapping with each other form the input/output electrodes 4. The first sealing substrate 6 made of ceramics is placed on and adhered to both side surfaces of the piezoelectric device substrate 5 to form the vibration cavity 9 along each vibrating electrode 3 of the piezoelectric device substrate 5 comprising the plurality of piezoelectric device 5A, thereby forming a substrate-layered member 11. The substrate-layered member 11 is cut along the lines C--C and D--D in FIG. 4B to obtain an individual resonator element 12. The outside electrodes 7 are formed at both lateral ends of the resonator element 12 so as to electrically communicate with the input/output electrodes 4 which extend to those ends. Also, the second sealing substrates 8 are adhered to both lateral side surfaces of the resonator element 12 to seal the vibration cavity 9 and thereby form the piezoelectric resonator 1 of FIG. 3.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a method of manufacturing a piezoelectric resonator which enables an effective preparation of a chip type piezoelectric resonator.
Another object of the present invention is to provide a method of manufacturing a piezoelectric resonator to facilitate work efficiency, mass-productivity and cost reduction for manufacturing a chip type piezoelectric resonator.
To achieve the objects above, according to the invention, a method of manufacturing a piezoelectric resonator is provided. This invention involves the following steps:
to first laminate and adhere a piezoelectric device substrate, which provided with a plurality of vibrating electrodes and input/output electrodes, at one side surface of the device substrate, to a first sealing substrate so as to form a vibration cavity on the vibrating electrode surfaces;
to then laminate and adhere the first sealing substrate to the other side of the piezoelectric device substrate to form a vibration cavity on vibrating electrodes thereat, and alternately laminating and adhering to each other the piezoelectric device substrates and the first sealing substrates to form a block-like shaped layered element;
to then cut the block-like shaped layered element including a number of resonator elements at a predetermined point to obtain a number of resonator elements, thereby forming a substrate-layered element having a number of resonator elements;
to then cut the substrate-layered element at a predetermined point so as to provide a single resonator element;
to adhere a second sealing substrate to both lateral side surfaces of the substrate-layered element or the single resonator element; and
to form outside electrodes, which electrically communicate with the input/output electrodes, at both end surfaces of the substrate-layered element or the individual resonator element to obtain a piezoelectric resonator.
The manufacturing method according to the present invention layers alternately the piezoelectric device substrates and the first sealing substrates to form the block-shaped layered element, and cuts the same to provide a piezoelectric resonator, so that a number of the resonator elements for forming the piezoelectric resonator can be prepared in a lump through laminating, adhering and cutting processes. Hence, it requires merely less number of repetition of the series of processes, thereby facilitating mass-productivity and reducing cost to produce.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a fragmentary perspective view of a piezoelectric device constituting a portion of the known piezoelectric resonator of FIG. 3;
FIGS. 1B and 1C are perspective views showing the manufacturing process performed in one example of the manufacturing method according to the present invention.
FIG. 2 is a partially sectional perspective view of an example of a piezoelectric resonator manufactured according to the manufacturing method of the present invention.
FIG. 3 is a partially sectional perspective view of a known type of piezoelectric resonator.
FIGS. 4A and 4B are perspective views showing a manufacturing process of the piezoelectric resonator of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An example of the present invention will be detailed with reference to the accompanied drawings. The same reference numbers are used for the elements corresponding to those of the conventional example.
In FIG. 1B, 13 shows a block-like shapd layered element comprising a number of piezoelectric device substrates 5 and first sealing substrates 14 each layered alternately. The piezoelectric device substrate 5, as seen in FIG. 1B, comprises a plurality of piezoelectric devices 5A which include piezoelectric substrates 2 provided at both of their major surfaces with a respective pair of electrodes, the devices 5A being arranged side by side. A plurality of the piezoelectric device substrates 5 are alternated with a plurality of first sealing substrates 14 made of ceramics so that the substrates 5 are adhered at their major surfaces to the plurality of first sealing substrates 14 and form a vibration cavity 9 adjacent the vibrating electrodes 3 of the piezoelectric device 5A, thereby providing the layered element 13 comprising layers of the piezoelectric device substrates 5 alternating with layers of the first sealing substrates 14. Each first sealing substrate 14 is adhered to the piezoelectric device substrate 5 at its rear major surface by an adhesive layer 10. Similarly, the piezoelectric device substrate 5 and the first sealing substrates 14 are alternately layered and adhered to each other to form a substrate-layered element 13 in a block-like shape as shown in FIG. 1B.
In the substrate-layered element 13, the first sealing substrate 14 has been previously recessed at its inner surface at a position corresponding to the portion of the vibrating electrodes 3 of the piezoelectric device substrate 5 so as to have a groove 15 larger in width than the vibrating electrodes 3 and extending over the whole length of the first sealing substrate 14, so that there is provided a vibration cavity 9 having height corresponding to the depth of the previously provided groove 15 plus the thickness of the applied adhesive 10. The vibrating electrodes 3 are formed on the substrate 2 and are located in the vibration cavity 9 (FIG. 2) by placing the first sealing substrate 14 over the substrate 2 with a spacing therebetween. The block-like shaped substrate-layered element 13 is then cut at the lines C--C in FIG. 1B to form a flat substrate-layered element 11 in unit width including a plurality of resonator elements 12 as shown in FIG. 1C.
Then, a draw-out electrode is formed at the end surface of the substrate-layered element 11 by printing or coating silver paste, or a like manner.
Next, a large second sealing substrate 8 is adhered to both lateral side surfaces of the substrate-layered element 11 in the following manner. An adhesive is coated on the upper surface of the large second sealing substrate 8, and then a number of flat substrate-layered elements 11 are placed in a row on the adhesive with their side surfaces being faced downward. Then a second sealing substrate 8 is coated with adhesive and placed on the upward-facing side surfaces of the substrate-layered element 11. In this case, a gap is formed along the lateral side surfaces of the vibrating electrodes 3, not by cutting the side surfaces, but rather by use of a layer of adhesive adhering between each lateral side surface near the vibrating electrode 3 and the second sealing substrate 8 to ensure a gap therebetween. Also, the second sealing substrate 8 may be recessed to have a groove for forming a gap along the lateral side surface near the vibrating electrode 3, thereby ensuring the gap.
After hardening the adhesive, the device is cut on the lines D--D and E--E in FIG. 1C by use of a cutter blade or a laser, or the like, to form a single resonator element or a plurality of resonator elements 12 with a preferable mass-productivity thanks to use of the large second sealing substrate, in that a single second sealing substrate 8 is usable to seal together a plurality of substrate layered elements 11, as explained above.
Then, the outside electrodes 7 are provided at the end surfaces of the resonator elements 12 (the end surfaces through which the input/output electrodes 4 provided in the piezoelectric devices 54 are exposed to the outside) by first sand blasting, grinding or a like process to reliably expose the end portions of the input/output electrode 4, followed by monel sputtering and galvanizing the same.
The first and second sealing substrates may be hard or soft ones, such as heat resisting film, ceramic plates, ceramic sheet or the like. The vibration cavities 9 surrounding the vibrating electrodes 3 are securely sealed by the sealing adhesive 10 and the second sealing substrate 8.
The course of manufacturing process as above may be changed as or when required by first cutting the flat shaped substrate-layered element 11 to obtain a desired resonator element 12 and then forming a required gap adjacent the piezoelectric substrate 2 by sand blasting, grinding, etching or the like process so as to provide the vibration cavities 9. The input/output electrodes are exposed at the ends of the element and the outside electrodes 7 are adhered thereto. The second sealing substrate 8 is adhered to the lateral sides of the element. This course of process also adopts the block-like shaped substrate-layered element, so that although it requires the same amount of working for laminating, adhering and cutting processes as in the first-cited course of manufacturing process, this can reduce times of repetition of the series of laminating, adhering and cutting processes to improve mass-productivity.
The piezoelectric device substrate may employ a plurality of pairs of vibrating electrodes on the front and rear major surfaces to obtain the same effect as in the above-identified example, and formation of the gap along the vibrating electrode portion may be adjusted by adjusting the specific thickness of the applied adhesive.
The present invention should not be limited in scope to the above examples but may be properly modified within the fair spirit and scope of the invention.
EFFECT OF THE INVENTION
As seen from the above, the method of manufacturing a piezoelectric resonator according to the present invention can further improve work efficiency and mass-productivity and reduce cost to produce in comparison with the conventional techniques.
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A method of manufacturing a piezoelectoric resonator includes the steps of alternately layering piezoelectric device substrates and first sealing substrates to form a block-shaped layered element, and then cutting the same to provide a piezoelectric resonator element, so that a number of the resonator elements for forming piezoelectric resonators can be prepared simultaneously through laminating, adhering and cutting processes. Hence, it reduces the number of steps thereby facilitating mass-productivity and reducing the cost to produce a chip-type piezoelectric resonator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/507,596, filed Jul. 22, 2009, now U.S. Pat. No. 8,425,647 which is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND
1. Technical Field
The present invention relates to blending plant fertilizer constituents and more particularly, the present invention relates to tailoring the ratio of nutrients in a fertilizer composition by colorizing fertilizer constituents according to their nutrient content and mixing the colorized fertilizers until the resultant color matches a reference color associated with a desired fertilizer composition.
2. State of the Art
Plants are harvested for a variety of useful products. Although some plants are coveted for their leaf such as spinach and lettuce, the stalk such as asparagus, and the root such as carrots, most plants are useful for some aspect of their reproductive cycle, such as the flowering portion (roses), the fruit such as avocado, and the seed such as corn and wheat. In addition to water and carbon dioxide that plants require to grow, plants also require minerals to grow in a healthy manner, and to provide us with those nutrients that are essential to our own health. These minerals are normally absorbed through the roots, though in some cases foliar application is effective. Although the specific needs and relative proportions of nutrients needed by different species of plants may vary, as a general rule, all plants require the same nutrients. The necessary proportions, however, vary from specie to specie, as well as throughout the life cycle of a plant. Environmental ranges of light, temperature, humidity, airflow, etc. can also have a controlling effect on ideal nutrient composition for various crops in their range.
“Primary nutrients” include nitrogen, phosphorus, and potassium, commonly referred by the triplet “NPK.” These are called primary because they are usually needed in the greatest proportion relative to other nutrients. “Secondary nutrients” include calcium, magnesium, and sulfur, usually in the form of sulfate. Trace element needs include iron, manganese, zinc, copper, boron, chloride, and molybdenum. Though the studies are in their formative stages, more recent evidence shows that cobalt, silicon, nickel and chloride are also needed, or helpful to plant growth, in trace amounts. The secondary nutrients are typically required in lesser quantities than the primary nutrients, but higher quantities than the trace elements. There is, however, some overlap. For example, calcium, listed above as a secondary nutrient, is often needed in higher quantities than phosphorus.
The required levels for some nutrients remain fairly stable over the life cycle of the plant. For other nutrients, however, the requirement levels vary significantly throughout the life cycle. Accordingly, the production of a healthy leaf at the beginning of a life cycle may have significantly different nutritional needs than the production of flower, fruit, or seed near the end of the life cycle.
Most plants are satisfied by a balance of nutrients at levels that remain fairly stable over the life of the plant. A few nutritional requirements, however, such as nitrogen, phosphate and magnesium often have a wide range of variation over the life of a plant for optimum growth, vigor, and yield. Young plants require high levels of nitrogen to enable their early structural growth of roots, stems, and foliage. At a later stage in a plants growth, such as the flowering, fruiting or seed production stages, the need for nitrogen decreases significantly. Simultaneously, the need for other nutrients may increase throughout the life of a plant. For example, phosphate and magnesium are important for flowering, and the required levels frequently increase during this stage of development. Because of this, it is not possible to maintain nutrients at optimal simply by increasing or decreasing the strength, or concentration, of a single general purpose fertilizer. The ratio between elements and their variation throughout the plant's lifecycle is a key to optimum growth and productivity.
As a consequence, gardeners, farmers, horticulturists and other plant growers collectively referred to herein as “growers,” will typically apply a variety of fertilizers throughout the life of a plant. Our method provides a simple building-block method for the grower to easily mix a huge range of precise fertilizer blends.
The first problem is the life cycle of a plant. It is not as if the plant shifts from one stage to another in digital fashion. The process is an analog one, where the need for one nutrient decreases gradually as the need for another gradually increases. The more frequently the formula is adjusted throughout a plant's life, the more closely the mixture can follow the optimal ratio. Additionally, there is the problem of plant types. Different types of plants have different needs throughout their life cycle. To optimally meet the nutritional needs of the multiple stages of a life cycle for hundreds of different types of plants, over a range of environmental variations like field and greenhouse, summer, and winter, requires many different fertilizer formulas. Because it is not practical to manufacture, purchase or store an exhaustive or even extensive range of different fertilizer formulations, growers commonly try to formulate optimal, or near optimal mixtures by mixing a handful of basic fertilizer products in different ratios throughout the life cycle of a plant. Typically the measuring and mixing is by weight percentages, or may be volumetric for less sophisticated growers. There are drawbacks of such mixtures, however. A first drawback is that an optimal mixture is seldom a simple integral ratio of small numbers, such as “three parts of a first fertilizer and two parts of a second fertilizer.” If an optimal ratio is closer to one hundred to one, and the grower does not need one hundred measures of fertilizer, the grower scales back the total amount of fertilizer and “eye-balls” the amounts used. The process immediately becomes an inexact science, forming a sub-optimal fertilizer. Another problem with volumetric measuring is that granulated solids, particularly fertilizers, can “clump” together, upsetting the measured volume required for an ideal ratio. Variations in the densities of fertilizers can occur through settling, impurities, and a variety of other causes. Moreover, in large commercial operations, fertilizers may not be placed in tidy graduated flasks before mixing. They can be dumped together from large bins or scoops lacking exact gradations, or being filled in very rough and inexact amounts. Air pockets can also form in a volume, affecting the actual amount of fertilizer used. Another problem with volumetric mixing is the language barrier. For example, in growing hydroponic tomatoes, the same fertilizer may be marketed in Mexico, Iran and China. Instructions for optimal fertilizer mixtures in Spanish will be of little value in Chinese or Farsi. In short, volumetric mixing of fertilizer formulas to obtain a particular formula for a particular stage of life of a particular plant can be inexact, tedious, boring, and difficult to communicate from language to language.
Coloring in the prior art includes U.S. Pat. No. 1,513,542 to Flagg. which is directed to using color coding to determine an amount of hemoglobin in the blood. U.S. Pat. No. 2,452,385 to Merckel relates to test apparatus for testing chemical presence and concentrations using colors. A translucent container has a colored translucent band around an upper portion of the container to serve as a color comparator against a solution within the container. Because the band is translucent, the light passing through the band serves as a concentration comparator as well. The apparatus can be used to test free chlorine in water, or can be used to test soils for mineral content such as nitrogen or potash. The soil sample is mixed in water with an indicator selected to react with the nitrogen or other mineral to produce a color. As the soil settles on the bottom, the color of the liquid can be compared to the colored band. Merckel teaches chemical alteration of a small test sample, not the entire target substance. Merckel selects a testing agent which produces certain shades and colors when it reacts with chemicals already in the sample substance. This testing agent may or may not produce a specific color, depending on the presence of underlying chemicals in the target substance. U.S. Pat. No. 4,126,417 to Edwards is directed to a testing and treatment kit for soil pH and nitrate levels. A stick with color coding allows the user to match a pH level or nitrate level to a color to determine concentrations. Pills can then be dissolved in water to adjust the pH or nitrate content of the soil. To distinguish nitrate enhancing pills from acid enhancing pills, nitrate enhancing pills are colored differently than acid enhancing pills. Modern commercial growers use ionic detection with computers to determine and maintain optimum nutrient character and strength at considerable cost and complexity. Examples of such complex system include the Priva™ Nutriflex™ and Priva™ Nutrifit™ systems from Priva B.V., The Netherlands; systems that may be used to control nutrients for state-of-the-art hydroponic greenhouses.
SUMMARY
The present invention is directed to a method and apparatus for tailoring the ratios of specific nutrients in a fertilizer to match the ideal needs of a plant at a particular stage of the life cycle, and/or under specific environmental conditions, by combining pre-existing fertilizers. The present invention provides for determining when a proper ratio of nutrients has been reached by mixing pre-existing fertilizers having different coloring agents and comparing a resultant hue with a reference hue in a look-up table. Embodiments of the present invention allow for the tailoring of nutrients for environmental phenomena as well as plant physiology.
The invention, in its several embodiments may include an industrial process of preparing a plant fertilizer comprising (not necessarily in the following order): (a) providing two or more colorized plant fertilizer concentrate components; (b) determining a reference hue for a concentrate blend of the two or more colorized plant fertilizer concentrate components; (c) blending a first portion of a first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components with a first portion of a second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components to make the concentrate blend having a resulting hue; and (d) adding to the concentrate blend, based on a difference between the reference hue and the resulting hue, at least one of: a second portion of the first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components and a second portion of the second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components. For some embodiments of the process, the first colorized plant fertilizer concentrate may be diluted into a first volume of water, the second colorized plant fertilizer concentrate may be diluted into a second volume of water, and the step of adding to the concentrate blend is further based on the first volume of water and the second volume of water. For some embodiments of the process, the first colorized plant fertilizer concentrate may be characterized by a specific gravity, the second colorized plant fertilizer concentrate may be characterized by a specific gravity, and the step of adding to the concentrate blend may be based on the specific gravity of the first colorized plant fertilizer concentrate and the specific gravity of the second colorized plant fertilizer concentrate.
In addition, the exemplary process embodiment may include steps of: (a) providing a reference electrical conductivity value for the concentrate blend; and (b) adding to the concentrate blend, based on a difference between the reference electrical conductivity value and a measured electrical conductivity value of the concentrate blend, at least one of: an additional portion of the first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components and an additional portion of the second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components.
An exemplary computing device embodiment of the present invention may include a processing unit and addressable memory, where the processing unit is configured to execute one or more instructions to (not necessarily in the following order): (a) determine a reference hue for a concentrate blend of two or more colorized plant fertilizer concentrate components; (b) generate a dispensing signal for a first valve to dispense a first portion of a first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components; (c) generate a dispensing signal for a second valve to dispense a first portion of a second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components to make a concentrate blend having a resulting hue; (d) generate, based on a difference between the reference hue and the resulting hue, at least one of: a dispensing signal for the first valve to dispense a second portion of the first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components and a dispensing signal for the second valve to dispense a second portion of the second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components. The exemplary computing device may be further configured to execute one or more instructions to: (a) determine a reference electrical conductivity value for the concentrate blend; and (b) generate, based on a difference between the reference electrical conductivity value and a measured electrical conductivity value of the concentrate blend, at least one of: a dispensing signal for the first valve to dispense an additional portion of the first colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components and a dispensing signal for the second valve to dispense an additional portion of portion of the second colorized plant fertilizer concentrate component of the two or more colorized plant fertilizer concentrate components. The processing unit of the exemplary computing device may be further configured to execute one or more instructions to determine a reference hue for a concentrate blend of two or more colorized plant fertilizer concentrate components based on at least one of: temperature, humidity, light intensity, available carbon dioxide, level of insect attack, and a level a disease attack. For example, a hot and dry environment may retard interplant calcium mobility and so the processor may be responsive to hot and dry conditions by increasing the proportion of calcium in the concentrate.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are illustrated by way of example and not limitation in the figures of the accompanying drawings, and in which:
FIG. 1 is a sample look-up table for use in conjunction with the claimed invention;
FIG. 2 is a flow chart of a process of mixing fertilizer according to the claimed invention;
FIG. 3 is a functional block diagram of a computing device embodiment of the present invention; and
FIG. 4 is a system block diagram of an embodiment of the present invention.
DETAILED DESCRIPTION
The present invention is directed to a method and apparatus that allows growers to mix at least two pre-formulated fertilizer products together in a select ratio to produce a third fertilizer product having a select ratio of nutrients. One advantage of the present invention is that, rather than having hundreds of pre-formulated fertilizers; a small number can serve as precursors for a wide variety of mixtures.
A method of fertilizing plants comprises the steps of mixing a first coloring agent into a first pre-formulated fertilizer having a first nutrient profile; mixing a second coloring agent into a second pre-formulated fertilizer having a second nutrient profile distinct from the first nutrient profile; mixing a first amount of the first pre-formulated fertilizer and second amount of the second pre-formulated fertilizer together to form a first fertilizer mixture having a third nutrient profile; forming a first aggregate hue according to a mixture of the first and second coloring agents in the first fertilizer mixture; comparing the first aggregate hue to a reference hue; determining that a variation exists between the first aggregate hue and the reference hue. The step of comparing may be performed by a digital computer, or by a human agent.
According to one embodiment, the method further comprises the steps of determining from the variation that an addition of the first pre-formulated fertilizer to the first fertilizer mixture is required to conform the first aggregate hue to the reference hue; and adding more of the first fertilizer to the first fertilizer mixture. The first mixture is placed in an aqueous solution and the conductivity is measured to determine a concentration of the first mixture. If the concentration is too low, more of said first fertilizer and more of said second fertilizer are added to the first fertilizer mixture.
The color mixing may be done with concentrates to make a blend of tailored concentrate that may be specialized for various crops and/or particular growth stages of one or more particular crops. Accordingly, the resulting color is indicative of the preferred application of the concentrate blend. For example, a resulting color of a concentrate blend may be keyed to a color indicating the presence of nitrogen in a growth-oriented formulation while another resulting color of a concentrate blend may be keyed to a color indicating the presence of phosphate and/or magnesium in a reproductive-oriented formulation. After a desired color of the concentrate blend is achieved, that concentrate blend may then be added to water to make a solution for application purposes, i.e., a user solution. A specialized concentrate blend may be further blended, i.e., diluted, with water volumetrically, or by weight, to make a user solution. A conductivity meter can yield approximations of a solution's strength but is not a precise indicator of elemental parts-per-million (ppm) since different components and derived blends have varying conductivity. Nonetheless the disclosed method embodiment still enables growers to achieve functional precision since the reference charts take into account the variations of conductivity/elemental content. For example, monopotassium phosphate and magnesium sulfate, while typically ingredients of fruiting or flowering formulas, show poor conductivity. Diluting instructions and/or conductivity meter readings may be addressed by tables to aid growers, as users, to estimate nutrient strength.
A third fertilizer comprises nutrients selected from among a group consisting of nitrogen, calcium, iron, manganese, zinc, molybdenum, cobalt, nickel and chloride. The third pre-formulated fertilizer is preferably added to the aqueous user solution by itself directly before or after the colorized blends are added. Preferably, the non-colorized fertilizer should not be added to any of the colorized fertilizers in concentrated form to avoid the mix precipitating calcium or magnesium phosphate. More particularly, the calcium is preferably kept separate until dilution in water of the colorized blend or non-colorized fertilizer. So generally, the third pre-formulated fertilizer may be mixed with the first fertilizer mixture to form a second fertilizer mixture prior to applying to plant roots, or after the first mixture has been applied to plant roots. The first fertilizer preferably comprises nutrients selected from among a group of nutrients consisting of nitrogen, phosphorous, potassium, calcium, magnesium and a sulfur compound. The first fertilizer mixture is applied to roots of a plant at a time corresponding to first stage of growth of the plant. An embodiment further comprises the steps of preparing a second fertilizer mixture according to a second reference hue color; and applying the second fertilizer mixture to the plant roots at a time corresponding to second stage of growth of the plant.
A fertilization system comprises a first pre-formulated fertilizer that is impregnated with a first coloring agent; a second pre-formulated fertilizer that is impregnated with a second coloring agent; and a color look-up table including a first hue configured to match a hue that will result from combining the first pre-formulated fertilizer and the second pre-formulated fertilizer at a first predetermined ratio.
The look-up table further includes a correlation of the first hue with a type of plant and a first stage of growth in a life of the plant, and an optimal concentration of the first mixture. The look up table can represent the first hue in digital format, or in a colorized format that is sensibly perceived by a person.
A third pre-formulated fertilizer is impregnated with a third coloring agent. The look-up table includes a second hue representing a hue created by a mixture of the first pre-formulated fertilizer and the third pre-formulated fertilizer at a second predetermined ratio. The second hue within the look-up table corresponds to a second stage of growth in the life of the plant. The color look-up table further includes a third hue representing a hue created by a mixture of the second coloring agent and the third coloring agent at a third predetermined ratio, the third hue within the look-up table corresponding to a third stage of life of a plant.
Experimental results indicate that for a two-part colorized formula—with or without an additional non-colorized blend containing the micro-nutrients, added separately to the water—a “grow blend,” i.e., a blend that may be comprised of a high proportion of nitrogen and a low concentration of phosphate, may be yellow in color and the “bloom blend,” i.e., a blend that may be comprised of a low proportion of nitrogen and high proportions of phosphate and magnesium may be blue or red in color. This results in a yellowish green color for a blend that may be termed “Grow” comprising a “grow blend” and micronutrients, and a bluish green color for a blend that may be termed “Bloom” comprising a “bloom blend” and micronutrients. An exemplary alternative coloring produces a grow blend that is blue and a bloom blend that is red. Micronutrients may include copper which adds a blue coloring and may include iron which adds a red coloring. Accordingly, adding the micronutrients into the two-part colorized blend may yield a bluish purple for Grow and a reddish purple for Bloom.
In a three-part colorized blend with a fourth non-colorized blend containing micro-nutrients, a balanced blend may have a blue color. In this example, the concentrates are in the primary colors of Yellow, Blue and Red. In this example, yellow may be used for the Grow enhancer, and red may be used for the Bloom enhancer. This results in an exemplary protocol where: the grower starts the plants with a yellowish-green, and transitions through pure green, and later bluish-green, and then pure blue. When reproductive growth is indicated, the grower may mix a bluish-purple transition to a reddish-purple, and may finish the cycle with a mix of pure red. For unique situations yellow can be mixed with the red to make ranges of orange. For example, the orange colored blend may be used as a foliar spray to help with unique nutrient needs, i.e., for orchids.
Recent tests have produced successful blends all necessary elements, including the reactive Calcium and color-difficult elements, e.g., the rust color of iron and the blue color of copper, into a two part complete mix. The color blue may be used for the grow mix—including the copper since it is blue; and the color red may be used for the bloom mix with the iron. If these two concentrates are mixed together directly, they precipitate calcium phosphate. Preferably, one dilutes of a first concentrate in a container with two to four times its volume with water followed by a dilution of a second concentrate in the same container. Accordingly, a resulting semi-concentrate becomes sufficiently diluted to prevent the precipitation and the color is good for comparison to the reference tables. Now we have a unique colorized semi-concentrate that may be mixed with water volumetrically or using conductivity meter to make a ‘user’ blend.
The fertilizer system may be embodied with two or more colorized pre-formulated fertilizer products. For example, a fertilizer system embodiment may comprise two or three colorized pre-formulated fertilizer products, as well as a third and/or a fourth non-colorized pre-formulated fertilizer product. For a three-color embodiment, the three colorized products may be colorized according to the primary colors red, yellow and blue for reasons that will be explained herein. For a two-color embodiment, the two colorized products may be colorized according to the colors blue and yellow and may be mixed according to color guide ranging from blue, through the many shades of green to yellow.
The first pre-formulated fertilizer product discussed herein will be designated as “General Purpose” formulation, for this example. The General Purpose formulation is a “middle of the road” fertilizer, with a good balance of primary and secondary nutrients discussed above. For exemplary purposes, the coloring agent selected herein for the General Purpose formulation is blue. The General Purpose formulation will normally serve as a “base” fertilizer, which may be supplemented with one of two other pre-formulated colorized fertilizers to form an optimal fertilizer for different plant species at different stages of growth.
The second pre-formulated fertilizer product, herein designated “enhancer” formulation, is basically a nitrogen supplement. It is typically added to another fertilizer, principally to enhance nitrogen. For exemplary purposes, the coloring agent selected herein for the Enhancer formulation is yellow. In some formulation, one may add calcium and/or sulfur and/or some micro-nutrients to the yellow “enhancer” and use it by itself—typically to overcome nitrogen deficiency or as a foliar spray, as may be typical of the two-part complete colorized blend embodiments.
The third pre-formulated fertilizer product herein designated the “Ripen” formulation, is high in phosphorous, magnesium, sulfate, and relatively high in potassium. It has little or no nitrogen. The Ripen formulation is mixed with a red coloring agent. If mixed with the General Purpose formulation, it decreases the ratio of available nitrogen, and increases the ratio of phosphorous in the fertilizer.
In addition to the colorized mixes, various micro-nutrients are included in a fourth mixture of fertilizer. Although calcium is not regarded as a micro-nutrient, because of its chemical reactivity, it is often included in the micro-nutrient mixture. Preferably, calcium nitrate is applied as a soluble calcium source, and this means that the fourth non-colorized blend also contains nitrogen. Some gardeners will use this non-colorized blend plus the red blend to make a very strong user mix for flowering, fruit or seed production when they want to nutritionally encourage the plants, i.e., a final harvest mix. If calcium is stored in a formulation containing phosphorous, it will typically turn into a non-soluble phosphate that is not biologically available to plants. This makes it impractical to add calcium to the General Purpose formulation or the Ripen formulation, both of which contain phosphorous, except in minor amounts. Although calcium could probably be added safely to the Enhancer formulation, a plant's need for calcium over the life cycle remains far more stable than the need for nitrogen. The Enhancer formulation may be used to provide enhanced nitrogen in high levels early in a plant's development, and curtailed around mid cycle. If calcium were therefore to be delivered in conjunction with the Enhancer formulation, a plant would receive excessive calcium in its early stages, and be starved of calcium in its later stages of growth. For this reason, it has been found to be advantageous to include most of the required calcium in the formulation of micro-nutrients. This prevents the calcium from becoming biologically unavailable to the plant, insures that the levels of calcium remain sufficiently stable through the life of a plant since the micronutrient formulation is used consistently through the plant's life.
A micro-nutrient such as copper turns a water-based solution blue and a micro-nutrient such as iron turns a water-based solution a caramel color. Because a micro-nutrient combination of iron and copper can turn a water-based solution a caramel-brown in water, it is difficult to colorize them with a color that will not be overpowered in appearance by the natural caramel-brown color, and laboratory results have yielded red blends with iron. Moreover, since the need for micro-nutrients is substantially invariant over the life of most plants, specialized blending is largely unnecessary.
FIG. 1 illustrates a comparison chart or look-up table that is prepared showing hues which are produced at particular mixtures of any two of the three colored precursors discussed above. The comparison chart lists a type of plant, such as a tomato. Embodiments are envisioned wherein a single chart may list multiple plants in parallel columns. The comparison chart correlates a reference hue to a day or week of growth, and also correlates the proper concentration to the listed day. According to the exemplary look up table of FIG. 1 , Day 1 is correlated to the color green, and to a concentration level of 800 ppm. The formulation of this color is illustrated as being a combination of the blue, or General Purpose formulation, and the yellow, or Enhancer formulation. That is, at the beginning of the plant's life, it requires the balanced General Purpose formulation, which is colored blue, but must be supplemented by extra nitrogen to facilitate the intense growth of green leaves and stems. The exact green hue depicted in the look-up chart is achieved by mixing the General Purpose formulation with the Enhancer formulation at an exact ratio. By blending a fertilizer until an exact color match is achieved, the ratio of nutrients in the blended fertilizer can be controlled very exactly, for this example.
Although the chart of FIG. 1 depicts the word “green” rather than the actual color, it is understood that, in actual application, look-up tables for use by growers will depict a visual or sensible reference hue corresponding to the proper mixture of fertilizer, not simply the word “green.” The grower can then visually compare the color of the fertilizer mixture under preparation with the reference hue in the look-up table, adding more of one ingredient or another until the mixture's color matches the reference hue. It has been estimated that the human eye can distinguish perhaps a million colors. As a result, a very accurate mixture is possible by preparing a tailored fertilizer to match the reference hue in the look-up table. In look-up tables used by computers in process control applications, the reference hue corresponding to the proper mixture of fertilizer is advantageously depicted in a binary code. However, because background lighting in factory environments is not constant, embodiments are envisioned wherein a photo-sensitive examination of a fertilizer mixture by a computer will be accompanied by a fresh examination of a visual reference hue in a look-up table, and a generation of a new binary code, rather than a comparison against a pre-existing binary code. That is, computer-controlled coloring of the concentrate blend may be embodied via a light sensor, e.g., a charge-coupled device (CCD), having sensitivity across at least a portion of the color spectrum, that may be combined with light color intensity feedback and reference intensity levels in order to effect input valves controlling the addition of constituent colorized ingredients. Electrical conductivity may be expressed in millisiemens (mS) per centimeter (cm) or microsiemens (μS)/cm. An aqueous sodium chloride solution having a concentration of 500 parts per million (ppm) of sodium chloride has an electrical conductivity of about 1 mS/cm.
The reference hue correlating to an exemplary Day 10 may be a blue-green hue, and to a concentration level of 780 ppm, e.g., an electrical conductivity measurement of 1.56 mS/cm. This exemplary stage illustrates that the need for nitrogen is still greater than the percentages present in the General Purpose formulation, but the amount of Enhancer formulation added on Day 10 is less than what was added on Day 1.
The reference hue correlating to Day 19 is the blue color, and refers to a concentration level of 710 ppm, e.g., an electrical conductivity measurement of 1.42 mS/cm. Because the chart indicates that there is only one ingredient, no balancing of colors is required in mixing. The only requirement will be to add the proper amount of General Purpose formulation to produce the correct concentration according to a process described in FIG. 2 , for this example. The use of the un-blended General Purpose formulation indicates that the nutritional requirements of the plant are “balanced” between leaf production and flower/fruit/seed production.
The reference hue correlating to Day 28 is a purple hue, and the concentration level is 610 ppm, e.g., an electrical conductivity measurement of 1.22 mS/cm. Purple is achieved by adding red and blue together. As discussed above, the red or Ripen formulation contains no nitrogen, and is particularly high in phosphorous, potassium, magnesium and sulfate. By adding the Ripen formulation to the General Purpose formulation, the aggregate levels of nitrogen are reduced below the General Purpose formulation, and the aggregate levels of phosphorous, potassium, magnesium and sulfate are increased above the basic levels found in the General Purpose formulation.
The reference hue correlating to Day 35 is the red color of the Ripen formulation, un-blended with any blue. The concentration level is 605 ppm, e.g., an electrical conductivity measurement of 1.21 mS/cm. As noted above, the Ripen formulation has no nitrogen, but has elevated levels of potassium and phosphorous which are essential for the fruit/seed bearing stages of many plants. As discussed, a mixture of micro nutrients is preferably added separately, or added to the mixture after the color balancing has been performed. The specific details of the above cycle, including the length of days between life cycle events, specific ratios of tailored fertilizer formulations, and concentration levels, are exemplary, but illustrate many features of the present invention.
An advantage of using four precursors or pre-formulated fertilizer mixtures according to the above illustration is that most tailored mixtures for various plant types may be created by mixing only one or two of the artificially colored mixtures together, plus the non-colorized, naturally caramel colored micro-nutrient precursor. It may be readily understood by those familiar with spectral colors that a continuous spectrum exists between any two primary colors, such as blue and yellow, blue and red, or yellow and red. As a result, by mixing two primary colors, if the desired reference hue is not instantly achieved, it is plain to the casual observer which of the two coloring agents must be added to transform the mixture to the desired reference hue. In contrast, if three color combinations were used and the desired hues were not achieved, it would not be so intuitively obvious which ingredients should be increased. Accordingly, the pre-formulated mixtures are advantageously either used individually, or mixed two at a time, but not three at a time. Because a very natural spectrum occurs between primary colors, the colorized pre-formulated mixtures will preferably be colorized according to the three primary colors of the spectrum, yellow, red and blue. However, the use of other coloring agents is envisioned in conjunction with the present invention. From the above example, it is understood that non-colorized formulations such as the micro-nutrients are not added until the color balancing are completed, including arriving at the proper concentration. However, since the micro-nutrients are eventually used to nourish the same plant, at some point they will be combined with the colorized mixture in final aqueous solution. The application of diluted micro-nutrients to a single or colorized blend is preferred in order to minimize precipitation. That is, preferably the micro-nutrients are added to water separately and before added to the colorized blend, or the micro-nutrient may be added to an already diluted colorized blend.
FIG. 2 illustrates a flow chart illustrating an exemplary process of the present invention. This method embodiment is a process set to a calendar of days where a particular day in the growth cycle, i.e., the day of growth, is determined (step 201 ) and may be located within a look-up table corresponding to the point in the life cycle of the plant being fertilized. This may be a day, such as the first day the plant is planted, or an event, such as two days after the beginning of bud formation.
Based on the determined day within the table look-up, identification (step 203 ) may be made of the associated colors that have previously been associated within the table with the pre-formulated fertilizer or fertilizers used at that point in time in the life cycle. A test (test 205 ) may be conducted to determine whether two or more colored ingredients are required. If only one pre-formulated fertilizer is used, then the single ingredient is added to water (step 207 ), and adjusts the concentration level may be adjusted, e.g., by adding incremental volumes of water and/or the single fertilizer (step 209 ) in to achieve a target concentration level as listed in the look-up table or a reference table or array of values that is preferable correlated to each reference hue. Concentration levels may be measured with an ammeter specifically calibrated to disclose PPM levels and/or Siemens/meter (S/m). Because different mixtures have different conductivity levels, a reading of an electrical conductivity measurement associated with 600 parts per million, i.e., approximately 1.2 mS/cm, for a mixture the green color of day one may actually have a concentration of 850 parts per million. The resulting mixture having its concentration level adjusted accordingly may then be applied as a plant fertilizer (step 211 ). Optionally, a mixture containing the micro-nutrients that are not colorized may be applied to the target plant or crops (step 213 ).
Returning to the test of two or more ingredients (test 205 ), if the look-up table entry determined day of growth indicates that two pre-formulated colorized ingredients are required, then two pre-formulated ingredients may be added together (step 215 ) and the resultant hue may be compared with the reference hue of the look-up table. If the resultant hue is not a match with the reference hue (test 217 ), e.g., by a color-based comparison and/or a conductivity comparison, the resultant hue may be adjusted (step 219 ) by adding portions of one or more of the pre-formulated colorized fertilizers having pigment required for hue adjustment. If the resultant hue of the mixture matches or is approximately close to the reference hue (test 217 ) on a color basis, the conductivity of the mixture may be tested (step 221 ) as a subsequent step. If the conductivity test (test 223 ) indicates that the conductivity is too low, then additional fertilizer of one or more types of ingredients (step 215 ) may be added or, as an option, adding one or more types of ingredients that also may affect the hue test results (step 219 ), may be repeated, thereby increasing the concentration level. If the conductivity is not too low (test 223 ), then the mixture of aqueous fertilizer may be added to the plant or crop (step 229 ), and, optionally or finally, and if so, preferably based on a separately diluted basis, the necessary micro-nutrients may be added to the aqueous or “user” solution to be given to the plant or crop (step 231 ).
FIG. 3 depicts a separate computing device as an alternative exemplary operating environment for the colorized fertilizer mixing control process as a portion of an exemplary embodiment of the present invention. The exemplary operating environment is shown as a computing device 320 comprising a processor 324 , such as a central processing unit (CPU), addressable memory 327 , an external device interface 326 , e.g., a universal serial bus (USB) port and related processing, and/or an Ethernet port and related processing, and an optional user interface 328 , e.g., an array of status lights and one or more toggle switches, and/or a display, and/or keyboard and/or pointer-mouse system and/or a touch screen. These elements may be in communication with one another via a data bus 330 . Via an operating system 325 such as a real-time operating system (RTOS), the processor 324 may be configured to execute steps of a colorized fertilizer mixing based on reference conductivity values and/or color intensity levels, and feedback of conductivity measurements and/or color intensity levels according to a management application 323 according to the exemplary embodiments of the present invention.
FIG. 4 is an exemplary system depiction 400 of an embodiment of the present invention where a computing device 320 may have a user interface such as a touch screen 401 that displays the state of a concentrate blend 430 and/or a diluted blend 470 . A user may start or stop the process and/or change reference settings via the exemplary touch screen 401 . The system 400 includes one or more sources 411 - 413 of colored ingredients where the sources 411 - 413 each may have an output under the control of a valve 421 - 423 and each valve may be actuated by commands from the computing device 320 . The system may include a conductivity processor or conductivity sensor/measuring device 440 that may be in communication with a conductivity probe 441 that may be submerged in the concentrate blend 430 . The conductivity sensor/measuring device 440 also may be in communication with a conductivity probe 442 that may be submerged in the diluted blend 470 . A color light sensor 450 such as a charge-coupled device (CCD) camera may in communication with the computing device 320 to provide feedback on the resulting hue of the concentration blend for display purposes and/or for regulation of the hue via the execution of one more valve 421 - 423 opening and closing commands of one or more colored ingredient sources 411 - 413 . A water source 460 may feed, via a control valve 461 under the control of the computing device 320 , to provide the principal volumetric component of the diluted blend 470 . The concentrate blend 430 may feed, via a control valve 431 under the control of the computing device 320 , to the diluted blend 470 . The diluted blend 470 may be output 480 via a valve 471 that may or may not be under the control of the computing device 320 .
The above method and apparatus of blending pre-formulated fertilizers into exact ratios according to color comparison has many notable advantages and benefits. On a mechanical level, as noted above, it avoids many of the liabilities and pitfalls associated with volumetric measuring such as inexact scoop size or filling, settling or clumping of a pre-formulated fertilizer, and calculating fractional ratios. Because of the incredible sensitivity and scope of the human eye, the blending of fertilizers according to a reference hue can be done with a high level of accuracy. In addition to these “mechanical” benefits, there is an aesthetic value in the color blending method. For example, school science projects commonly use colors to enhance comprehension, such as snap-together molecules using black for carbon, and other colors for oxygen, nitrogen and hydrogen. On a similar level, school science projects may use hydroponic plant growing to teach certain fundamentals of biology, and enhance the student's intuitive grasp of plant nutrients by having students mix optimal fertilizer blends from color impregnated fertilizer precursors as described above.
In some embodiments, micro-nutrients may be added together with the colored mix after color balance is achieved, or may be added to a plant separately. The process of adjusting the hue and the conductivity may be executed in an analog manner of continuously adding fertilizer and continuously monitoring the conductivity, rather than the step-by-step approach disclosed in the flow chart within FIG. 2 . Colorized blend embodiments of the present invention may include non-nutrient additives such as plant growth regulators, which may comprise plant hormones, and these plant growth regulators may trigger special effects in growing plants, e.g., enhanced rooting, stem elongation, uniform flowering and fruit production. Colorized blend embodiments of the present invention may include pesticides that are used to deter insects and diseases, and may be staged concentrations according to a particular phase of growth of the target plant.
Alterations and variations may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and as such should not be taken as limiting the invention as defined by the following claims.
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Colorized components of a fertilizer concentrate blend may be apportioned according to a reference hue that may be associated with a target plan growth cycle and the apportionment may be refined according to referenced and measured electrical conductivity values of the blend in progress.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention describes phenazopyridine covalently attached to various conjugates. These compounds and compositions are useful for providing increased (oral) bioavailability with reduced side effects.
2. Related Art
Various publications are cited herein, the disclosures of which are incorporated by reference in their entireties. However, the citation of any reference herein should not be construed as an admission that such reference is available as prior art to the present application.
Phenazopyridine is an analgesic compound indicated for urinary tract pain, burning, irritation, and discomfort, as well as urgent and frequent urination caused by urinary tract infections, surgery, injury, or examination procedures. Phenazopyridine, while an effective analgesic, carries with it a foreboding side effect profile, with nausea, vomiting, and general GI upset being the most severe events. In an effort to improve the side effect profile and expand the use of phenazopyridine, it is proposed to pursue the development of a prodrug compound that results in the formation of the active drug following transport across the gastrointestinal epithelium.
Phenazopyridine or 2,6-pyridinediamine, 3-(phenylazo), monochloride (CAS number 94-78-0) is an azo dye that exerts topical analgesic or local anesthetic action on the urinary tract mucosa and provides symptomatic relief of pain, burning, urgency, frequency and other discomforts arising from irritation of lower urinary tract caused by infections, trauma, surgery, endoscopic procedures or use of catheters. Phenazopyridine has been marketed since 1925 and since 1951 has had a dual status of prescription and over-the-counter (OTC).
Phenazopyridine is marketed as single agent 100 and 200 mg tablets under a number of brand names including Nefrecil, Phenazodine, Pyridiate, Pyridium, Sedural, Uricalm, Uropyrine, Urodine, and Urogesic. Single agent OTC medications include Azo-Gesic, Azo-Standard, and Uristat (95 mg tablets), ReAzo (97 mg tablets), and URIRelief and Baridium (97.2 mg tablets). Phenazopyridine is available as a combined prescription with sulfisoxazole or sulfamethoxazole/trimethoprim and as Phenazopyridine plus in combination with hyosciamine and secbarbitol.
The usual adult dosage is 100-200 mg three times daily after meals for no more than two days and 12 mg/kg/day in three divided doses after meals in children for no more than two days. The pharmacological mechanism of the analgesic effect of phenazopyridine is unknown.
Phenazopyridine is absorbed from the gastrointestinal tract following oral administration. Although the absolute bioavailability in humans has not been determined it is apparently poorly absorbed with the highest prescribed dose of 200 mg yielding maximum plasma levels between 10 and 20 ng/mL. Phenazopyridine is rapidly excreted up to 65% unchanged in urine with approximately 90% of a single dose cleared within 24 hours. Metabolites include aniline, N-acetyl-p-aminophenol (NAPA or acetaminophen) and p-amino phenol. Aniline may contribute to the analgesic effect of orally administered phenazopyridine in the urinary tract mucosa.
Adverse reactions associated with therapeutic doses of phenazopyridine include headache, rash pruritus, gastrointestinal disturbances (nausea, vomiting, and diarrhea), orange to red urine discoloration and staining of soft contact lenses. In cases of insufficient renal clearance phenazopyridine can tinge skin, sclera or fluids yellow due to accumulation of the drug. Methemaglobenemia, hemolytic anemia, renal and hepatic toxicity have been reported, usually at overdose levels. Anaphylactoid reactions have been reported.
Phenazopyridine and the metabolite aniline can cause oxidative stress within red blood cells by conversion of hemoglobin to methemaglobin. Patients with glucose-6-phosphate dehydrogenase deficiency may be predisposed to hemolytic anemia. Phenazopyridine should not be administered to patients with impaired renal function. Exceeding the recommended dose may lead to increased serum levels and toxic reactions. Methemaglobinemia generally follows excessive acute overdose. Considering the long history and fairly widespread use of phenazopyridine, reports of serious toxicity are relatively uncommon.
Long term (2 years) administration of phenazopyridine hydrochloride induced adenomas and adenocarcinomas in the large intestine of rats and lifetime administration caused hepatocellular adenomas and carcinomas in female mice. Phenazopyridine has been shown to be mutagenic in bacteria and mutagenic and clastogenic in mammalian cells. In one limited epidemiological study of 2,214 patients who received phenazopyridine hydrochloride there was no observed increase in the occurrence of any type of cancer over a minimum period of 3 years. Current phenazopyridine product labeling indicates: “Long term administration of phenazopyridine hydrochloride has induced neoplasia in rats (large intestine) and mice (liver). Although no association between phenazopyridine hydrochloride and human neoplasia has been reported, adequate epidemiological studies along these lines have not been conducted.”
Reproduction studies at doses up to 50 mg/kg/day or 110 mg/kg/day in rats and 39 mg/kg/day in rabbits showed no effects on fertility or embryo-fetal development. Phenazopyridine is currently classified in pregnancy category B. There have been no adequate and well controlled studies of phenazopyridine exposure in pregnant women. Surveillance studies have been reported with no link of phenazopyridine use to congenital defects. The Collaborative Perinatal Project monitored 50,282 mother-child pairs with 1,109 exposures recorded during pregnancy and 219 exposures during the first trimester. No association was found with major or minor malformations or individual defects. Surveillance of 229,101 Michigan Medicaid patents identified 469 phenazopyridine exposures during the first trimester. No data was obtained to indicate any association of the drug with abnormalities.
The acute toxicity LD50 for phenazopyridine has been reported as 472 mg/kg (oral) and 200 (i.p.) in rats; and 180 mg/kg (i.p.) in mice. Adequate safety pharmacology and repeat dose nonclinical toxicology studies have not been performed for phenazopyridine.
BRIEF SUMMARY OF THE INVENTION
The invention provides covalent attachment of phenazopyridine and derivatives or analogs thereof to a variety of chemical moieties. The chemical moieties may include any substance which results in a prodrug form, i.e., a molecule which is converted into its active form in the body by normal metabolic processes. For example, the chemical moieties may be single amino acids, dipeptides, or polypeptides.
The chemical moiety is covalently attached either directly or indirectly through a linker to the phenazopyridine. The site of attachment is typically determined by the functional group(s) available on the phenazopyridine.
In one embodiment, the phenazopyridine is attached to a single amino acid which is either naturally occurring or a synthetic amino acid. In another embodiment, the phenazopyridine is attached to a dipeptide or tripeptide, which could be any combination of the naturally occurring amino acids and synthetic amino acids. In another embodiment, the amino acids are selected from L-amino acids for digestion by proteases.
Other objects, advantages and embodiments of the invention are described below and will be obvious from this description and practice of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a graph showing the plasma concentrations of various phenazopyridine-amino acid conjugates in rats following oral administration of the phenazopyridine conjugates. Phenazopyridine (PAP) plasma concentrations versus time profiles are shown following administration of PAP.HCl, Gly-PAP, alanyl-PAP, methionyl-PAP, histidinyl-PAP, tryptophanyl-PAP, valyl-PAP, and lysyl-PAP.
FIG. 2 is a depiction of 2-amino-6-aminoacetamido-3-E-phenazopyridine dihydrochloride.
FIG. 3 is a graph showing mean rat (male) plasma concentration curves of 1) phenazopyridine from phenazopyridine hydrochloride (2.8 mg/kg containing 2.5 mg/kg phenazopyridine base), 2) phenazopyridine from Gly-PAP (4 mg/kg, containing 2.5 mg/kg phenazopyridine base), and 3) Gly-PAP intact prodrug from Gly-PAP (4 mg/kg, containing 2.5 mg/kg phenazopyridine base).
FIG. 4 is a graph showing mean rat (male) plasma concentration curves of 1) phenazopyridine from phenazopyridine hydrochloride (2.8 mg/kg containing 2.5 mg/kg phenazopyridine base) and 2) phenazopyridine from Gly-PAP (0.9 mg/kg, containing 0.6 mg/kg phenazopyridine base).
FIG. 5 is a table showing the solubility of Gly-PAP at room temperature as a free base and HCl salt.
FIG. 6 is a table showing the solubility of Gly-PAP salts in water and bioavailability in rats.
FIG. 7 is a table showing the results of a stability study of Gly-PAP by UV-HPLC.
FIG. 8 is a table showing the results of a stability study of Gly-PAP-HCl in water solution at 4° C. by UV-HPLC at 0.2 mg/ml.
FIG. 9 is a table showing the results of a stability study of Gly-PAP-HCl in water solution at 4° C. by UV-HPLC at 8.8 mg/ml.
FIG. 10 is a table showing the results of a stability study of Gly-PAP-HCL in water solution at room temperature by UV-HPLC.
FIG. 11 is a table summary of phenazopyridine pharmacokinetics following oral administration of Gly-PAP or phenazopyridine HCl in male rats.
FIG. 12 is a table summary of Gly-PAP pharmacokinetics following oral administration of Gly-PAP in male rats.
FIG. 13 is a graph showing mean dog (male) plasma concentration curves of 2) phenazopyridine from phenazopyridine hydrochloride (5.9 mg/kg containing 5 mg/kg phenazopyridine base), 2) phenazopyridine from Gly-PAP (8.1 mg/kg, containing 5 mg/kg phenazopyridine base), and 3) Gly-PAP intact prodrug from Gly-PAP (8.1 mg/kg, containing 5 mg/kg phenazopyridine base).
FIG. 14 is a table summary of pharmacokinetic parameters in plasma collected from male dogs following a single oral administration of Gly-PAP (Group 1) or PAP HCl (Group 2).
FIG. 15 is a table summary of concentrations of PAP and Gly-PAP in urine following a single oral dose of Gly-PAP (Group 1) or PAP HCl (Group 2) to male dogs.
FIG. 16 is a synthetic scheme for production of 2-amino-6-aminoacetamido-3-E-phenazopyridine dihydrochloride.
FIG. 17 is a table demonstrating oral bioavailability of Gly-PAP salts in rats.
FIG. 18 is a table demonstrating reduction of the GI side effect of emesis.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this application the use of “peptide” is meant to include a single amino acid, a dipeptide, a tripeptide, an oligopeptide, a polypeptide, or the carrier peptide. Oligopeptide is meant to include from 2 amino acids to 70 amino acids. Further, at times the invention is described as being an active agent attached to an amino acid, a dipeptide, a tripeptide, an oligopeptide, polypeptide or carrier peptide to illustrate specific embodiments for the active agent conjugate. Preferred lengths of the conjugates and other preferred embodiments are described herein.
A “composition” as used herein refers broadly to any composition containing a described molecule conjugate(s). The composition may comprise a dry formulation, an aqueous solution, or a sterile composition. Compositions comprising the molecules described herein may be stored in freeze-dried form and may be associated with a stabilizing agent such as a carbohydrate. In use, the composition may be deployed in an aqueous solution containing salts, e.g., NaCl, detergents, e.g., sodium dodecyl sulfate (SDS), and other components.
“Phenazopyridine” shall mean:
Compounds useful in the present invention are represented by Formula I:
wherein,
R 1 and R 2 are independently
(a) hydrogen; (b) the residue of an amino acid or peptide; (c)
wherein R 3 is an optionally substituted alkyl or arylalkyl; or
(d) the residue of an amino acid wherein the amine of the amino acid is protected with a t-butylcarbonyl;
wherein at least one of R 1 and R 2 is other than hydrogen.
This patent is meant to cover all compounds discussed regardless of absolute configurations. Thus, natural, L-amino acids are discussed but the use of D-amino acids are also included.
Use of the phrases such as, “decreased”, “reduced”, “diminished” or “lowered” is meant to include at least a 10% change in side effects with greater percentage changes being preferred. For instance, the change may also be greater than 25%, 35%, 45%, 55%, 65%, 75%, 85%, 95%, 96%, 97%, 98%, 99%, or increments therein.
The purity of the prodrug will preferably be greater than 25%, 35%, 45%, 55%, 65%, 75%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, or increments therein.
The term increments is shall include without limitation, ones, tens, and fractions thereof, for instance, 1, 2, 3, 4, . . . or 0.1, 0.2, 0.3, 0.4 etc.
For each of the recited embodiments, the amino acid or peptide may comprise one or more of glycine or of the naturally occurring (L-) amino acids: alanine, arginine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, histidine, isoleucine, leucine, lysine, methionine, proline, phenylalanine, serine, tryptophan, threonine, tyrosine, and valine. In another embodiment, the amino acid or peptide is comprised of one or more of glycine or of the naturally occurring (D) amino acids: alanine, arginine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, histidine, isoleucine, leucine, lysine, methionine, proline, phenylalanine, serine, tryptophan, threonine, tyrosine, and valine. In another embodiment, the amino acid or peptide is comprised of one or more unnatural, non-standard or synthetic amino acids such as, aminohexanoic acid, biphenylalanine, cyclohexylalanine, cyclohexylglycine, diethylglycine, dipropylglycine, 2,3-diaminopropionic acid, homophenylalanine, homoserine, homotyrosine, naphthylalanine, norleucine, ornithine, (4-fluoro)phenylalanine, (2,3,4,5,6 pentafluoro)phenylalanine, (4-nitro)phenylalanine, phenylglycine, pipecolic acid, sarcosine, tetrahydroisoquinoline-3-carboxylic acid, and tert.-leucine. In another embodiment, the amino acid or peptide comprises one or more amino acid alcohols, for example, serine and threonine. In another embodiment the amino acid or peptide comprises one or more N-methyl amino acids, for example, N-methylaspartic acid. In another embodiment, the amino acid or peptide comprises one or more cyclic amino acids, for example, cis-4-hydroxy-D-proline.
In another embodiment, the specific carriers are utilized as a base short chain amino acid sequence and additional amino acids are added to the terminus or side chain. In another embodiment, the above amino acid sequence may have one more of the amino acids substituted with one of the 20 naturally occurring amino acids. It is preferred that the substitution be with an amino acid which is similar in structure or charge compared to the amino acid in the sequence. For instance, isoleucine (Ile)[I] is structurally very similar to leucine (Leu)[L], whereas, tyrosine (Tyr)[Y] is similar to phenylalanine (Phe)[F], whereas serine (Ser)[S] is similar to threonine (Thr)[T], whereas cysteine (Cys)[C] is similar to methionine (Met)[M], whereas alanine (Ala)[A] is similar to valine (Val)[V], whereas lysine (Lys)[K] is similar to arginine (Arg)[R], whereas asparagine (Asn)[N] is similar to glutamine (Gln)[Q], whereas aspartic acid (Asp)[D] is similar to glutamic acid (Glu)[E]. In the alternative, the preferred amino acid substitutions may be selected according to hydrophilic properties (i.e., polarity) or other common characteristics associated with the 20 essential amino acids. While preferred embodiments utilize the 20 natural amino acids for their GRAS characteristics, it is recognized that minor substitutions along the amino acid chain which do not affect the essential characteristics of the amino acid chain are also contemplated.
In one embodiment, the carrier range is between one to 12 chemical moieties with one to 8 moieties being preferred. In another embodiment, the number of chemical moieties is selected from 1, 2, 3, 4, 5, 6, or 7.
Formulations of the invention suitable for oral administration can be presented as discrete units, such as capsules, caplets or tablets. These oral formulations also can comprise a solution or a suspension in an aqueous liquid or a non-aqueous liquid. The formulation can be an emulsion, such as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The oils can be administered by adding the purified and sterilized liquids to a prepared enteral formula, which is then placed in the feeding tube of a patient who is unable to swallow.
Soft gel or soft gelatin capsules may be prepared, for example by dispersing the formulation in an appropriate vehicle (vegetable oils are commonly used) to form a high viscosity mixture. This mixture is then encapsulated with a gelatin based film using technology and machinery known to those in the soft gel industry. The industrial units so formed are then dried to constant weight.
Chewable tablets, for example may be prepared by mixing the formulations with excipients designed to form a relatively soft, flavored, tablet dosage form that is intended to be chewed rather than swallowed. Conventional tablet machinery and procedures, that is both direct compression and granulation, i.e., or slugging, before compression, can be utilized. Those individuals involved in pharmaceutical solid dosage form production are versed in the processes and the machinery used as the chewable dosage form is a very common dosage form in the pharmaceutical industry.
Film-coated tablets, for example may be prepared by coating tablets using techniques such as rotating pan coating methods or air suspension methods to deposit a contiguous film layer on a tablet.
Compressed tablets, for example may be prepared by mixing the formulation with excipients intended to add binding qualities to disintegration qualities. The mixture is either directly compressed or granulated then compressed using methods and machinery known to those in the industry. The resultant compressed tablet dosage units are then packaged according to market need, i.e., unit dose, rolls, bulk bottles, blister packs, etc.
The invention also contemplates the use of biologically-acceptable carriers which may be prepared from a wide range of materials. Without being limited thereto, such materials include diluents, binders and adhesives, lubricants, plasticizers, disintegrants, colorants, bulking substances, flavorings, sweeteners and miscellaneous materials such as buffers and adsorbents in order to prepare a particular medicated composition.
Binders may be selected from a wide range of materials such as hydroxypropylmethylcellulose, ethylcellulose, or other suitable cellulose derivatives, povidone, acrylic and methacrylic acid co-polymers, pharmaceutical glaze, gums, milk derivatives, such as whey, starches, and derivatives, as well as other conventional binders known to persons skilled in the art. Exemplary non-limiting solvents are water, ethanol, isopropyl alcohol, methylene chloride or mixtures and combinations thereof. Exemplary non-limiting bulking substances include sugar, lactose, gelatin, starch, and silicon dioxide.
Preferred plasticizers may be selected from the group consisting of diethyl phthalate, diethyl sebacate, triethyl citrate, cronotic acid, propylene glycol, butyl phthalate, dibutyl sebacate, castor oil and mixtures thereof, without limitation. As is evident, the plasticizers may be hydrophobic as well as hydrophilic in nature. Water-insoluble hydrophobic substances, such as diethyl phthalate, diethyl sebacate and castor oil are used to delay the release of water-soluble vitamins, such as vitamin B6 and vitamin C. In contrast, hydrophilic plasticizers are used when water-insoluble vitamins are employed which aid in dissolving the encapsulated film, making channels in the surface, which aid in nutritional composition release.
It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention can include other suitable agents such as flavoring agents, preservatives and antioxidants. Such antioxidants would be food acceptable and could include vitamin E, carotene, BHT or other antioxidants known to those of skill in the art.
Other compounds which may be included by admixture are, for example, medically inert ingredients, e.g., solid and liquid diluent, such as lactose, dextrose, saccharose, cellulose, starch or calcium phosphate for tablets or capsules, olive oil or ethyl oleate for soft capsules and water or vegetable oil for suspensions or emulsions; lubricating agents such as silica, talc, stearic acid, magnesium or calcium stearate and/or polyethylene glycols; gelling agents such as colloidal clays; thickening agents such as gum tragacanth or sodium alginate, binding agents such as starches, arabic gums, gelatin, methylcellulose, carboxymethylcellulose or polyvinylpyrrolidone; disintegrating agents such as starch, alginic acid, alginates or sodium starch glycolate; effervescing mixtures; dyestuff; sweeteners; wetting agents such as lecithin, polysorbates or lauryl sulfates; and other therapeutically acceptable accessory ingredients, such as humectants, preservatives, buffers and antioxidants, which are known additives for such formulations.
For oral administration, fine powders or granules containing diluting, dispersing and/or surface-active agents may be presented in a draught, in water or a syrup, in capsules or sachets in the dry state, in a non-aqueous suspension wherein suspending agents may be included, or in a suspension in water or a syrup. Where desirable or necessary, flavoring, preserving, suspending, thickening or emulsifying agents can be included.
Liquid dispersions for oral administration may be syrups, emulsions or suspensions. The syrups may contain as carrier, for example, saccharose or saccharose with glycerol and/or mannitol and/or sorbitol. The suspensions and the emulsions may contain a carrier, for example a natural gum, agar, sodium alginate, pectin, methylcellulose, carboxymethylcellulose or polyvinyl alcohol.
The dose range for adult human beings will depend on a number of factors including the age, weight and condition of the patient. Tablets and other forms of presentation provided in discrete units conveniently contain a daily dose, or an appropriate fraction thereof, of one or more of the compounds of the invention. For example, units may contain from 5 mg to 500 mg, but more usually from 10 mg to 250 mg, of one or more of the compounds of the invention.
It is also possible for the dosage form to combine any forms of release known to persons of ordinary skill in the art. These include immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting, and combinations thereof. The ability to obtain immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting characteristics and combinations thereof is known in the art.
Compositions of the invention may be administered in a partial, i.e., fractional dose, one or more times during a 24 hour period, a single dose during a 24 hour period of time, a double dose during a 24 hour period of time, or more than a double dose during a 24 hour period of time. Fractional, double or other multiple doses may be taken simultaneously or at different times during the 24 hour period. The doses may be uneven doses with regard to one another or with regard to the individual components at different administration times.
Likewise, the compositions of the invention may be provided in a blister pack or other such pharmaceutical package. Further, the compositions of the present inventive subject matter may further include or be accompanied by indicia allowing individuals to identify the compositions as products for a prescribed treatment. The indicia may additionally include an indication of the above specified time periods for administering the compositions. For example, the indicia may be time indicia indicating a specific or general time of day for administration of the composition, or the indicia may be a day indicia indicating a day of the week for administration of the composition. The blister pack or other combination package may also include a second pharmaceutical product.
It will be appreciated that the pharmacological activity of the compositions of the invention can be demonstrated using standard pharmacological models that are known in the art. Furthermore, it will be appreciated that the inventive compositions can be incorporated or encapsulated in a suitable polymer matrix or membrane for site-specific delivery, or can be functionalized with specific targeting agents capable of effecting site specific delivery. These techniques, as well as other drug delivery techniques, are well known in the art.
In another embodiment of the invention, the solubility and dissolution rate of the composition is substantially changed under physiological conditions encountered in the intestine, at mucosal surfaces, or in the bloodstream. In another embodiment the solubility and dissolution rate substantially decrease the bioavailability of the phenazopyridine, particularly at doses above those intended for therapy.
For each of the described embodiments, one or both of the following characteristics may be realized: The toxicity or side effects associated with the phenazopyridine conjugate are substantially lower than that of phenazopyridine itself. Some of the additional proposed benefits include the fact that the prodrug is hydrolyzed following oral administration, resulting in increased bioavailability, Tmax increase, increased polarity and solubility, and possible active transport by PepT1 or other transporters. As such the benefits of the prodrug may also provide reduced GI exposure to PAP (and commensurate reduction in side effects), a reduced total dose and longer duration of action.
Another embodiment of the present invention provides phenazopyridine covalently bound to any single amino acid which include the twenty naturally occurring amino acids such as isoleucine, leucine, lysine, methionine, phenylalanine, threonine, tryptophan, valine, alanine, asparagine, aspartate, cysteine, glutamate, glutamine, glycine, proline, serine, tyrosine, arginine, or histidine.
In another embodiment, phenazopyridine is covalently bound to a dipeptide or a polypeptide.
In another embodiment, phenazopyridine is covalently bound to glycine.
In another embodiment, phenazopyridine is covalently bound to at least one glycine and an additional amino acid.
In another embodiment, phenazopyridine conjugates of the present invention are administered in a therapeutically effective amount to a patient to treat, for example, urinary tract pain, burning, irritation, discomfort, or urgent or frequent urination caused by urinary tract infections, surgery, injury, or examination procedures, wherein the amount administered to the patient is 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 5%, 1%, or other fractional amount of the standard dose of unconjugated phenazopyridine that would be administered according to standard clinical protocols.
In one embodiment, the phenazopyridine conjugates of the present invention are administered to a patient and the levels of observed side effects such as, for example, nausea, vomiting, and general GI upset, are reduced by 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, or more relative to the levels of side effects observed when a standard dose of phenazopyridine is administered to a patient.
For each of the recited embodiments, covalent attachment may comprise an amide or carbamate bond.
The abbreviations used herein have their conventional meaning within the chemical and biological arts, unless otherwise specified. For example: “h” or “hr” means hour(s), “min” means minute(s), “sec” means second(s), “d” means day(s), “μL” means microliter(s), “mL” means milliliter(s), “L” means liter(s), “μM” means micromolar, “mM” means millimolar, “M” means molar, “mol” means mole(s), “mmol” means millimole(s), “μg” means microgram(s), “mg” means milligram(s), “×g” means times gravity, “aa” means amino acid(s), “k” means kilo, “μ” means micro, “° C.” means degrees Celsius, “THF” means tetrahydrofuran, “DME” means dimethoxyethane, “DMF” means dimethylformamide, “NMR” means nuclear magnetic resonance, “BOC” means t-butoxycarbonyl, “psi” refers to pounds per square inch, and “TLC” means thin layer chromatography.
The term “alkyl” as used herein by itself or part of another group refers to a straight-chain, branched, or cyclic saturated aliphatic hydrocarbon having from one to ten carbons or the number of carbons designated (C 1 -C 10 means 1 to 10 carbons). Exemplary alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, isohexyl, n-heptyl, 4,4-dimethylpentyl, n-octyl, 2,2,4-trimethylpentyl, nonyl, decyl and the like.
The term “optionally substituted alkyl” as used herein by itself or part of another group refers to an alkyl as defined above that is optionally substituted with one to three substituents independently selected from nitro, cyano, amino, optionally substituted cycloalkyl, optionally substituted heteroaryl, optionally substituted heterocycle, alkoxy, aryloxy, arylalkyloxy, alkylthio, carboxamido, sulfonamido, —COR, —SO 2 R, —N(R)COR, —N(R)SO 2 R or —N(R)C═N(R)-amino, wherein R may be an alkyl group. Exemplary substituted alkyl groups include —CH 2 OCH 3 , —CH 2 CH 2 NH 2 , —CH 2 CH 2 CN, —CH 2 SO 2 CH 3 and the like.
The compounds of the present invention may form salts which are also within the scope of this invention. Reference to a compound of the present invention herein is understood to include reference to salts thereof, unless otherwise indicated. The term “salt(s)” as used herein denotes acidic and/or basic salts formed with inorganic and/or organic acids and bases. In addition, when a compound of the present invention contains both a basic moiety and an acidic moiety, zwitterions (“inner salts”) may be formed and are included within the term “salt(s)” as used herein. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, although other salts are also useful, e.g., in isolation or purification steps which may be employed during preparation. Salts of the compounds of the present invention may be formed, for example, by reacting a compound with an amount of acid or base, such as an equivalent amount, in a medium such as one in which the salt precipitates or in an aqueous medium followed by lyophilization.
The compounds of the present invention which contain a basic moiety may form salts with a variety of organic and inorganic acids. Exemplary acid addition salts include acetates (such as those formed with acetic acid or trihaloacetic acid, for example, trifluoroacetic acid), adipates, alginates, ascorbates, aspartates, benzoates, benzenesulfonates, bisulfates, borates, butyrates, citrates, camphorates, camphorsulfonates, cyclopentanepropionates, digluconates, dodecyl sulfates, ethanesulfonates, fumarates, glucoheptanoates, glycerophosphates, hemisulfates, heptanoates, hexanoates, hydrochlorides (formed with hydrochloric acid), hydrobromides (formed with hydrobromic acid), hydroiodides, 2-hydroxyethanesulfonates, lactates, maleates (formed with maleic acid), methanesulfonates (formed with methanesulfonic acid), 2-naphthalenesulfonates, nicotinates, nitrates, oxalates, pectinates, persulfates, 3-phenylpropionates, phosphates, picrates, pivalates, propionates, salicylates, succinates, sulfates (such as those formed with sulfuric acid), sulfonates (such as those mentioned herein), tartrates, thiocyanates, toluenesulfonates such as tosylates, undecanoates, and the like.
The compounds of the present invention which contain an acidic moiety may form salts with a variety of organic and inorganic bases. Exemplary basic salts include ammonium salts, alkali metal salts such as sodium, lithium, and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, salts with organic bases (for example, organic amines) such as benzathines, dicyclohexylamines, hydrabamines (formed with N,N-bis(dehydroabietyl)ethylenediamine), N-methyl-D-glucamines, N-methyl-D-glucamides, t-butyl amines, and salts with amino acids such as arginine, lysine and the like.
The stereochemical terms and conventions used in the specification are consistent with those described in Pure & Appl. Chem. 68:2193 (1996), unless otherwise indicated.
The term “enantiomeric excess” or “ee” refers to a measure for how much of one enantiomer is present compared to the other. For a mixture of R and S enantiomers, the percent enantiomeric excess is defined as |R−S|*100, where R and S are the respective mole or weight fractions of enantiomers in a mixture such that R+S=1. With knowledge of the optical rotation of a chiral substance, the percent enantiomeric excess is defined as ([α] obs /[α] max )*100, where [α] obs is the optical rotation of the mixture of enantiomers and [α] max is the optical rotation of the pure enantiomer. Determination of enantiomeric excess is possible using a variety of analytical techniques, including NMR spectroscopy, chiral column chromatography or optical polarimetry.
The terms “enantiomerically pure” or “enantiopure” refer to a sample of a chiral substance all of whose molecules (within the limits of detection) have the same chirality sense.
The terms “enantiomerically enriched” or “enantioenriched” refer to a sample of a chiral substance whose enantiomeric ratio is greater than 50:50. Enantiomerically enriched compounds may be enantiomerically pure.
The term “asymmetric carbon atom” refers to a carbon atom in a molecule of an organic compound that is attached to four different atoms or groups of atoms.
The term “predominantly” means in a ratio greater than 50:50.
The term “leaving group” or “LG” refers to an atom or group that becomes detached from an atom or group in what is considered to be the residual or main part of the substrate in a specified reaction. In amide coupling reactions, exemplary leaving groups include —F, —Cl, —Br, —OC 6 F 5 and the like.
The term “isolated” for the purposes of the present invention designates a material (e.g. a chemical compound) that has been removed from its original environment (the environment in which it is naturally present).
Pharmaceutically acceptable carriers include fillers such as saccharides, for example lactose or sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, as well as binders such as starch paste, using, for example, maize starch, wheat starch, rice starch, potato starch, gelatin, tragacanth, methyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, and/or polyvinyl pyrrolidone. If desired, disintegrating agents may be added such as the above-mentioned starches and also carboxymethyl-starch, cross-linked polyvinyl pyrrolidone, agar, or alginic acid or a salt thereof, such as sodium alginate. Auxiliaries are flow-regulating agents and lubricants, for example, silica, talc, stearic acid or salts thereof, such as magnesium stearate or calcium stearate, and/or polyethylene glycol. In one embodiment, dragee cores are provided with suitable coatings which, if desired, are resistant to gastric juices. For this purpose, concentrated saccharide solutions may be used, which may optionally contain gum arabic, talc, polyvinyl pyrrolidone, polyethylene glycol and/or titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. In order to produce coatings resistant to gastric juices, solutions of suitable cellulose preparations such as acetylcellulose phthalate or hydroxypropylmethyl-cellulose phthalate, are used. Dye stuffs or pigments may be added to the tablets or dragee coatings, for example, for identification or in order to characterize combinations of active compound doses.
Other pharmaceutical preparations which can be used orally include push-fit capsules made of gelatin, as well as soft, sealed capsules made of gelatin and a plasticizer such as glycerol or sorbitol. The push-fit capsules can contain the active compounds in the form of granules or nanoparticles which may optionally be mixed with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate and, optionally, stabilizers. In one embodiment, the active compound is dissolved or suspended in suitable liquids, such as fatty oils, or liquid paraffin, optionally with stabilizers.
Fatty oils may comprise mono-, di- or triglycerides. Mono-, di- and triglycerides include those that are derived from C 6 , C 8 , C 10 , C 12 , C 14 , C 16 , C 18 , C 20 and C 22 acids. Exemplary diglycerides include, in particular, diolein, dipalmitolein, and mixed caprylin-caprin diglycerides. Preferred triglycerides include vegetable oils, fish oils, animal fats, hydrogenated vegetable oils, partially hydrogenated vegetable oils, synthetic triglycerides, modified triglycerides, fractionated triglycerides, medium and long-chain triglycerides, structured triglycerides, and mixtures thereof. Exemplary triglycerides include: almond oil; babassu oil; borage oil; blackcurrant seed oil; canola oil; castor oil; coconut oil; corn oil; cottonseed oil; evening primrose oil; grapeseed oil; groundnut oil; mustard seed oil; olive oil; palm oil; palm kernel oil; peanut oil; rapeseed oil; safflower oil; sesame oil; shark liver oil; soybean oil; sunflower oil; hydrogenated castor oil; hydrogenated coconut oil; hydrogenated palm oil; hydrogenated soybean oil; hydrogenated vegetable oil; hydrogenated cottonseed and castor oil; partially hydrogenated soybean oil; partially soy and cottonseed oil; glyceryl tricaproate; glyceryl tricaprylate; glyceryl tricaprate; glyceryl triundecanoate; glyceryl trilaurate; glyceryl trioleate; glyceryl trilinoleate; glyceryl trilinolenate; glyceryl tricaprylate/caprate; glyceryl tricaprylate/caprate/laurate; glyceryl tricaprylate/caprate/linoleate; and glyceryl tricaprylate/caprate/stearate.
Suitable formulations for parenteral administration include aqueous solutions of the ligand in water-soluble form, for example, water-soluble salts and alkaline solutions. In addition, suspensions of the active agent as appropriate oily injection suspensions may be administered. Suitable lipophilic solvents or vehicles include fatty oils, for example, sesame oil, or synthetic fatty acid esters, for example, ethyl oleate or triglycerides or polyethylene glycol-400. Aqueous injection suspensions may contain substances which increase the viscosity of the suspension include, for example, sodium carboxymethyl cellulose, sorbitol, and/or dextran. Optionally, the suspension may also contain stabilizers.
Examples of antioxidants which may be added to the pharmaceutical compositions include BHA and BHT.
Pharmaceutical compositions may contain from 0.01% to 99% by weight of the active agent. Compositions may be either in single or multiple dose forms. The amount of ligand in any particular pharmaceutical composition will depend upon the effective dose, that is, the dose required to elicit the desired gene expression or suppression
Suitable routes of administering the pharmaceutical compositions include oral, buccal, sublingual, parenteral (including subcutaneous, intramuscular, intravenous, and by naso-gastric tube). It will be understood by those skilled in the art that the preferred route of administration will depend upon the condition being treated and may vary with factors such as the condition of the recipient. The pharmaceutical compositions may be administered one or more times daily.
EXAMPLES OF GENERAL SYNTHETIC METHODS
Synthesis of Aminoacyl-phenazopyridine (PAP) Derivatives
Example 1
Preparation of Boc-glycyl-phenazopyridine
To a solution of 875 mg (5 mmol) of Boc-glycine in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 22 h at room temperature at which point an additional 875 mg (5 mmol) of Boc-glycine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride were added. After stirring for an additional 48 h, the precipitated solid was filtered and the filtrate was concentrated to dryness. The residue was dissolved in 40 mL of ethyl acetate and washed with two 40-mL portions of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give 2.24 g of the crude product as an orange oil. The product was purified by column chromatography on 62 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-glycyl-phenazopyridine was obtained as an orange oil: yield 330 mg (18%); 1 H NMR (CDCl 3 ) δ 1.58 (s, 9H), 4.00 (d, 2H, J=4 Hz), 7.47 (m, 4H), 7.80 (m, 2H), 8.17 (d, 1H, J=9 Hz) and 8.29 (br s, 1H). Anal. Calcd for C 18 H 22 N 6 O 3 .0.25 H 2 O: C, 57.67; H, 6.05; N, 22.42. Found: C, 57.86; H, 6.01; N, 22.42.
Example 2
Preparation of Glycyl-phenazopyridine (6-N-Glycylphenazopyridine)
To a solution of 330 mg (0.89 mmol) of Boc-glycyl-phenazopyridine in 20 mL of dichloromethane was added 3.10 mL (41.3 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 2.5 h at which point the reaction was complete. The reaction mixture was poured into 40 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated sodium bicarbonate solution. After drying over sodium sulfate, filtration and removal of the solvent under diminished pressure, glycyl-phenazopyridine was obtained as an orange solid: yield 140 mg (58%); 1 H NMR (CDCl 3 ) δ 3.5 (s, 2H), 7.4-7.6 (m, 3H), 7.75-7.8 (m, 3H) and 8.2 (d, 1H); mass spectrum (ESI), m/z 271 (M+H) + and 293 (M+Na) + . Anal. calcd for C 13 H 14 N 6 O.0.50 H 2 O: C, 55.90; H, 5.41; N, 30.09. Found: C, 56.13; H, 5.16; N, 29.87.
Example 3
Preparation of Glycyl-phenazopyridine Hydrochloride Salt
To a cooled (0-5° C.) solution of 1.0 g (2.70 mmol) of Boc-glycyl-phenazopyridine in 20 mL of EtOAc was bubbled slowly dry HCl (g) [prepared by adding a 36% solution of HCl (5 mL) to H 2 SO 4 ]. The reaction mixture was stirred at room temperature for 3 h following which HPLC analysis showed that the reaction was complete. The thick mixture was filtered and the product was washed with four 15-mL portions of EtOAc and dried under diminished pressure over P 2 O 5 at 45° C. for 6 h. Glycyl-phenazopyridine dihydrochloride was obtained as an orange solid: yield 878 mg (94%); 1 H NMR (DMSO-d 6 ) δ 3.88 (s, 2H), 7.51 (m, 4H), 7.89 (d, 2H, J=7.2 Hz), 8.09 (d, 1H, J=8.7 Hz), 8.46 (m, 3H) and 11.10 (s, 1H). Anal. calcd for C 13 H 16 Cl 2 N 6 O.0.80 H 2 O: C, 43.66; H, 4.96; N, 23.50; Cl, 19.83. Found: C, 43.96; H, 4.64; N, 23.60; Cl, 20.10.
Example 4
Preparation of Glycyl-phenazopyridine Mesylate Salt
To a solution of 300 mg (0.8 mmol) of Boc-glycyl-phenazopyridine in 8 mL of dioxane was added dropwise 207 μL (3.2 mmol) of methanesulfonic acid. The reaction mixture was stirred at room temperature for 90 min after which only 4% conversion was observed. After 1 h 45 min, another 414 μL (6.4 mmol) of methanesulfonic acid were added and stirring was continued at room temperature for 3 h. The precipitated product was filtered, washed with three 6-mL portions of 1,4-dioxane and three 6-mL portions of acetone and dried under vacuum at 45° C. over P 2 O 5 for 18 h. Glycyl-phenazopyridine mesylate salt was obtained as an orange solid: yield 352 mg (94%); 1 H NMR (DMSO-d 6 ) δ 2.41 (s, 6H), 3.89 (s, 2H), 7.43-7.56 (m, 4H), 7.89 (d, 2H, J=7.5 Hz), 8.10 (m, 4H) and 10.87 (s, 1H). Anal. calcd for C 13 H 14 N 6 O.2.65 CH 3 SO 3 H: C, 35.81; H, 4.72; N, 16.01; S, 16.19. Found: C, 35.47; H, 4.79; N, 15.82; S, 15.85.
Example 5
Preparation of Boc-alanyl-phenazopyridine
To a solution of 945 mg (5 mmol) Boc-alanine in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 65 h at room temperature at which point an additional 945 mg (5 mmol) of Boc-alanine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added. After stirring for an additional 24 h, the reaction mixture was concentrated to dryness, dissolved in 40 mL of ethyl acetate and extracted with two 40-mL portions of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate and filtered. The filtrate was concentrated under diminished pressure to give 2.1 g of an orange oil. The oil was purified by column chromatography on 60 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-alanyl-phenazopyridine was obtained as an orange oil: yield 610 mg (32%).
Example 6
Preparation of Alanyl-phenazopyridine
To a solution of 610 mg (1.59 mmol) of Boc-alanyl-phenazopyridine in 15 mL of dichloromethane was added 5.51 mL (73.6 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 3 h at which point the reaction was complete. The reaction mixture was poured into 40 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. Alanyl-phenazopyridine was obtained as an orange solid: yield 290 mg (64%); 1 H NMR (DMSO-d 6 ) δ 1.3 (d, 3H), 3.6 (q, 1H), 7.4-7.7 (m, 4H), 7.9-8.0 (m, 2H) and 8.1 (d, 1H); mass spectrum (ESI), m/z 285 (M+H) + and 307 (M+Na) + .
Example 7
Preparation of Boc-methionyl-phenazopyridine
To a solution of 1.24 g (5 mmol) of Boc-methionine in 10 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h at which point an additional 1.24 g (5 mmol) of Boc-methionine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added. After stirring for an additional 48 h, the reaction mixture was concentrated to dryness, dissolved in 40 mL of ethyl acetate and extracted with two 40 mL portions of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude orange oil was purified by column chromatography on 32 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-methionyl-phenazopyridine was obtained as an orange oil: yield 700 mg (32%).
Example 8
Preparation of Methionyl-phenazopyridine
To a solution of 700 mg (1.57 mmol) of Boc-methionyl-phenazopyridine in 15 mL of dichloromethane was added 2.3 mL (31.4 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 2 h at which point the reaction was complete. The reaction mixture was poured into 60 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed with 40 mL of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. Methionyl-phenazopyridine was obtained as an orange solid: yield 247 mg (46%); 1 H NMR (CDCl 3 ) δ 1.8-1.9 (m, 1H), 2.1 (s, 3H), 2.2-2.4 (m, 1H), 2.6-2.8 (m, 2H), 3.7 (m, 1H), 7.4-7.6 (m, 3H), 7.8-7.9 (m, 3H) and 8.2 (d, 1H); mass spectrum (ESI), m/z 345 (M+H) + and 367 (M+Na) + .
Example 9
Preparation of bis-Boc-tryptophanyl-phenazopyridine
To a solution of 2.0 g (5 mmol) of bis-Boc-tryptophan in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 6 h at room temperature at which point an additional 2.0 g (5 mmol) of bis-Boc-tryptophan and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride were added. After stirring for an additional 72 h, the reaction mixture was filtered and the filtrate was concentrated under diminished pressure. The residue was dissolved in 40 mL of ethyl acetate and extracted with two 40-mL portions of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give 5.47 g of an orange foam. The crude product was purified by column chromatography on 41 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Bis-Boc-tryptophanyl-phenazopyridine was obtained as an orange solid: yield 2.43 g (81%).
Example 10
Preparation of Tryptophanyl-phenazopyridine
To a solution of 360 mg (0.60 mmol) of bis-Boc-tryptophanyl-phenazopyridine in 15 mL of dichloromethane was added 1.80 mL (24.0 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 1.5 h at which point the reaction was complete. The reaction mixture was poured into 50 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude product was purified by chromatography on 41 g of silica gel using 50:50 hexane-ethyl acetate as eluant. Tryptophanyl-phenazopyridine was obtained as an orange solid: yield 10 mg (4%); 1 H NMR (CDCl 3 ) δ 3.0-3.2 (m, 1H), 3.4-3.6 (m, 1H), 3.8-4.0 (m, 1H), 7.0-7.3 (m, 4H), 7.4-7.6 (m, 4H), 7.8-8.0 (m, 2H), 8.2 (d, 1H) and 10.0 (br s, 1H); mass spectrum (ESI) m/z 400 (M+H) + and 422 (M+Na) + .
Example 11
Preparation of Boc-valyl-phenazopyridine
To a solution of 1.51 g (7.0 mmol) of Boc-valine in 10 mL of THF was added 1.33 g (7.0 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.5 g (7.0 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h at which point an additional 1.51 g (7.0 mmol) of Boc-valine, 1.33 g (7.0 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride and 1.4 g (14 mmol) of N-methylmorpholine were added, and the mixture was stirred for an additional 24 h. The solvent was concentrated under diminished pressure and the residue was dissolved in ethyl acetate and washed two times with saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude product was purified by column chromatography on silica gel eluting with 1:1 hexanes-ethyl acetate to give Boc-valyl-phenazopyridine as an orange oil: yield 300 mg (10%).
Example 12
Preparation of Valyl-phenazopyridine
To a solution of 300 mg (0.73 mmol) of Boc-valyl-phenazopyridine in 10 mL of dichloromethane was added 1.72 g (1.1 mL, 14.6 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 3.5 h, then was added dropwise to a saturated aqueous sodium bicarbonate solution. The layers were separated and the aqueous layer was extracted once with dichloromethane. The combined organic layer was dried over sodium sulfate, filtered and the filtrate concentrated under diminished pressure. Valyl-phenazopyridine was obtained as an orange solid: yield 110 mg (48%); 1 H NMR (CDCl 3 ) δ 0.95 (d, 3H), 1.05 (d, 3H), 2.4 (m, 1H), 3.4 (s, 1H), 7.4-7.6 (m, 3H), 7.7-7.9 (m, 3H) and 8.1 (d, 1H); mass spectrum (ESI), m/z 313 (M+H) + and 335 (M+Na) + .
Example 13
Preparation of bis-Boc-lysyl-phenazopyridine
To a solution of 1.73 g (5 mmol) of bis-Boc-lysine in 10 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h. The solvent was removed under diminished pressure and the residue was dissolved in ethyl acetate and washed twice with saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give the crude product as a red oil. Purification of the crude product on a silica gel column, eluting with 1:1 hexanes-ethyl acetate, gave bis-Boc-lysyl-PAP as an orange oil: yield 360 mg (13%).
Example 14
Preparation of Lysyl-phenazopyridine
To a solution of 360 mg (0.66 mmol) of bis-Boc-lysyl-phenazopyridine in 20 mL of dichloromethane was added 3.40 g (2.2 mL, 29.7 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 22 h. An additional 1.53 g (13.4 mmol) of trifluoroacetic acid was added and stirring was continued at room temperature for 2 h. The reaction mixture was added to saturated aqueous sodium bicarbonate solution, causing an orange solid to precipitate. The product was filtered, washed twice with heptane and isopropanol, and dried under diminished pressure at room temperature: yield 200 mg (88%); 1 H NMR (CD 3 OD) δ 1.5-2.2 (m, 6H), 2.9 (t, 2H), 3.7 (t, 1H), 7.5-7.7 (m, 4H), 8.0 (m, 2H) and 8.3 (d, 1H); mass spectrum (ESI), m/z 342 (M+H) + and 364 (M+Na) + .
Example 15
Preparation of Boc-(N-tosyl-histidinyl)-phenazopyridine
A sample of 1.40 g (7.33 mmol) of EDCI was added in one portion to a solution of 3.00 g (7.33 mmol) of Boc-his(Tos)-OH in 60 mL of anhydrous THF. The reaction mixture was stirred at room temperature for 30 min, then 1.56 g (7.33 mmol) of phenazopyridine was added in one portion. The reaction mixture was stirred at room temperature for 96 h (until no further reaction progress was detected by HPLC). The solvent was concentrated under diminished pressure and the residue was dissolved in 200 mL of EtOAc, washed successively with 150 mL of water, 150 mL of satd. aq. NaHCO 3 solution, 150 mL of brine, and dried (Na 2 SO 4 ). The solvent was concentrated under diminished pressure. To remove unreacted phenazopyridine, the oily residue was purified by chromatography on an alumina oxide column (elution with CHCl 3 , then 99:1 CHCl 3 -MeOH). Further purification on a silica gel column (elution with 99:1 CHCl 3 -MeOH, then 98:2 CHCl 3 -MeOH) afforded the product as an orange solid: yield 0.43 g (10%).
Example 16
Preparation of N-Tosyl-histidinyl-phenazopyridine
A sample of 1.28 mL (17.2 mmol) of trifluoroacetic acid was added dropwise to a solution of 0.26 g (0.43 mmol) of Boc-(N-tosylhistidinyl)-phenazopyridine in 12 mL of anhydrous CH 2 Cl 2 . The reaction mixture was stirred at room temperature for 3 h, and then added to a saturated aqueous solution of NaHCO 3 . The organic layer was separated and dried (Na 2 SO 4 ). The solvent was concentrated under diminished pressure to give the crude product as an orange solid: yield 200 mg (100%). A pure sample was obtained using preparative HPLC (93% yield); elution was with 0.1% HOAc in a gradient of CH 3 CN; mass spectrum (ESI) m/z 505 (M+H) + and 527 (M+Na) + . Anal. calcd for C 24 H 24 O 3 S.HOAc: C, 55.31; H, 5.00; N, 19.85. Found: C, 55.71; H, 4.78; N, 19.57.
Example 17
Preparation of Histidinyl-phenazopyridine
A sample of 65 mg (0.48 mmol) of 1-hydroxybenzotriazole was added to a suspension of 12 mg (0.24 mmol) of N-tosylhistidinyl-phenazopyridine (0.12 g, 0.24 mmol) in 10 mL of anhydrous THF. The reaction mixture was stirred at room temperature for 2 h before an additional 65 mg (0.48 mmol) portion of 1-hydroxybenzotriazole was added and the mixture was stirred for an additional 3 h. The solvent was concentrated under diminished pressure and the residue was dissolved in 15 mL of EtOAc and extracted with two 10-mL portions of 0.05 N HCl. The combined aqueous layer was adjusted to pH˜8 by the addition of a saturated aqueous solution of Na 2 CO 3 and then extracted with three 15-mL portions of EtOAc. The combined organic layer was dried (Na 2 SO 4 ) and the solvent was concentrated under diminished pressure to give an orange solid. It was purified by preparative HPLC to give the product as a dark orange solid: yield 40 mg (41%); 1 H NMR (500 MHz, DMSO-d 6 ) δ 1.86 (s, 6H), 3.19-3.31 (m, 2H), 4.39 (br s, 1H), 7.46-7.53 (m, 6H), 7.88 (d, 2H), 8.07 (d, 1H), 8.45 (br s, 4H) and 9.03 (s, 1H); mass spectrum (ESI) m/z 373 (M+Na + ); mass spectrum (ESI) m/z 373 (M+Na) + .
Synthesis of Phenazopyridine (PAP) Carbamates
Example 18
Preparation of Ethylcarbamyl-phenazopyridine
A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide (LiHMDS) (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min, a solution of 0.26 g (0.23 mL, 2.40 mmol) of ethyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 1 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (17×3 cm). Elution with a stepwise gradient of dichloromethane in hexane (20→80%) gave the monocarbamate as an orange solid: yield 203 mg (30%); 1 H NMR (CD 3 OD) δ 1.32 (t, 3H, J=7.0 Hz), 4.22 (q, 2H, J=7.0, 14.2 Hz), 7.33 (d, 1H, J=9.0 Hz), 7.40 (m, 1H), 7.48 (t, 2H, J=7.2 Hz), 7.82 (d, 2H, J=9.9 Hz) and 8.06 (d, 1H, J=9.0 Hz); mass spectrum (ESI) m/z 286 (M+H) + and 308 (M+Na) + .
Example 19
Preparation of Benzylcarbamyl-phenazopyridine
A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide (LiHMDS) (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min, a solution of 0.41 g (0.34 mL, 2.40 mmol) of benzyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 1 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with a stepwise gradient of dichloromethane in hexane (50→80%), then 1% Et 3 N in dichloromethane gave the monocarbamate as an orange solid: yield 273 mg (33%); 1 H NMR (CD 3 OD) δ 5.21 (s, 2H), 7.32-7.50 (m, 9H), 7.81 (d, 2H, J=9.0 Hz) and 8.06 (d, 1H, J=8.7 Hz); mass spectrum (ESI) m/z 348 (M+H) + and 370 (M+Na + ) + .
Example 20
Preparation of Isobutylcarbamyl-phenazopyridine
A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min., a solution of 0.32 g (0.31 mL, 2.40 mmol) of isobutyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 18 h. The solvent was concentrated under diminished pressure and the residue purified on a silica gel column (17×3 cm). Elution with a stepwise gradient of EtOAc in hexane (0 to 15%) gave the bis-carbamate as an orange solid: yield 140 mg (14%), followed by the monocarbamate as an orange solid: yield 202 mg (27%); 1 H NMR (DMSO-d 6 ) δ 0.93 (d, 6H, J=6.9 Hz), 1.92 (m, 1H), 3.89 (d, 2H, J=6.6 Hz), 7.31 (d, 1H, J=8.7 Hz), 7.44 (m, 1H), 7.52 (t, 2H, J=8.7 Hz), 7.86 (d, 2H, J=8.1 Hz) and 8.02 (d, 1H, J=8.7 Hz); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + .
Example 21
Preparation of Dodecylcarbamyl-phenazopyridine
A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min at −5° C., a solution of 0.59 g (0.65 mL, 2.40 mmol) of dodecyl chloroformate in 5 mL of THF (5 mL) was added dropwise to the reaction mixture at −5° C. over a period 5 min. The reaction mixture was stirred at −5° C.-0° C. for 1 h and then at room temperature for 24 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with 20% EtOAc in hexane gave the slightly impure monocarbamate as an orange solid. The product was dissolved in hot EtOAc (5 mL) and the mixture was left to cool to room temperature. The precipitated product was collected by filtration and dried under diminished pressure. The phenazopyridine dodecyl monocarbamate was obtained as an orange solid: yield 361 mg (36%); 1 H NMR (DMSO-d 6 ) δ 0.83 (t, 3H, J=6.3 Hz), 1.22 (m, 18H), 1.6 (m, 2H), 4.09 (t, 2H, J=6.6 Hz), 7.30 (d, 1H, J=8.7 Hz), 7.43 (m, 1H), 7.51 (t, 2H, J=7.6 Hz), 7.61 (br s, 2H), 7.85 (d, 2H, J=8.4 Hz), 8.01 (d, 1H, J=8.7 Hz) and 10.08 (s, 1H). Anal. calcd for C 24 H 35 N 5 O 2 .1.25 H 2 O: C, 64.33; H, 8.44; N, 15.63. Found: C, 63.96; H, 7.83; N, 15.44.
Example 22
Preparation of 2-Ethylhexylcarbamyl-phenazopyridine
A solution of 2.81 mL (2.81 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 13 min at −5° C., to a cooled solution of 0.3 g (1.40 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min. at −5° C., a solution of 0.28 g (0.28 mL, 1.45 mmol) of 2-ethylhexyl chloroformate in 35 mL of THF was added dropwise at −5° C. over a period of 5 min. The reaction was stirred at 0° C. for 1 h and then at room temperature for 24 h. The solvent was concentrated under diminished pressure and the residue was purified by chromatography on a silica gel column (17×3 cm). Elution with a stepwise gradient of EtOAc in heptanes (0→10%) gave the bis-carbamate as an orange syrup: yield 57 mg (7%), followed by the monocarbamate as an orange syrup: yield 309 mg (59%); 1 H NMR (DMSO-d 6 ) δ 0.86 (m, 6H), 1.26-1.40 (m, 8H), 1.56 (m, 1H), 4.01 (d, 2H, J=5.7 Hz), 7.31 (d, 1H, J=8.4 Hz), 7.43 (m, 1H), 7.51 (t, 2H, J=7.5 Hz), 7.85 (d, 2H, J=8.1 Hz), 8.01 (d, 1H, J=8.7 Hz) and 10.09 (s, 1H); mass spectrum (ESI) m/z 370 (M+H) + and 392 (M+Na) + .
Anal. calcd for C 20 H 27 N 5 O 2 : C, 65.02; H, 7.37; N, 18.96. Found: C, 65.41; H, 7.43; N, 18.51.
Example 23
Preparation of tert.-Butylcarbamyl-phenazopyridine
A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 8 min at 5° C., to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min. at −5° C., a solution of 0.53 g (2.46 mmol) of (Boc) 2 O in 5 mL of THF was added dropwise at 0° C. over a period of 10 min. The reaction mixture was stirred at 0° C. for 1 h and then at room temperature for 2 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with a stepwise gradient of EtOAc in hexanes (0→10%) gave a mixture of the mono and bis-carbamates. The mixture was purified further on a preparative HPLC column. The mono carbamate (R t 19.9 min.) was obtained as an orange foam: yield 451 mg (61%); 1 H NMR (DMSO-d 6 ) δ 1.60 (s, 9H), 7.40 (d, 1H, J=9 Hz), 7.56 (m, 1H), 7.63 (t, 2H, J=7.6 Hz), 7.97 (d, 2H, J=8.4 Hz), 8.11 (d, 1H, J=9.0 Hz) and 9.89 (s, 1H); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + . Anal. calcd for C 16 H 19 N 5 O 2 : C, 61.33; H, 6.11; N, 22.35. Found: C, 61.37; H, 6.26; N, 22.15. The bis carbamate (R t 22.5 min.) was obtained as an orange syrup: yield 118 mg (12%); mass spectrum (ESI) m/z 414 (M+H) + and 436 (M+Na) + .
Example 24
Preparation of Trichloroethylcarbamyl-phenazopyridine
To a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF was added 0.64 g (4.68 mmol) of oven-dried K 2 CO 3 followed by a solution of 0.5 g (0.32 mL, 2.4 mmol) of trichloroethyl chloroformate in 5 mL of THF (added dropwise at room temperature over a period of 20 min.). The reaction mixture was stirred at room temperature for 4 days. The insoluble material was filtered and the solvent was concentrated under diminished pressure. The residue was purified on a silica gel column (16×3 cm), eluting with a stepwise gradient of EtOAc in hexane (0→8%). The product was obtained as a mixture of mono and bis carbamates. This mixture was fractionated on a preparative HPLC column. The mono carbamate (R t 20.3 min) was obtained as an orange solid: yield 169 mg (18%); 1 H NMR (DMSO-d 6 ) δ 4.97 (s, 2H), 7.26 (d, 1H, J=8.4 Hz), 7.44 (m, 1H), 7.55 (t, 2H, J=7.5 Hz), 7.63 (brs, 2H), 7.87 (d, 2H, J=8.4 Hz), 8.05 (d, 1H, J=9.0 Hz) and 10.69 (s, 1H); mass spectrum (ESI) m/z 390 (M+H) + and 413 (M+Na+H) + . Anal. calcd for C 14 H 12 Cl 3 N 5 O 2 : C, 43.27; H, 3.11; N, 18.02; Cl, 27.56. Found: C, 43.50; H, 3.11; N, 17.78; Cl; 27.56. The bis carbamate (R t 22.9 min) was obtained as an orange solid: yield 58 mg (4%); mass spectrum (ESI) m/z 564 (M) + .
Example 25
Preparation of n-Butylcarbamyl-phenazopyridine
To a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF was added 0.64 g (4.68 mmol) of oven-dried K 2 CO 3 followed by a solution of 0.32 g (0.31 mL, 2.4 mmol) of n-butyl chloroformate in 5 mL of THF (added dropwise at room temperature over a period of 10 min). The reaction mixture was stirred at room temperature for 4 days. The insoluble material was filtered and the solvent was concentrated under diminished pressure. The residue was purified on a short pad of silica, eluting with 20% EtOAc in hexane. The product was purified further on a preparative HPLC column. The mono carbamate (R t 20.1 min) was obtained as an orange solid: yield 252 mg (34%); 1 H NMR (DMSO-d 6 ) δ 0.91 (t, 3H, J=7.2 Hz), 1.38 (m, 2H), 1.60 (m, 2H), 4.11 (t, 2H, J=5.8 Hz), 7.30 (d, 1H, J=8.7 Hz), 7.44 (m, 1H), 7.52 (t, 2H, J=7.2 Hz), 7.86 (d, 2H, J=7.2 Hz), 8.02 (d, 1H, J=8.4 Hz) and 10.09 (s, 1H); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + . Anal. calcd for C 16 H 19 N 5 O 2 : C, 61.33; H, 6.11; N, 22.35. Found: C, 61.23; H, 6.11; N, 22.08.
Example 26
Preparation of N α -Boc-glycine Cyanomethyl Ester
To a solution containing 2.0 g (11.4 mmol) of N α -Boc-glycine in 25 mL of EtOAc was added 1.73 g (2.38 mL, 17.1 mmol) of triethylamine followed by 2.05 g (1.19 mL, 17.1 mmol) of bromoacetonitrile. The reaction mixture was stirred at 60° C. under an argon atmosphere for 16 h. The heterogeneous mixture was cooled to room temperature and filtered through a short pad of silica, washing with EtOAc to remove the precipitated triethylamine hydrobromide. The filtrate was concentrated under diminished pressure to give N α -Boc-glycine cyanomethyl ester as a colorless syrup which solidified upon standing. The crude product was used directly in the next step without further purification: yield 2.12 g (87%); 1 HNMR (500 MHz, CDCl 3 ) δ 1.45 (s, 9H), 4.05 (d, 2H, J=5.5 Hz) and 4.79 (s, 2H).
Example 27
Preparation of 6-N-Boc-phenazopyridine and 2,6-N,N-bis-Boc-phenazopyridine
To a solution of 3.2 g (15 mmol) of phenazopyridine in 20 mL of anhydrous THF under argon atmosphere was added 30 mL (30 mmol) of a 1 M solution of LiHMDS in THF over a period of 15 min. After further 10 min, a solution of 3.27 g (15 mmol) of (Boc) 2 O in 15 mL of anhydrous THF was added slowly over a period of 20 min and the reaction was allowed to proceed for a further 3 h at room temperature. The solvent was concentrated under diminished pressure and the residue was partitioned between 100 mL of dichloromethane and 100 mL of 0.1 N aqueous HCl. The organic layer was washed with two 50-mL portions of water, dried (Na 2 SO 4 ) and concentrated under diminished pressure. Purification by chromatography on a silica gel column (20×4 cm), eluting with hexanes-ethyl acetate (7:1 and 6:1) gave successively 2,6-N,N-bis-Boc-phenazopyridine as an orange foam: yield 1.28 g (20%); silica gel TLC R f 0.44 (5:1 hexanes-ethyl acetate); 1 H NMR (500 MHz, CDCl 3 ) δ 1.51 (s, 9H), 1.57 (s, 9H), 7.47 (d, 1H, J=7.0 Hz), 7.52 (t, 2H, J=7.5 Hz), 7.83 (d, 2H, J=9.5 Hz), 8.15 (t, 2H, J=9.7 Hz) and 10.18 (s, 1H); mass spectrum (ESI) m/z 414 (M+H) + and 436 (M+Na) + , then a mixture of 6-N-Boc-phenazopyridine and 2,6-N,N-bis-Boc-phenazopyridine in 8:1 ratio: yield 1.15 g, and finally 6-N-Boc-phenazopyridine: yield 0.99 g. Another 0.61 g of 6-N-Boc-phenazopyridine was recovered from the mixture by crystallization from 32 mL of 7:1 hexanes-ethyl acetate. 6-N-Boc-phenazopyridine was obtained as an orange solid: yield 1.6 g (34%); silica gel TLC R f 0.34 (5:1 hexanes-ethyl acetate); 1 H NMR (500 MHz, CDCl 3 ) δ 1.53 (s, 9H), 7.39 (m, 1H), 7.48 (m, 3H), 7.79 (d, 2H, J=8.0 Hz) and 8.13 (d, 1H, J=8.5 Hz); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + .
Example 28
Preparation of 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine
To a solution of 215 mg (0.68 mmol) of 6-N-Boc-phenazopyridine in 9 mL of anhydrous THF was added dropwise 0.69 mL (0.69 mmol) of a 1 M solution of LiHMDS in THF followed by 147 mg (0.69 mmol) of N α -Boc-glycine cyanomethyl ester. The reaction mixture was stirred at room temperature for 45 min. Another 0.69 mL (0.69 mmol) of a 1 M solution of LiHMDS in THF was added dropwise followed by 147 mg (0.69 mmol) of N α -Boc-glycine cyanomethyl ester. This procedure was repeated four more times every 45 min. and stirring was continued for another 19 h at room temperature. The reaction was quenched by slow addition of 25 mL of water and the reaction mixture was extracted with two 25-mL portions of ethyl acetate. The combined organic layer was dried (Na 2 SO 4 ) and concentrated under diminished pressure. Purification by chromatography on a silica gel column (15×4 cm) eluting with a stepwise gradient of EtOAc in hexanes (10→50%) gave 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine as a brown solid: yield 94 mg (29%); 1 H NMR (500 MHz, CDCl 3 ) δ 1.47 (s, 9H), 1.55 (s, 9H), 4.56 (s, 2H), 7.47-7.53 (m, 3H), 7.83-7.88 (m, 2H), 8.17 (d, 11-1, J=9.0 Hz), 8.35 (s, 1H) and 10.40 (s, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 47.04, 80.21, 81.68, 107.09, 122.71, 129,24, 129.55, 131.29, 133.06, 145.73, 152.12, 152.81, 156.22 and 169.71; mass spectrum (ESI) m/z 471 (M+H) + and 493 (M+Na) + . Anal. calcd for C 23 H 30 N 6 O 5 .1.2 H 2 O: C, 56.13; H, 6.64; N, 17.08. Found: C, 56.03; H, 6.47; N, 17.02.
Example 29
Preparation of 2-N-Glycyl-phenazopyridine Hydrochloride
To 34 mg (0.07 mmol) of 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine was added 2.5 mL (2.5 mmol) of a 1 M solution of HCl in EtOAc. The reaction mixture was stirred at 65° C. for 2.5 h. Another 2 mL (2 mmol) of 1 M HCl in EtOAc was added and stirring was continued at 65° C. for another 45 min. The precipitated product was filtered, washed with two 5-mL portions of EtOAc and dried under vacuum for 24 h. 2-N-Glycyl-phenazopyridine hydrochloride was obtained as a brown solid: yield 20.8 mg (84%); 1 H NMR (DMSO-d 6 , 500 MHz) δ 4.16 (d, 2H, J=5.0 Hz), 6.49 (d, 1H, J=9.0 Hz), 7.45 (m, 1H), 7.51 (m, 2H), 7.87 (d, 2H, J=9.0 Hz), 7.96 (d, 1H, J=9.0 Hz) and 8.30 (br s, NH); 13 C NMR (DMSO-d 6 , 125 MHz) δ 42.70, 106.90, 122.88, 128.01, 129.36, 129.66, 130.60, 148.10, 152.62, 160.15 and 167.58; mass spectrum (ESI) m/z 271 (M+H) + , 272 (M+2H) + , 293 (M+Na) + .
Example 30
Oral Bioavailability of PAP Prodrug in Rats
The oral bioavailability of PAP (phenazopyridine) prodrugs was evaluated in healthy rats. All the PAP amide (amino acid derivatives) bases were dissolved in 0.1N HCl (the same result can be obtained with a lower molarity), while the carbamates were dissolved in PEG-400 due to the very poor aqueous solubility of the PAP-carbamates. The physicochemical properties of various PAP derivatives are shown in Table 1. In general, all of the amino acid amide derivatives of PAP had higher water solubility than those of the PAP-carbamates. In another PK study, PAP.HCl salt, Gly-PAP.HCl salt and Gly-PAP.mesylate salt were dissolved in water, affording a clear solution in each case prior to oral administration.
The rats were fasted overnight prior to dosing. Appropriate amount of each compound was administered via gastric gavages, and at predetermined time (1, 2, 4, 6, and 24 h) blood samples were withdrawn from the rats. The whole blood was centrifuged immediately, and supernatant (plasma) was collected. The plasma samples were assayed for PAP using LC-MS-MS.
TABLE 1
Physicochemical properties of PAP-prodrug
and administered oral dose in rats
Mol.
Solubility in
Oral Dose,
PAP
Compound's
Wt.
0.1 N HCl
mg/kg
free-base
Generic name
(g/mol)
(mg/mL)
prodrug
equivalent
PAP · HCl
249.7
0.5
10.0
8.5
Gly-PAP
270.3
>2
13.4
10.6
Alanyl-PAP
284.3
2
14.2
10.6
Methionyl-PAP
344.4
1
10.0
6.2
Ethylcarbamyl-PAP
285.3
<0.1
13.4
10.0
Benzylcarbamyl-PAP
347.4
<0.1
8.2
5.0
Isobutylcarbamyl-PAP
313.4
<0.1
7.4
5.0
Histidinyl-PAP
350.4
>10
8.2
5.0
Tryptophanyl-PAP
399.0
0.5
9.4
5.0
Valyl-PAP
312.0
>2.5
14.6
10.0
Lysyl-PAP
341.0
>2.5
16.0
10.0
TABLE 2
Pharmacokinetic analysis of PAP prodrugs following oral administration in rats
PAP-free
Actual
base
Relative
Dose
equivalent
C max
T max
AUC 0-24
Bioavailability
Compound
(mg/kg)
(mg/kg)
(ng/mL)
(h)
(ng · h/mL)
(%)
PAP•HCl
10
8.5
54
<1
182 ± 12
100
Gly-PAP
13.6
10
344
<1
2235 ± 132
985
Alanyl-PAP
14.4
10
173
<1
511 ± 41
225
Methionyl-PAP
10
5.9
80
<1
193 ± 46
145
Ethylcarbamyl-PAP
13.4
10
BQL
ND
0
0
Isobutylcarbamyl-
7.4
5
8.6
6
136 ± 25
127
PAP
Benzylcarbamyl-PAP
8.2
5
8
<1
65 ± 7
61
Histidinyl-PAP
8.2
5
13.7
<1
172 ± 3.4
161
Tryptophanyl-PAP
9.4
5
17.1
2
145 ± 4.6
135
Valyl-PAP
14.6
10
213
0.5
225 ± 25
105
Lysyl-PAP
16.0
10
249
0.5
821 ± 97
383
AUC: area under curve of plot plasma concentration vs. time, 0-24 hr
Relative Bioavailability (%) = [AUC(prodrug)/AUC(drug) × Dose(drug)/Dose(prodrug)] 100
BQL: below quantitation limit (<0.5 ng/mL)
C max : peak plasma concentration
T max : time to reach peak plasma concentration (C max )
The pharmacokinetics data is summarized in Table 2. The relative bioavailability of PAP prodrug was in the following order: glycine>lysine>alanine>histidine>methionine>tryptophan>valine>isobutylcarbamyl>benzylcarbamyl>ethylcarbamyl. T max was longer for isobutylcarbamyl-PAP and tryptophanyl-PAP, while the T max for the rest of PAP derivatives were less than an hour.
The pharmacokinetics data for various salt forms of Gly-PAP is shown in Table 3. The free base of Gly-PAP, as well as the HCl and mesylate salts, have significantly enhanced bioavailability as compared with the HCl salt of PAP.
The pharmacokinetics data for various salt forms of Gly-PAP is shown in Table 3. The free base of Gly-PAP, as well as the HCl and mesylate salts, have significantly enhanced bioavailability as compared with the HCl salt of PAP.
TABLE 3
PAP Pharmacokinetics in rats following oral administration of PAP•HCl
salt, Gly-PAP freebase, Gly-PAP•HCl salt, and Gly-PAP•mesylate salt
Vehicle
used to
Dose
AUC 0-6
dissolve
(mg/kg,
C max
(ng ·
com-
PAP base
(ng/
T max
h/mL)
T 1/2
Compounds
pound
equivalent)
ml)
(h)
(SD)
(h)
PAP•HCl
Water
2.5
58
0.25
105 (20)
0.8
Gly-PAP•HCl
Water
2.5
140
1.0
433 (12)
1.5
Gly-
Water
2.5
102
1.0
237 (51)
1.6
PAP•mesylate
Gly-PAP•free
0.1 N
2.8
211
0.5
378 (57)
1.7
base
HCl
Example 31
Alternative Synthesis of 2-Amino-6-aminoacetamido-3-E-phenazopyridine Dihydrochloride
Chemical formula: C 13 H 16 Cl 2 N 6 O
Molecular Weight: 343.21
Description of Manufacturing Process depicted in FIG. 16 . Gly-PAP is an amide prodrug of phenazopyridine with the carboxyl group of glycine covalently bound to the nitrogen of the 6-amine of phenazopyridine.
In the first step of the production of Gly-PAP, phenazopyridine hydrochloride (PAP) was converted to the free base using aqueous potassium carbonate. The free base was extracted into ethyl acetate and isolated by concentration of the solvent in 92% yield. In the second step of the process, phenazopyridine free base was treated with BOC-glycine-OSu in DMF using sodium hydride as the base. The intermediate was isolated by adding water to the reaction mixture which caused the product to precipitate. The product was isolated by filtration, washed with water and recrystallized from isopropyl alcohol to give the intermediate in 34% yield. In the third step BOC-Gly-PAP was deprotected by treatment with HCl in ethyl acetate. The product was isolated in 96% yield by filtration, followed by washing with ethyl acetate and drying at 45° C. under vacuum.
EXPERIMENTAL PROCEDURES
Preparation of Phenazopyridine Free Base from the HCl Salt
To a solution of 27.6 grams (200 mmol) of potassium carbonate in 200 mL of water was added 20.0 grams (80 mmol) of phenazopyridine hydrochloride followed by 200 mL of ethyl acetate. The mixture was stirred at room temperature for 30 minutes. The layers were separated and the aqueous layer was extracted one time with 100 mL of ethyl acetate. The ethyl acetate layer was dried over sodium sulfate, and filtered. The filtrate was concentrated under diminished pressure and the product was dried under vacuum at room temperature to give an orange solid: yield 15.1 grams (92%). NMR (300 MHz, CDCl 3 ) δ 4.80 (br s, 4H), 6.06 (d, 1H), 7.34 (m, 1H), 7.48 (m, 2H), 7.76 (m, 2H), and 7.93 (d, 1H).
Treatment of Phenazopyridine Free Base with N-Boc-Glycine Succinimide Ester
To a suspension of 5.39 g (224.5 mmol) of NaH in 500 mL DMF maintained at 0-5° C. was added dropwise a solution of 16.0 g (74.40 mmol) of phenazopyridine in 250 mL of DMF and the reaction was stirred at 0-5° C. for 30 min. N-Boc-glycine succinimide ester (25.4 g, 93.50 mmol) in DMF (190 mL) was added dropwise at 0-5° C. then the mixture was warmed to room temperature and stirred for 1.5 h. Isopropyl alcohol (25 mL) was added dropwise and the mixture was stirred at room temperature for 15 min. To the reaction mixture was added 60 grams of Celite™ and it was stirred for 15 minutes. The reaction mixture was filtered and the filter cake was washed two times with 100 mL of DMF. Water (2,500 mL) was added to the DMF solution causing an orange solid to precipitate. The mixture was stirred at room temperature for 30 minutes then the precipitated product was filtered, washed with four 250 mL portion of water and then dried under vacuum over P 2 O 5 at 45° C. for 18 h. The crude product was obtained as an orange powder: yield 12.63 g (46%), purity 95.9% by HPLC.
The crude product (12.63 grams, 34.1 mmol) was dissolved in 170 mL iPrOH at 80° C. to form a clear dark orange solution. It was cooled slowly to room temperature and then to 0-5° C. The crystallized product was collected by filtration and dried under vacuum over P 2 O 5 at 45° C. for 2 hours. The product, BOC-glycine-phenazopyridine, was obtained as a light orange solid: yield 9.4 g (74%), purity 98.2% by HPLC. Overall yield 34%. 1 H NMR (300 MHz, CDCl 3 ) δ 1.58 (s, 9H), 4.00 (d, 2H, J=4 Hz), 7.47 (m, 4H), 7.80 (m, 2H), 8.17 (d, 1H, J=9 Hz), and 8.29 (br s, 1H).
Deprotection of Boc-Glycine-Phenazopyridine to Form Gly-Pap Dihydrochloride
To a solution of 9.3 grams (25.1 mmol) of BOC-glycine-phenazopyridine in 236 mL of ethyl acetate was bubbled HCl gas generated by adding concentrated HCl (46 mL, 55.2 grams, 1.53 moles) to 133 mL of concentrated sulfuric acid in a separate flask. After the addition of HCl was complete, the reaction mixture was stirred at room temperature for 3.5 hours. The solid that was formed was isolated by filtration and was washed with 500 mL of ethyl acetate. The product was dried under full vacuum at room temperature to give 8.4 grams of Gly-PAP as an orange solid: yield 98.1%, 98.9% purity by HPLC. 1 H NMR (300 MHz, D 2 O) δ 3.8 (s, 2H), δ 6.5 (d, 1H), δ 7.3 (br s, 3H), δ 7.6 (br s, 2H), δ 8.0 (d, 1H)
Raw Materials and Reagents
Raw Material/
Supplier
Reactant
Part number (P/N)
Purity
CAS number
Phenazopyridine
Spectrum
>99%
136-40-3
hydrochloride
Chemicals
P/N: P1059
Boc-glycine-OSu
Chem-Impex
99%
3392-07-02
International
P/N: 03793
Sodium hydride
Aldrich
95%
7646-69-7
P/N: 223441
DMF
Sigma-Aldrich
99.8%
68-12-2
P/N: 227056
Isopropanol
EMD Chemicals
99.9%
67-63-0
P/N: PX1834-1
HCl (Conc.)
Fisher Scientific
37.0%
7647-01-1
P/N: A144-212
Ethyl acetate
Fisher Scientific
99.9%
141-78-6
P/N: E195-4
H 2 SO 4 (Conc.)
Fisher Scientific
96.1%
7664-93-9
P/N: A484-212
Example 32
Oral Biovailability of PAP and Gly-PAP (Improved Bioavailability, Limited Gly-PAP Exposure, Sustained Release of PAP from Gly-PAP, Increased Delivery to Site of Action
Pharmacokinetics for PAP and Gly-PAP (intact prodrug) were assessed in male rats following administration by oral gavage of mg/kg doses. Rats were fasted overnight prior to dosing. Blood samples were withdrawn at 0.25, 0.5, 1, 2, 4, 6, and 24 hours. The whole blood was centrifuged immediately, and supernatant (plasma) was collected. The plasma samples were assayed for PAP and Gly-PAP by LC-MS-MS.
At a Gly-PAP dose of 4.0 mg/kg (containing 2.5 mg/kg phenazopyridine base approximating 30 mg of a phenazopyridine HCl human equivalent dose (HED*), an increase of roughly 3-fold was observed for phenazopyridine from Gly-PAP compared to the equivalent phenazopyridine hydrochloride dose (2.5 phenazopyridine base content). Plasma levels of Gly-PAP were <5% of those for phenazopyridine from Gly-PAP, illustrating efficient hydrolysis of Gly-PAP with limited systemic exposure to the prodrug. Results are illustrated in FIGS. 1 , 3 , 4 , 11 , and 12 .
Pharmacokinetics for phenazopyridine for Gly-PAP were determined for a lower dose of 0.9 mg/kg Gly-PAP (0.6 mg/kg phenazopyridine base). When plotted with concentrations of phenazopyridine from an approximately 4-fold higher dose of 2.8 mg/kg phenazopyridine HCl (2.5 mg/kg phenazopyridine base) the lower Gly-PAP dose afforded sustained release of phenazopyridine and approximately equal AUC ( FIGS. 3 and 12 ).
When compared to levels of phenazopyridine following oral administration of 100, 200 and 300 mg in humans (approximate human equivalent dose (HED) based on 60 kg person (6.2 rat conversion factor)—Guidance for Industry: Estimating the Maximum Safe Starting Dose for Initial Clinical Trials for Therapeutics in Adult Healthy Volunteers), the levels of phenazopyridine where considerably higher in rats at HEDs of approximately 100 mg or less for both Gly-PAP and phenazopyridine hydrochloride. Although the absolute bioavailability of phenazopyridine hydrochloride in humans has not been determined it appears to be poorly absorbed. (Shang E, et al. Determination of phenazopyridine in human plasma via LC - MS and subsequent development of a pharmacokinetic model. Anal Bioanal Chem. 2005 May; 382(1):216-22). Rat pharmacokinetics have been found to be highly correlated with human pharmacokinetics. (See Chiou, W. L, et al., Pharm. Res. 17:135-140 (2000); Chiou, W. L., et al., Pharm. Res. 15:1474-1479 (1998); and Chiou, W. L., et al., J. Clin. Pharmacol. Ther. 38:532-539 (2000).
Pharmacokinetics for PAP and Gly-PAP (intact prodrug) were assessed in dogs following administration by oral gavage of mg/kg doses. Blood (approximately 2 mL) was collected from a jugular vein into tubes containing lithium heparin anticoagulant predose and at 0.083, 0.25, 0.5, 1, 2, 4, 8, 12, and 24 hours postdose. Urine was collected into plastic containers surrounded by wet ice predose (−18 to 0) and 0 to 24 hours postdose. The volume of each sample was recorded. Plasma and urine samples were assayed for PAP and Gly-PAP by LC-MS-MS.
In dogs Gly-PAP afforded effective delivery of phenazopyridine following oral administration of 8.1 mg/kg Gly-PAP, approximating a HED (Approximate human equivalent dose (HED) based on 60 kg person (1.8 dog conversion factor—Guidance for Industry: Estimating the Maximum Safe Starting Dose for Initial Clinical Trials for Therapeutics in Adult Healthy Volunteers) of 200 mg of phenazopyridine HCl. Phenazopyridine from phenazopyridine HCl containing an equivalent amount of phenazopyridine resulted in greater plasma bioavailability of phenazopyridine; however, a greater amount of phenazopyridine was delivered to the urine from Gly-PAP. The site of action for phenazopyridine is the bladder and urethra. Plasma T max was increased for phenazopyridine from Gly-PAP as compared to phenazopyridine from phenazopyridine HCl, illustrating sustained release. Exposure (AUC 0-24 ) to Gly-PAP was less than 10% of that for phenazopyridine in dogs following administration of Gly-PAP ( FIGS. 13-15 ).
The pharmacokinetics of various salts of Gly-PAP were compared following oral administration to rats. All salt forms improved the oral bioavailability of phenazopyridine as compared to bioavailability from phenazopyridine HCl. Gly-PAP HCl afforded the highest bioavailability ( FIG. 17 ).
Example 33
Reduced Emesis in Dogs
Dogs (1 male/1 female) were dosed by oral gavage 3 times (TID), once every 8 hours, with 40 mg/kg Gly-PAP or 29 mg/kg phenazopyridine HCl (doses contained an equivalent amount of 24.8 mg/kg phenazopyridine base). A single observation of vomitus was observed for Gly-PAP compared to four observations of vomitus for phenazopyridine HCl. Results showing reduction of the GI side effect of emesis are illustrated in FIG. 18 .
Having now fully described this invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof. All patents, patent applications and publications cited herein are fully incorporated by reference herein in their entirety.
|
The present invention is directed to substituted phenazopyridines represented by Formula I. The present invention also relates to the discovery that compounds of Formula I have increased bioavailability as compared to unconjugated phenazopyridine.
| 2
|
RELATED APPLICATIONS
[0001] This application claims priority to Korean Patent Application Serial No.: 10-2007-0110930, filed Nov. 1, 2007, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The disclosed subject matter is directed to apparatus and methods for joining supporting structures, such as flexible poles, that are used to support structures such as tents.
BACKGROUND
[0003] Camping and backpacking tents are designed to be light-weight, compact and easily and quickly set up. As such, all modem tents are made of highly flexible fabrics and a structurally supportive assembly of poles. The total structural assembly is usually referred as a “pole set”. The “pole set” includes multiple poles, each of the poles are formed from multiple sections. Typically, pole sections are strung together longitudinally with an elastic cord to provide a small longitudinal tensioning force that facilitates pole assembly and handling during set up.
[0004] For example, tent poles are typically assemblies of long tubes that are longitudinally interconnected by slide-fit joints to make long thin structural supports. These poles are flexed into curved shapes that then interface with and support the tent fabric For example, a classic two-pole wedge tent for two people would typically have a simple pole set comprised of two 146.5″ long, straight poles, each pole composed of ten 16″ long sections, each section with means to interconnect with the next section resulting in a 1.5″ overlap in length at each of the nine interconnections; the pole sections being held together by an elastic shock cord threaded lengthwise down the middle of the tubular sections.
[0005] Increasingly, modem tents have branched pole structures due to between-pole interconnections. This is done to save weight and to increase strength. In the case of clipping the poles to fabric, there are two distinct types of clips. One type simply encircles the pole and another kind mates to components fixed on the pole.
[0006] Erecting a conventional tent includes laying out the fabric body of the tent, assembling the pole sections into poles, and connecting the poles to the tent. In the case of sleeves in the tent, the poles are threaded through the sleeves by being slid through the long thin channel of fabric, that is the sleeve. It is very difficult, if not impossible, to thread an interconnected or branched pole through a sleeve.
SUMMARY
[0007] The present disclosed subject matter is directed to an apparatus for facilitating the interlocking of support poles in a quick and easy manner, normally as one of the last steps in setting up the requisite structure, just before the structure is erected. As used herein, “structure” is a collective term for any form of shelter, enclosure, dwelling, housing, or the like, and may include a tent. This allows for easy set up of the structure, and allows for new support configurations to be used for structures.
[0008] The present disclosed subject matter allows for tent poles to be attached to each other in a robust and convenient manner once the tent is substantially erected. This attachment may occur after poles have been threaded through sleeves in the tent fabric and/or clips have been used to attach the tent poles to the tent fabric.
[0009] The present disclosed subject matter includes a clipping structure, allowing for the apparatus to clip to the tent fabric. This clipping structure allows a branched and interconnected pole structure to be installed and removed, with minimal strength and difficulty, even by inexperienced outdoors people. For example, separate poles may be selectively attached and removed from an apparatus of the disclosed subject matter rather than as a single unwieldy unit.
[0010] The apparatus of the present disclosed subject matter allows the poles to be interlocked after they have been assembled into the desired supporting structure. This may occur both before and after the poles have been threaded through sleeves in the tent fabric. For example, after the pole is threaded, the apparatus of the disclosed subject matter allows the pole to be interlocked to a mating pole, thus establishing an interlocking pole structure for the tent. Additionally, disassembly of the poles from the apparatus of the disclosed subject matter is easier, when compared to conventional tent pole assemblies.
[0011] The apparatus of the present disclosed subject matter also allows the relative positioning of poles that have been secured together.
[0012] The disclosed subject matter is directed to an apparatus for connecting at least a first pole and a second pole. The apparatus includes a body, for example, of a resilient material. The body includes a bore extending through the body, that receives and retains a first pole. There is also a channel extending into the body for receiving a second pole in a snap-fit, or other interlocking fit, and retaining the pole in the channel in a locking manner. The channel is shaped so as to be partially cylindrical, of, for example, a cross sectional shape that is partially rounded or partially circular. The partially cylindrical shape extends into the body, and is, for example, of an arc greater than 180°. The channel includes an open area, defining an opening for receiving the second pole. The body is such that the bore and the channel are, for example, oriented substantially perpendicularly to each other. The channel may also include grooves and/or protruding ridges for receiving poles with ring members, for seating in the grooves, or gaps, for fitting over the protruding ridges, respectively, for additional securement of the pole in the channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Attention is now directed to the drawings, where like numerals or characters indicate corresponding or like components. In the drawings:
[0014] FIG. 1 is a perspective view of a tent showing the disclosed subject matter in an exemplary operation;
[0015] FIG. 2 is a diagram of an alternate arrangement of apparatus of the disclosed subject matter of FIG. 1 ;
[0016] FIG. 3 is a perspective view of a first embodiment of the disclosed subject matter;
[0017] FIG. 4 is a side view of the body of the first embodiment of FIG. 3 ;
[0018] FIG. 5 is a cross-sectional view of the body of the first embodiment taken along line 3 - 3 of FIG. 3 ;
[0019] FIGS. 6-9 are cross-sectional views of the first embodiment taken along line 3 - 3 of FIG. 3 showing pole assembly;
[0020] FIG. 10 is a perspective view of a second embodiment of the disclosed subject matter;
[0021] FIG. 11 is a cross-sectional view of the body of the second embodiment taken along line 10 - 10 of FIG. 10 ;
[0022] FIG. 12 is a cross-sectional of assembly of mating pole ends for the second embodiment;
[0023] FIGS. 13-16 are cross-sectional views of the second embodiment taken along line 10 - 10 of FIG. 10 showing pole assembly;
[0024] FIG. 17 is a cross-sectional view of the second embodiment taken along line 11 - 11 of FIG. 11 showing the pole assembly complete;
[0025] FIG. 18 is a perspective view of a third embodiment of the disclosed subject matter;
[0026] FIG. 19 is a cross-sectional view of the body of the third embodiment taken along line 18 - 18 of FIG. 18 ;
[0027] FIG. 20 is a perspective view of the third embodiment of the disclosed subject matter showing pole assembly complete;
[0028] FIG. 21 is a cross-sectional view of the third embodiment shown in FIG. 20 taken along line 19 - 19 of FIG. 19 ;
[0029] FIG. 22 is a perspective view of a fourth embodiment of the disclosed subject matter;
[0030] FIG. 23 is a side view of a fourth embodiment of the disclosed subject matter;
[0031] FIG. 24 is a cross-sectional view of the fourth embodiment shown in FIG. 22 taken along line 24 - 24 of FIG. 23 ;
[0032] FIGS. 25A and 25B are cross-sectional views of the fourth embodiment shown in FIG. 22 taken along line 25 - 25 of FIG. 23 ;
[0033] FIG. 26 is a side view of an apparatus in accordance with the fourth embodiment shown in an exemplary operation attached to tent fabric;
[0034] FIG. 27 is a perspective view of a fifth embodiment of the disclosed subject matter;
[0035] FIG. 28 is a cross-sectional view of the apparatus of FIG. 27 , taken along line 27 - 27 of FIG. 27 ;
[0036] FIG. 29 is a perspective view of a sixth embodiment of the disclosed subject matter; and,
[0037] FIG. 30 is a cross-sectional view of the apparatus of FIG. 29 , taken along line 29 - 29 of FIG. 29 .
DETAILED DESCRIPTION
[0038] FIG. 1 shows a pole connector apparatus P 1 (representative of pole connector apparatus 100 a, 100 b, 100 c, 100 d, 100 f, and 100 g, all detailed below) in an exemplary operation in use with a tent 10 , for connecting tent poles 50 , 60 , that form the support for the fabric 20 of the tent 10 . The poles 50 , 60 , for example, are flexible, and may be flexed or flex into curved shapes (orientations). The tent material 20 may include material loops 21 for receiving the tent poles 50 , 60 . Apparatus P 1 may include a clip 300 ( FIG. 24 ) that allows it to attach to the fabric 20 of the tent 10 , to further support the fabric 20 . FIG. 2 is similar to FIG. 1 , but a tent 10 a includes multiple connector apparatus, a central apparatus P 1 and peripheral apparatus P 2 , that connect tent poles 50 , 60 , 70 in an alternate manner. Similar to apparatus P 1 , apparatus P 2 is also representative of apparatus 100 a, 100 b, 100 c, 100 d, 100 f, and 100 g, all detailed below.
[0039] FIG. 3 shows a connector apparatus 100 a in an exemplary operation with tent poles 50 , 60 . The tent poles 50 , 60 are typically identical and universal, of lightweight materials, such as polymers, composites, metals, fiberglass, and the like, and may be assembled from male 51 , 61 (with edge surfaces 51 a, 61 a and extension portions 51 b, 61 b ) and female 52 , 62 segments (with edge surfaces 52 a, 62 a and receiver portions 52 b, 62 b ) (and also FIGS. 6-9 ). These segment 51 , 52 , 61 , 62 receive each other in a slideable manner in a male-female fit. The fit is frictionally snug, when the poles 50 , 60 are flexed, such that the poles 50 , 60 remain attached, until the segments are unflexed and separated from each other by strong manual pulling forces from a human, when the structure which the poles 50 , 60 support is being disassembled
[0040] Turning also to FIGS. 4 and 5 , the connector apparatus 100 a includes a body 100 , with a channel 110 , that includes an opening 111 . The channel 110 is, for example, of a partially circular cylindrical shape, at a first end E 1 of the body 100 . This channel 110 receives the pole 50 , for example, along its surface 111 a in a frictionally secure engagement, such as a snap fitting engagement. For example, the channel 110 may be of a slightly lesser curvature, than the curvature of the pole 50 , to additionally facilitate the frictional engagement. Additionally, the arc of the channel 110 attributable to the space of the opening 111 is less than 180°, or alternately, less than half the circumference of the channel 110 (and accordingly, the arc formed by the channel surface 111 a is greater than 180°, or alternately, greater than half the circumference of the channel 10 ) so that the pole 50 , when inserted into the channel 110 is engaged and interlocked therein (as shown, for example in FIG. 9 ).
[0041] Legs 112 with openings 113 into the body 100 are positioned laterally to the channel 110 . The leg openings 113 provide additional resilience (elasticity or spring-like behavior) to the legs when during pole engagement and interlocking, as detailed below. An outwardly tapered ledge 111 b may extend from the periphery 111 c of the channel 110 , to provide a clear path for the pole 50 upon engagement into the channel 110 (detailed further below).
[0042] Openings 120 are in the midsection M of the body 100 , and a bore 121 extends between the openings 120 . The bore 121 , for example, includes portions of two diameters, a smaller diameter portion 121 a between larger diameter portions 121 b. The difference in the diameter portions 121 a, 121 b creates a shoulder 121 a′ ( FIG. 5 ) that serves as a stop surface or limit of travel for pole segments 61 , 62 , or poles 60 , that are placed into and engaged in the bore 121 , through the respective openings 120 . The bore portions 121 a, 121 b are of a diameter that allows the pole segments 61 , 62 or poles 60 , to be slid into the respective portions 121 a, 121 b through the openings 120 , and remain retained in the portion 121 a in a frictionally tight manner along the surface 121 x (between the shoulders 121 a′ ). The surface 121 x is of constant length (the length indicated by the dimension “x” in FIG. 5 ), and although shown as continuous, may be discontinuous.
[0043] The opposite end E 2 of the body 100 terminates in a foot 130 . The foot 130 may attach to a clip or the like, that is for fastening the body 100 to the fabric of the tent or other structure, as shown in FIG. 26 and described below.
[0044] The body 100 is, for example, a unitary member, made of resilient materials such as plastics, elastomers and the like that allow for a pole to be snap fit into the channel 110 and frictionally engaged therein, as well as frictionally engaged in the bore portion 121 a. Example materials, suitable for use as the body include, Polycarbonates, such as LEXAN® (General Electric Plastics) and Acetyl, such as DELRIN® (DuPont). The body 100 may be formed of these materials by conventional forming techniques, such as injection molding, machining, and the like.
[0045] FIGS. 6-9 show a cross sectional view of the body 100 , to show the connector apparatus 100 a in an exemplary connection operation, where tent poles 50 , 60 are connected. Initially, as shown in FIG. 6 , a male tent pole segment 61 has been inserted (for example, by sliding) into the bore portion 121 a. This male tent pole segment 61 (the extending portion 61 b ) is received in the female segment 62 (in the receiving portion 62 b ), for example by sliding into a male-female engagement, that is given sufficient tolerance so as to allow force transfer without noticeable wobble, yet be easy to take apart by hand when disassembling. There is a gap 63 between the edge 61 a of the male member 61 , and the edge 62 a of the female member 62 , for example, of a length “G.” This length “G” is, for example, slightly greater than the length “x”, and corresponds to the small diameter bore portion 121 a, as the respective edge surfaces 61 a, 62 a abut shoulders 121 a′ of the bore portion 121 a, with a tolerance limiting their travel and movement in the bore 121 .
[0046] Continuing in FIG. 7 , the pole 50 now rests on the ledge 111 b at the opening 111 of the channel 110 (outside of the channel 110 ). The pole 50 is now ready to be attached to the body 100 , by being pushed into the channel 110 of the body 100 , in the direction of the arrow 150 .
[0047] As shown in FIG. 8 , the inward pushing of the pole 50 into the channel 110 (in the direction of the arrow 150 ) causes the legs 112 of the body 100 to flex outward, in the direction of the arrows 152 . Once the pole 50 seats in the channel 110 , the legs 112 snap back (inward) to their initial positions or similar to these initial positions (depending on the curvature of the channel 111 ) moving in direction of the arrows 154 . With the legs 112 having returned to an inwardly oriented position, the pole 50 is frictionally engaged in the channel 110 of the body 100 (and the pole 50 is in contact with the surface 111 a of the channel 110 ), as shown in FIG. 9 . Alternately, in this interlocked position, the pole 50 may be in contact with some of the surface 111 a of the channel 110 (for example, as shown in FIG. 16 ).
[0048] FIGS. 10 and 11 show another embodiment apparatus 100 b of the disclosed subject matter. This apparatus 100 b is similar to apparatus 100 a, in components, construction and materials. Identical and/or similar components for this apparatus 100 b have the same numbers, as those for apparatus 100 a, and these components are in accordance with the descriptions above, for apparatus 100 a. The differences between apparatus 100 b and apparatus 100 a are detailed below.
[0049] The apparatus 100 b includes a groove 114 in the channel 110 , in the body 100 . The groove 114 is cut into the body 100 at the channel 110 , and is of a depth and width suitable for accommodating a ring 200 or other surrounding member on the pole 50 , that is engaged in the channel 110 . For example, the depth of the groove 114 is such that the pole 50 can rest in the channel 110 in frictional contact with all or some of the channel surface 111 a, while the width of the groove 114 is slightly greater than the width “g” of the ring 200 , as shown in FIG. 12 to receive the ring 200 in a frictionally secure manner. The ring 200 , when seated in the groove 114 of the channel 110 , prevents the pole 50 from sliding, once the pole 50 is engaged or interlocked in the channel 110 , as shown in FIG. 17 .
[0050] FIGS. 12-17 detail an exemplary assembly of tent poles 50 and 60 into the apparatus 100 b. FIG. 12 details assembly of the pole 50 from a male segment 51 and a female segment 52 . The male segment 51 includes a main portion 51 b′ from which the extension portion 51 b protrudes. The extension portion 51 b is of a lesser diameter than that of the main portion 51 b′, such that a shoulder 51 a′, defining an edge surface 51 a, is formed at the junction of the portions 51 b′, 51 b. The edge surface 51 a of the shoulder 51 a serves as a limit of travel for the ring 200 (or the female segment 52 at its edge surface 52 a should the ring 200 not be present).
[0051] The extension portion 51 b is, for example, of a constant diameter, such that the ring 200 can slide onto the portion 51 b and remain thereon in a frictionally snug manner, and the receiving portion 52 b of the female segment 52 receives the extension portion 51 b as it slides into the receiving portion 52 b, in a frictionally snug manner. In a typical engagement, to define a connected pole 50 , the ring 200 abuts the edge surface 51 a, and the edge surface 52 a (of the receiving portion 52 b of the female segment 52 ) abuts the ring 200 . The ring 200 is, for example, of a width slightly less than “g” (the gap 53 in the pole 50 between segments 51 , 52 ) and is dimensioned to sit in this gap 53 upon the pole 50 being fully assembled (for engagement and retention in the channel 110 ). In FIG. 13 , the pole 60 has been connected to the apparatus 100 b, similar to that for apparatus 100 a, detailed above. The now connected pole 50 is positioned with respect to the body 100 of the apparatus 100 b, such that the ring 200 aligns with the groove 114 . The pole 50 is moved into contact with the channel 110 , in the direction of the arrow 160 , such that the ring 200 seats in the groove 114 , as shown in FIGS. 14-16 .
[0052] Continued movement in the direction of the arrow 160 causes the legs 112 , to move outward, in the direction of the arrows 162 , as shown in FIG. 15 . Once the pole 50 seats in the channel 110 , the legs 112 snap back (inward) to their initial positions or similar to these initial positions (depending on the curvature of the channel 110 ) moving in direction of the arrows 164 , as shown in FIG. 16 . With the legs 112 having returned to an inwardly oriented position, the ring 100 is seated in the groove 114 , with the surface of the pole in frictional contact with all or some of the surface 111 a of the channel 110 . The pole 50 is engaged in the channel 110 of the body 100 , as shown in FIG. 17 . While the apparatus 100 b has been shown with a single groove 114 , multiple grooves 114 in the channel 110 are also possible. These multiple grooves may accommodate a pole 50 with one or more rings 200 .
[0053] FIGS. 18 and 19 show another embodiment apparatus 100 c of the disclosed subject matter. This apparatus 100 c is similar to apparatus 100 a, 100 b in components, construction and materials. Identical and/or similar components for this apparatus 100 c have the same numbers, as those for apparatus 100 a and 100 b, and these components are in accordance with the descriptions above, for apparatus 100 a and 100 b. The differences between apparatus 100 c and apparatus 100 a and 100 b are detailed below.
[0054] The apparatus 100 c includes a ridge 115 in the channel 110 , in the body 100 . The ridge 115 protrudes from the surface of the channel 110 , and is of a height suitable for accommodating a corresponding gap 53 , in the pole 50 . For example, the gap 53 may be formed along the extension portion 51 b of the male segment 51 , between the edge surface 51 a of the male segment 51 and the edge surface 52 a of the receiving portion 52 b of the female segment 52 . The gap 53 may be, for example, of a height and a width “g” ( FIG. 21 ) suitable for holding the pole 50 (that is correspondingly configured) in a frictionally secure engagement, to prevent sliding of the pole 50 in the channel 110 . Assembly of the poles 50 (pole 50 of FIG. 18 ), 60 into the apparatus 100 c is similar to that described above for apparatus 100 a and 100 b. The resultant engagement of the poles 50 , 60 in the apparatus 100 c, is similar to that described above for apparatus 100 a and 100 b, and shown in FIGS. 20 and 21 .
[0055] While the apparatus 100 c has been shown with a single ridge 115 , multiple ridges 115 in the channel 110 are also possible. These multiple ridges may accommodate a pole 50 with one or more gaps 53 .
[0056] Alternately, apparatus similar to apparatus 100 a, 100 b and 100 c may be such that the channel 110 may include grooves 114 and ridges 115 in any number, provided they accommodate corresponding rings 200 and/or gaps 53 .
[0057] FIGS. 22-25B show another embodiment apparatus 100 d of the disclosed subject matter. This apparatus 100 d is similar to apparatus 100 b in components, construction and materials. Identical and/or similar components for this apparatus 100 d have the same numbers, as those for apparatus 100 b, and these components are in accordance with the descriptions above, for apparatus 100 b. The differences between apparatus 100 d and apparatus 100 b are detailed below.
[0058] The apparatus 100 d includes openings 120 , that include base holes 122 and outwardly tapered opening sections 124 , that allow the pole 60 to pivot therein, for example, in the direction of the double headed arrow 170 . The openings include base holes 122 . The bore portion 121 a includes cam surfaces 126 , that form the major surfaces of the bore portion 121 a (the minor surfaces of the bore portion 121 a are between the major surfaces, and are represented by the line 126 x in FIG. 24 ). The cam surfaces 126 , for example, are diamond-like in shape and formed of edges 126 a. The edges 126 a are formed of curved portions 127 and straight portions 128 . The cam surfaces 126 are symmetrical, concentric (and coaxial along the axis Y 1 ) and disposed opposite to each other. The cam surfaces 126 , as shown further in FIGS. 25A and 25B , are, for example, of a width between the curved edges 128 , and between oppositely oriented straight edges 128 , slightly less than the length (dimension) G′ (that may be equal to the length (dimension) G, detailed above) of the gap 63 between the male 61 and female 62 sections of the pole 60 . The cam surfaces 126 are such that they serve as a guide for the pole 60 , upon pivoting (in the direction of the double headed arrow 170 ).
[0059] For example, in FIG. 25A , the pole 60 is in an initial orientation, where the gap 63 extends between the curved portions 127 of edges 126 a of the cam surfaces 126 . Once pivoted, as shown in FIG. 25B , by movement in any direction of the arrow 170 a, the gap 63 extends between the straight portions 128 of the edges 126 a, with the pivoting limited, as the respective male 61 and female 62 sections of the pole 60 abut their respective opening sections 124 .
[0060] FIG. 26 shows apparatus 100 d, exemplary of apparatus 100 a, 100 b and 100 c, in an example operation. In this operation, the body 100 , via the foot 130 , is connected to a clip 300 . The clip 300 may be, for example, a conventional spring clip. The clip 300 engages a tab 310 of material of the tent 20 in a clamping manner, to hold the tent 20 on the respective poles.
[0061] FIGS. 27 and 28 show another embodiment apparatus 100 f of the disclosed subject matter. This apparatus 100 f is similar to apparatus 100 d in components, construction, materials and operation, as it allows for a pole (for example, a pole 60 similar to that shown in FIGS. 22-25B ) to pivot in the bore 121 . Identical and/or similar components for this apparatus 100 f have the same numbers, as those for apparatus 100 d, and these components are in accordance with the descriptions above, for apparatus 110 d. Apparatus 100 f differs from apparatus 100 d only in that the legs 112 ′ are not open (when compared to the legs 112 of apparatus 100 d ) and the body 100 is solid in its midsection M, except for the bore 121 .
[0062] FIGS. 29 and 30 show another embodiment apparatus 100 g of the disclosed subject matter. This apparatus 100 g is similar to apparatus 100 f in components, construction, materials and operation, as it allows for the pole 60 to pivot in the bore 121 . Identical and/or similar components for this apparatus 100 g have the same numbers, as those for apparatus 100 f, and these components are in accordance with the descriptions above, for apparatus 100 f. Apparatus 100 g differs from apparatus 100 f only in that it has a wide base 131 and lacks the foot 130 of apparatus 100 f, at the end E 2 (opposite end E 1 ).
[0063] While preferred embodiments of the disclosed subject matter have been described, so as to enable one of skill in the art to practice the disclosed subject matter, the preceding description is intended to be exemplary only. It should not be used to limit the scope of the disclosed subject matter, which should be determined by reference to the following claims.
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An apparatus and system allows for poles, for example, tent poles, to be interlocked after they have been assembled into the desired supporting structure. The apparatus includes a body with a bore extending through the body for accommodating a pole and a channel extending into the body for accommodating another pole. The channel facilitates attachment of the pole in a snap-fit or other interlocking fit. The poles may be formed of segments, for example, that join together in male-female fits.
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This application is a continuation-in-part of U.S. patent application Ser. No. 10/811,590 filed on Mar. 29, 2004, now U.S. Pat. No. 7,211,314.
BACKGROUND
Mats have many residential, commercial and industrial uses. Some of the most demanding uses involve factory applications. Mats are commonly placed around industrial machines. There they are subject to heavy traffic, as well as liquid, solid and chemical contamination.
Most industrial mats are fabricated from rubber. The rubber must be hard for durability. On the other hand, it should be resilient and compressive for the comfort and health of the user. These two properties are significantly incompatible with each other. A hard mat is not resilient and compressive. A soft mat, while resilient and compressive, is not durable.
Most mats are supported by legs. Mats are often placed upon metal gratings surrounding a machine or a work area. The gratings are necessary to receive and contain liquid and solid waste and contaminants. The use of mats with legs on top of metal gratings is problematic because the legs tend to sink into and embed within the gratings.
Many mats are fabricated to have surface drain holes to promote liquid and solid drainage. The holes are typically contained within the horizontal top surface of the mat. The problem with such a drain hole configuration is that the holes easily clog. They readily catch and retain foreign objects. A hard object trapped in an upright position within a drain hole often presents a serious safety hazard. The problem could be alleviated by positioning drain holes within a vertical wall on the top mat surface. Unfortunately, vertical wall drain holes are difficult to cost effectively mold into rubber.
Another problem with mats is that they are often subject to liquid, oily or slippery environments. Such environments constitute serious safety hazards because of the unsafe footing to which users are subjected. This problem can be alleviated by bonding grit to the top surface of a mat. However, it is often not cost-effective to cover a mat with grit. Further, the compressive forces to which a mat is subjected by users causes flexure of the mat which tends to break the bond holding the grit to the mat. As a result, it is difficult to keep sufficient grit bonded to a mat during the life expectancy of the mat.
The manufacturing cost of a grit covered mat could be reduced by only applying grit to selective areas of the mat. This becomes problematic because the adhesives typically used to bond grit to a mat are liquid or semiliquid. The adhesives tend to flow out of any surface area or channel to which they are applied. Further, there are no known methods to easily apply adhesives and grit to selective areas of mats.
There is a need for an improved mat which would have one or more of the following features. It could be manufactured from hard rubber for durability, yet feel compressive and resilient when stepped upon. When placed upon a grating it would not sink into or embed within the grating. It would have drain openings which are positioned within vertical surfaces on top of the mat. It would have areas of selectively placed grit bonded onto its top surface. A substantial portion of the selectively placed grit would be below the mat surface. The selectively placed grit would also have support from underneath to inhibit flexure causing the grit to become unbonded. Additionally, a cost-effective method for applying selectively placed grit to the top of the mat is needed. The tendency of a liquid adhesive to flow away from the area where it is initially placed needs to be minimized.
Because of the difficulty of cost effectively molding drain holes into vertical wall surfaces on top of a mat, there is also a need for a cost-effective process for creating drain holes within a vertical wall surface on top of a mat.
SUMMARY
The present invention provides a solution for these problems. One version of the invention is comprised of a mat base, a plurality of long legs, a plurality of short legs, a plurality of ribs, a plurality of channels, a plurality of grit trenches and grit. The mat base has a top surface and a bottom surface. The long legs are perpendicularly attached to the bottom surface of the mat base. This provides resilient support for the mat base.
The short legs are also perpendicularly attached to the bottom surface of the mat base. The short legs support the mat base and modify the resiliency of the mat. The long legs and the short legs are adapted to provide a selected mat compression when a load is applied to the top surface of the mat.
Each rib connects a pair of legs. The length of each rib, as measured along the dimension perpendicular to the mat when the rib is attached to the legs, is approximately the length of the legs to which it is attached. However, its length is not longer than either of the legs to which it is attached. When the mat is placed on top of a floor grating the rib between the legs tends to prevent the mat from becoming embedded within the grating.
The channels subdivide the mat top surface into mat segments. Each channel has a floor and a lateral wall surface. The lateral wall surface is vertically oriented with respect to the top surface of the mat. The lateral wall surface has a drain opening. The drain opening permits drainage from the top surface of the mat to below the bottom surface of the mat.
The grit trenches are embedded within the top surface of the mat. Each trench has two ends. Each end has a retention lip. The retention lip forms a dam for retaining adhesive and grit. The grit is bonded into the trenches by an adhesive. In order to reduce flexure within the trenches at least one trench is supported by some of the long legs perpendicularly attached to the bottom surface of the mat.
The preferred improved mat is constructed with all of the described features. An improved mat may also be constructed with less than all of the described features.
The invention includes a process for fabricating lateral drain openings into the top surface of a mat. The first step of the process is to mold a mat. The mat has a top surface and a bottom surface. Channels subdivide the mat top surface into mat segments. The channels have a floor and a lateral wall surface. The mat is also constructed to have a rib perpendicularly molded into the bottom surface of the mat below each channel.
The next step of the process is to remove material from the floor of at least one channel, at least one of its lateral wall surfaces and its underlying rib. The material is removed to a depth which is below the bottom surface of the mat base. The removal of the material will cause the formation of a drain opening within the lateral wall of the channel. The material can be removed with a grooving tool such as a tire groover.
Preferably, a programmable cartesian robot is used to remove the material. A grooving tool, such as a tire groover is attached to the programmable cartesian robot. The grooving tool has a heated blade. The programmable cartesian robot is programmed to remove the material from the floor of each channel and its underlying rib. The mat is secured onto the workbed of the programmable cartesian robot. The programmable cartesian robot and the attached grooving tool are then used to remove the material from the floor of at least one channel, at least one of its lateral wall surfaces and its underlying rib.
Preferably, a programmable cartesian robot is also used to bond grit into the trenches embedded within the top surface of the mat. An adhesive dispenser is attached to the programmable cartesian robot. The robot is programmed to fill the trenches with adhesive. The mat is secured onto the workbed of the robot. The robot then fills the trenches with adhesive. After the adhesive is placed, grit is spread over the top surface of the mat. Finally, the excess, non bonded, grit is removed. This may be done by shaking the grit off of the mat.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a perspective view of a mat segment of an improved mat.
FIG. 2 is a bottom plan view of an improved mat.
FIG. 3 is a side elevation sectional view of a section of the improved mat of FIG. 2 .
FIG. 4 is a another side elevation sectional view of a section of the improved mat of FIG. 2 .
FIGS. 5 a, 5 b and 5 c are side elevation sectional views of a section of the improved mat of FIG. 2 showing the compression of short legs and long legs of the mat when a compressive load is applied to the top surface of the mat.
FIG. 6 is a perspective view of the mat segment of FIG. 1 after grit has been bonded into the grit trenches of the mat segment.
FIGS. 6 a, 6 b and 6 c are sectional views of a channel of an improved mat showing the process for creating a drain opening within the lateral walls of the channel.
FIG. 7 is a bottom plan view of an improved mat showing drainage paths.
FIG. 8 is a top plan fragmentary view of the mat segment of FIG. 1 showing the application of adhesive to a grit trench.
FIG. 9 is a top plan fragmentary view of the mat segment of FIG. 1 showing the application of grit to a grit trench.
FIG. 10 is a side elevation sectional view of the mat segment of FIG. 9 showing grit bonded by an adhesive into the grit trench of the mat segment.
DESCRIPTION
The preferred embodiment of the improved mat 30 and methods for fabricating it are shown in FIGS. 1 through 10 . Preferably, the mat 30 is molded from a hard rubber. This will promote durability. The mat 30 is comprised of a mat base 32 , long legs 38 , short legs 40 , ribs 44 , channels 52 , grit trenches 64 , adhesive 72 and grit 70 . The mat base 32 has a top surface 34 and a bottom surface 36 .
The long legs 38 are perpendicularly attached to the bottom surface 36 of the mat base 32 . This will provide resilient support for the mat base 32 . The short legs 40 are perpendicularly attached to the bottom surface of the mat base 32 . The long legs 38 and the short legs 40 are adapted to provide a selected mat compression when a load is applied to the top surface 34 of the mat base 32 . The combination of long legs 38 and short legs 40 causes the mat 30 which is constructed from hard rubber to feel and function as if it were constructed from a softer, more compressive rubber.
This function is shown in FIGS. 5 a, 5 b and 5 c. There, a compressive force 42 is applied to the top surface 34 of the mat base 32 . Before the compressive force 42 is applied the long leg 38 is in contact with the ground. The short legs 40 are raised above the ground. The compressive force 42 causes the long leg 38 to compress thereby bringing the short legs 40 closer to the ground. Finally, in FIG. 5 c, the short legs 40 contact the ground and begin to compress. The result is a mat 30 constructed from hard rubber which compresses as if it were constructed from a softer material. We have found that when using a configuration similar to that depicted in FIG. 2 to fabricate an 18 inch by 18 inch by three-quarter inch mat, the combination of 504 long legs and 144 short legs 40 provides the preferred compression of the mat.
The molded mat 30 contains a number of different rib 44 styles. Shorts support ribs 45 are used to provide structural integrity, especially near the drain openings 58 described below. Long ribs 48 are used to connect legs 38 , 40 . Each long rib 48 is approximately the length of the legs 38 , 40 to which it is to be attached. However, the long ribs 48 do not exceed the length of the legs 38 , 40 to which they are attached. A plurality of long ribs 48 are each connected to a pair of legs 38 , 40 . The long ribs 48 will thereby prevent the mat 30 from sinking into and becoming embedded into a grating upon which it is placed. The mat 30 , may also be used on top of a solid floor. If only long ribs 48 were used to connect the legs 38 , 40 , drainage from the top of the mat 30 to the exterior of the mat 30 and air circulation within the mat 30 may be inhibited. Therefore, a plurality of short ribs 46 are used, instead of long ribs 48 , to interconnect some legs 38 , 40 . This will result in expanded gapping between the floor and the short ribs 46 , thereby promoting drainage and circulation, as shown by the drain paths 60 in FIG. 7 .
The channels subdivide the mat top surface 34 into mat segments 62 , as shown in FIG. 1 . Each channel 52 has a floor 54 and a lateral wall surface 56 . Most channels 52 have two lateral wall surfaces 56 . Preferably, the lateral wall surfaces 56 contain drain openings 58 . Such drain openings 58 are positioned upon a vertical lateral wall surface 56 rather than horizontally oriented, as in current mats. Because the drain openings 58 are on vertically oriented surfaces the drain openings are less likely to become clogged by contaminants. The drain openings 58 are also much less likely to trap hard and dangerous objects resulting in safety hazards. Liquids and other contaminants drain through the drain openings 58 to the bottom of the mat 30 and to the exterior of the mat 30 by way of the drain paths 60 .
The grit trenches 64 are embedded within the top surface 34 of the mat base 32 . The grit trenches 64 are intended to hold grit 70 . Each grit trench 64 has two ends 66 . Each end 66 has a retention lip 68 forming a dam for retaining adhesive 72 and grit 70 . The retention lip 68 prevents the adhesive 72 from flowing out of the grit trench 64 , while the adhesive 72 is in a liquid form. This enhances the ability to selectively place grit 70 upon the top surface 34 of the mat 30 .
Grit 70 is securely bonded into the grit trenches 64 with the adhesive 72 . The preferred grit 70 is silicon carbide. The preferred adhesive 72 is cyanoacrylate. In order to minimize the likelihood of mat 30 flexure causing the grit 70 to become unbonded, the grit 70 and adhesive 72 are placed substantially below the top surface 34 of the mat 30 , as shown in FIG. 10 . However, some of the grit 70 must protrude above the top surface 34 of the mat base 32 in order for the grit 70 to increase the coefficient of friction of the top surface 34 of the mat base 32 . To further reduce unbonding of grit 70 by flexure, long legs 38 are perpendicularly attached to the bottom surface 36 of the mat base 32 below the grit trenches 64 in order to provide support for the grit trenches 64 . Because the grit 70 and adhesive 72 are substantially below the top surface 34 of the mat base 32 and because the grit trenches 64 are supported by long legs 38 grit 70 may be selectively placed upon the top surface 34 without significant unbonding being caused by flexure.
Lateral drain openings 58 positioned upon a lateral wall surface 56 are difficult to cost effectively fabricate by molding. Another technique is needed to fabricate the drain openings 58 . First, a mat 30 is molded such that it has a top surface 34 and a bottom surface 36 . It is molded such that channels 52 subdivide the mat top surface 34 into mat segments 62 . As previously described, the channels 52 have a floor 54 and a lateral wall surface 56 . The mat 30 is fabricated such that a rib 48 is perpendicularly molded into the bottom surface 34 of the mat 30 below each channel 52 .
Drain openings 58 may be created within the lateral wall surfaces 56 of each channel 52 by removing material from the floor 54 , at least one lateral wall surface 56 and the underlying rib 48 , 46 of the channel. The material must be removed to a depth which is below the bottom surface 36 of the mat base 32 in order to form a drain opening 58 .
The material may be removed with a grooving tool such as a tire groover. The grooving tool has a heated blade 74 for removing rubber. Preferably, the material is removed from the floor 54 of each channel 52 and its underlying rib 48 , 46 by a process which uses a programmable cartesian robot. The first step of the process is to attach a grooving tool having a heated blade 74 to the robot. Preferably, the grooving tool is a tire groover. The robot is programmed to remove the material from the floor 54 of each channel 56 and its underlying rib 46 , 48 . After the groover is attached to the robot and the robot is programmed, the mat 30 is secured onto the workbed of the robot. Then, the material is removed from the floor 54 of at least one channel 52 , at least one of its lateral wall surfaces 56 and its underlying rib 46 , 48 with the robot and the attached groover, thereby forming a drain opening 58 .
The robot may also be used to automate the bonding of grit 70 into the trenches 64 embedded within the top surface 34 of a mat 30 . First an adhesive dispenser 76 is attached to the robot. The robot is programmed to fill the trenches 64 with adhesive 72 . The mat 30 is secured onto the workbed of the robot. The robot then fills the trenches 64 with adhesive 72 . Before the adhesive 72 sets grit 70 is spread over it. Finally, the excess grit 70 is removed from the mat 30 . Optionally, the programmable cartesian robot may be equipped with a grit dispenser 78 for selectively spreading grit 70 , as shown in FIG. 9 .
A superior grit 70 —mat 30 bond may be obtained by applying two layers of adhesive 72 . An adhesive dispenser 76 is attached to the robot. The robot is programmed to fill the trenches 64 with adhesive 72 . The mat 30 is secured onto the workbed of the robot. A make coat of adhesive 72 is applied by filling the trenches 64 with adhesive 72 . The robot is used to fill the trenches with adhesive 72 . The grit 70 is bonded to the mat by spreading grit 70 over the top surface of the mat 30 . This bonds the grit 72 to the mat 30 . At this point excess grit 70 should be removed from the mat 30 . Following this, the cartesian robot is used to bond the grit 70 to itself by spreading another layer of adhesive 72 over the grit 70 within the trenches 64 . This is known as the size coat. The preferred adhesive 72 is cyanoacrylate. The preferred grit 70 is silicon carbide. It should be clear, however, that this inventive process may be used with many types of adhesive 72 and grit 70 .
Although the invention has been shown and described with reference to certain preferred embodiments, those skilled in the art undoubtedly will find alternative embodiments obvious after reading this disclosure. With this in mind, the following claims are intended to define the scope of protection to be afforded the inventor, and those claims shall be deemed to include equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
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An improved mat is disclosed. Long and short legs support the mat and cause it to feel resilient although it is fabricated from hard rubber. The mat has drain holes on vertical surfaces. Ribs prevent the mat from embedding within grating. Grit is selectively placed upon the mat and physically supported. Adhesive for bonding the grit is retained by retention lips. Also disclosed is a process for creating drain holes on vertical surfaces of mats by attaching a grooving tool to a robot and programming the robot to cut through molded mat channels to create the desired drain holes. The claimed process uses the robot to selectively place adhesive upon the mat. An adhesive dispenser is attached to the robot and the robot is appropriately programmed.
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RELATED APPLICATIONS AND PATENT
This application is a continuation-in-part of pending U.S. patent application Ser. No. 417,554, filed Sept. 13, 1982 now U.S. Pat. No. 4,492,058, which itself was a continuation-in-part of then-pending U.S. patent application Ser. No. 233,495, filed Feb. 11, 1981, and now abandoned. The latter application was in turn a continuation-in-part of U.S. patent application Ser. No. 121,645, filed Feb. 14, 1980, and issued Dec. 22, 1981, as U.S. Pat. No. 4,306,375.
BACKGROUND
1. Field
This invention is in the field of toy vehicles, and particularly relates to self-powered ultraminiature toy vehicles capable of negotiating in water as well on steep and irregular surfaces.
2. Prior Art
An amphibious toy vehicle offered at one time by the Eldon Company had the capability of operation on rough surfaces or in water. This vehicle was about a foot long, was driven by a battery-powered mechanism, and had a separate screw drive for propulsion in water. The entire body of the vehicle served as flotation hull.
The Eldon toy suffered from the major disadvantage that its size virtually prevented use anywhere except at a real pond or beach. A suitably sized "water/land terrain" for such a toy should be at least ten or twenty times the length of the toy itself, which in the case of the Eldon toy requires a space essentially the size of an entire room. Thus size itself--or, more precisely, size of the toy in relation to the size of ordinary play areas, especially indoor play areas--can be of great importance in this particular field of toys.
The Eldon toy also had the important disadvantage of depending exclusively upon its entire outer hull for flotation. If the hull developed a leak below the water line, the toy would fill with water and would sink. If the vehicle sank, its drive mechanism would be completely exposed to water and it would shortly rust and in due course become inoperative. In addition the toy had a screw-type propulsion system for operation in water, adding additional complexity and also adding a potential point of leakage--one very likely to be below the water line.
Many water-play toys have been made to resemble boats or water creatures and to propel themselves along the surface of a body of water. Some of these toys depended for propulsion (but not to any significant extent for flotation) upon rotating wheels or other rotating elements rotatably fixed to the sides of the toys. For example, the Tomy Company has offered bathtub toys configured as toy penguins, fish, dolphins, frogs, and so forth, which float and whose limbs rotate to propel them. The same company has offered bathtub toys configured as toy paddlewheel boats, with lateral, rotatably fixed propulsive paddlewheels.
These toys are all made for water use exclusively, rather than for amphibious use. In the case of the paddlewheel toys, it does not appear that the paddlewheels would both at the same time touch a surface on which the toys were placed, and, even if they would, neither the paddlewheels nor the toy bodies generally were suitably configured to provide good traction or effective operation over rough surfaces. In the case of the rotating-limb toys, the dynamic visual effect of such toys operating on a dry surface would be to lurch forward erratically, producing--at best--generally a comic or silly impression.
All of these tube toys may well be adequate for their intended purpose. They would not be suitable for a toy amphibious vehicle that is intended to suggest the operation of a real amphibious vehicle--e.g., a swamp buggy or a military amphibious carrier. Such a real vehicle should operate very tenaciously and effectively over rough surfaces as well as operate in water, to produce an exciting, "adventure" kind of impression rather than one that is comic or silly.
BRIEF SUMMARY OF THE INVENTION
Our invention provides a self-propelled amphibious miniature toy vehicle for operation along the surface of a pool of water and also on a steep, irregular nonwater surface.
Preferably the vehicle is used with some means for providing electrical energy to power the vehicle; we refer to these means as "electrical battery means." They typically include an elongated dry-cell battery that has a longitudinal axis. When such "battery means" are in use with the vehicle, the vehicle has major weight components positioned to provide a generally symmetrical, compact, balanced and relatively low arrangement. These constraints may be in a certain sense regarded as the context in which our invention operates. As further discussed below and as defined by the appended claims, however, with respect to some of the preferred embodiments of our invention they are also part of the invention itself.
Certain preferred embodiments of our invention have a frame, hollow "wheel means" mounted to the frame for rolling rotation, and an electric motor mounted to the frame and operatively connected to drive at least one of the "wheel means."
We intend the phrase "wheel means" to encompass not only wheels but various forms and types of tires, cleating, paddling structures, half-track- or tank-style endless belts, and/or even skids at one end in combination with rotary driving structures at the other. The wheel means are mounted to the chassis for rolling rotation (of at least some member, such as the driving rollers in the case of a half-track belt) about at least one laterally extending axis.
In the instance of relatively more conventional wheel means, the wheel means have more than one such axis--generally, mutually parallel but spaced-apart front and rear axes. In certain preferred embodiments of our invention the distance between the front and rear axes is generally about two inches.
The wheel means preferably extend below the frame, to effect propulsion of the vehicle along such a nonwater surface, when the vehicle is placed on such a surface. The volume-to-weight ratio of each of the wheel means themselves, however, is sufficiently high that when the vehicle is placed in water the wheel means contribute significantly to flotation of the vehicle.
We prefer to provide cleated tires mounted to the wheel means. The cleats should be adapted and sufficiently pronounced to propel the vehicle along a water surface--provided that generally the bottom half of each wheel means is submerged in the water and generally the top half of each wheel means is above the water. The overall flotation characteristics of the vehicle are, accordingly, made such that when the vehicle is placed in a sufficiently deep pool of water the vehicle floats just that way--i.e., with very generally the bottom half of each wheel means submerged and very generally the top of each wheel means above the water.
Preferred embodiments of our invention also have a separate flotation chamber affixed to the frame. This chamber must be adapted and sized to contribute significantly to flotation of the vehicle in water.
In principle, any compartment that is provided to house the working internal parts of an amphibious toy vehicle can be sealed effectively enough to contribute significantly to flotation. If this is done, a separate flotation compartment is unnecessary--and this arrangement is within the scope of our invention.
It is not, however, in accordance with the embodiments of our invention which we prefer. Keeping the working internal parts of an amphibious toy vehicle dry is relatively very expensive, since seals must be provided for the shafts that drive the wheel means and for the on-off control, as well as along passive seams. We therefore prefer to construct embodiments of our invention on the assumption that water will enter any compartment that may be provided to house the working parts.
Thus we make the working parts operate even when fully submerged in water. Furthermore, since any such compartment that is full of water will not contribute at all to flotation, we prefer to construct embodiments of our invention with adequate flotation provided by the wheels and flotation chamber--not depending at all upon any mechanism compartment for flotation.
By "contribute significantly to flotation of the vehicle" we therefore mean to include, as one extreme case, that the flotation chamber in combination with the wheel means is sufficient to float the vehicle. That constraint, however, need not necessarily be met for a toy vehicle to be within the scope of our invention: a lesser fraction of the necessary flotation may be supplied by a flotation chamber, so long as the fraction is significant. (Yet other embodiments of our invention may require no flotation chamber at all.)
We find it particularly advantageous to provide a flotation chamber that is generally coextensive in width and length with the frame of the vehicle, and disposed below the frame. The wheel means must then extend below the flotation chamber. By making the chamber coextensive with the frame, a desirably compact arrangement of parts is preserved, and the external appearance of the vehicle can be made generally compatible with that of nonamphibious vehicles such as those described in the above-mentioned U.S. patent.
Returning to the subject of operability of the toy mechanism even when fully exposed to water, preferred embodiments of our invention should also have some means for effecting operative electrical connection between the motor and a battery, when such a battery is in place in the toy. We refer to these means as "contact means," and they should in particular be corrosion-resistant, electrically conductive, and fixed to the frame. They should be electrically connected to the motor, and they should be positioned to contact the terminals of a battery when such a battery is mounted in the frame.
Cooperating with the contact means there should also be means for operatively mounting a battery in the frame to power the motor.
The contact means, moreover, also preferably include an electrical on-off switch that is fixed to the frame. This switch has a self-wiping action that protects the switch against any corrosion that may result from exposure of the switch to water.
Such a switch is effectively provided by the following construction. First, there is a first corrosion-resistant formed metal contact fixed to the frame, and disposed and adapted for electrical contact with one terminal of a battery--when the battery is in place. This metal contact has a springy portion, whose purpose will shortly be explained.
Next, there is a second corrosion-resistant formed metal contact, also fixed to the frame and also having a springy portion. This contact, however, is disposed and adapted for electrical contact with the motor rather than with the battery.
Finally, there is a bridging corrosion-resistant formed metal contact that is slidably fixed to the frame. When actuated, this contact slides between two positions. In a first position it is not touching at least one of the first and second contacts mentioned above. In a second position it does touch both of the contacts--at their respective springy portions.
The two springy portions of the respective two metal contacts press firmly against the bridging contact when the bridging contact is in the second position. The direction of motion of the bridging contact, relative to the directions in which the springy portions press, is such that in the course of its sliding motion the bridging contact firmly wipes the springy portions of the first and second contacts where they touch the bridging contact.
This firm wiping action tends to keep the touching areas free from corrosion and thus electrically conductive after the switch parts have been exposed to water, and even while they are submerged.
In addition the motor must be made operable under similar conditions. We have found that this can be done by using a motor whose electrical brushes and bearings are of a corrosion-resistant material, and whose electrical windings are of insulated wire. In particular, enameled copper wire is suitable.
In preferred embodiments of our invention, as stated earlier, the compactness and weight distribution of the parts of the toy vehicle are to be considered important features or elements of our invention. The following six paragraphs elaborate upon these features.
First, the frame defines a chassis with upright walls, and the chassis walls in turn define an interior compartment. Second, the wheel means are hollow wheel means mounted to the chassis for rolling rotation about respective mutually parallel front and rear axes. These axes are spaced apart, generally by about two inches.
Third, the electrical motor is mounted in the interior compartment. We prefer to provide some means in this interior compartment to releasably support the earlier-mentioned electrical battery means. Typically the electrical battery means include an elongated dry-cell battery which has a pronounced longitudinal axis, and the support means should releasably support the battery means with that longitudinal axis extending substantially front-to-back of the vehicle.
In accordance with the preferred size mentioned in the preceding paragraph, the vehicle is quite small, with a very short wheelbase (when there are front and rear wheel means)--so that a single "Penlight" battery cell extends at least substantially the full distance between the previously-mentioned front and rear axes.
Fourth, the vehicle also is provided with some means for electrically connecting the battery means, when the latter is in place, to the motor--so that the battery means power the motor.
Fifth, transmission means are mounted in the interior compartment. These means include a speed-reduction mechanism connecting the motor driveshaft to both the front wheel means and the rear wheel means, to transmit rotation from the driveshaft to the wheel means. This mechanism is made to effect this transmission with reduced speed and increased power--i.e., with a mechanical advantage between the motor shaft and wheel means. We have found that a mechanical advantage between 55:1 and 65:1 is particularly preferable. A mechanism at each end of the motor using a worm and worm gear is especially well-suited to this purpose.
Sixth, at least major portions of these major weight components--the transmission means, the motor, and the battery means when in place--are at about the same height as the front and rear wheel means. Further, these three major weight components, when all are in place, substantially fully occupy the interior compartment.
We have found that observing these constraints upon our toy vehicle design provides a remarkably effective climbing-toy operation. The characteristics of such operation have been described at length in the earlier-mentioned patent. Briefly, however, these characteristics encompass the ability to negotiate steep and irregular surfaces without tipping over--either backward or sideward.
By carrying these constraints into the configuration of a miniature amphibious toy vehicle, we have been able to obtain the entirely new result of an amphibious vehicle which can propel itself along the surface of a pool of water and which, upon emerging from such a pool and without the necessity for any adjustments or new control settings--can proceed to operate as a climbing toy. This result presents to the user (i.e., generally a child) of such miniature vehicles a striking and extremely appealing overall effect.
When the constraints just discussed are combined with certain other features of our invention previously discussed, the impact of the toy is further enhanced.
In addition it is beneficial to provide a toy vehicle body that is mounted to the frame. The body advantageously conceals the motor, worms, worm gears, and dry-cell mounting means (as well as the dry cell itself, when the latter is in place), and is a fantasy design or a scale model derived from at least one real vehicle body. The vehicle-body scale used should be such that the axle spacing turns out to match the spacing between the axes of wheel-means rotation of the toy. The outside diameter of the tires, however, should be at least three times overscale, to produce an exaggerated effect of power and traction--as well as to help supply the buoyancy or flotation capability discussed previously.
All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the appended drawings, of which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of our invention, with a battery in place but partly cut away, and with a mechanism cover shown removed to illustrate the internal parts.
FIG. 2 is a perspective view of the FIG. 1 embodiment shown operating upon a toy terrain that is suitable for being filled or partly filled with water to exercise the amphibious capabilities of the invention.
FIG. 3 is a side elevation, with the terrain shown in section, of the same scene as in FIG. 2.
FIG. 4 is a similar side elevation as in FIG. 3 but showing the terrain partly filled with water and the FIG. 1 embodiment operating along the surface of the water.
FIG. 5 is a plan view of the FIG. 1 embodiment, but without the battery or mechanism cover.
FIG. 6 is a side elevation of the FIG. 1 embodiment, taken along the line 6--6 of FIG. 5.
FIG. 7 is an exploded perspective view of the electrical contacts and switch for the FIG. 1 embodiment, shown dissociated from the chassis.
FIG. 8 is an end elevation of the same embodiment, partly in section and taken along the line 8--8 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1, 5, 6, and 8, a preferred embodiment of our invention is built in and around a chassis 10 consisting of upstanding left and right side walls 11, front end wall 12 and rear end wall 13, all erected about the periphery of an extended horizontal floor 19. The front end wall 12 may have a forward protrusion (not shown) which supports and contains functional connections for a small light bulb, and which also supports a transparent light distributor, all as illustrated and described in detail in the previously-mentioned patent.
The front end wall 12 also has a generally rectangular slot 15, 16 formed in it; and the rear end wall 13 has a similar slot 17, 18--both slots being provided for a purpose to be described.
The chassis 10 serves both as a frame to support and as a partial enclosure to conceal and protect the power source and train.
Mounted below the chassis for rolling rotation with respect to it are two mutually parallel but spaced-apart axles, an axle 36 near the front and an axle 46 near the rear of the chassis. Secured to the ends of these two axles 36 and 46 are respective pairs of wheels--front wheels 237 and rear wheels 247, with corresponding tires 37 and 47, which are thus in effect mounted to the frame for rolling rotation about respective mutually parallel but spaced-apart axes (the centerlines of the axles 36 and 46), one such axis being in front of the other.
Mounted atop the chassis floor 19 at a position between the two axles (or wheel rotation axes) is an electric motor 27. The motor 27 is located against one of the side walls 11, and oriented so that its driveshaft 283 (FIG. 5) is perpendicular to the two wheel-rotation axes. This motor is of a type whose driveshaft extends both fore and aft from the motor housing. The motor 27 is secured against longitudinal motion by two blocks 319, which are integral with the chassis floor 19 and the adjacent side wall.
Mounted to the two ends of the motor driveshaft 283 are respective drive pinions 31 at the front and 41 at the rear, which are firmly secured for rotation with the driveshaft.
Below the pinions 31 and 41 and meshed with them are respective spur gears 32 and 42, which rotate on corresponding shafts 35 and 45 oriented parallel to the driveshaft. The spur-gear shafts 35 and 45 are each journalled at one of their respective ends into one of the motor blocks 319, and at the other of their respective ends into the corresponding end wall 12 or 13, in a manner to be detailed below. Sharing the spur-gear shafts 35 and 45 with the spur gears 32 and 42, and firmly secured to those spur gear shafts to rotate with them, are respective worms 33 and 43.
Below these worms 33 and 43, and oriented and disposed to mesh with them, are respective worm gears 34 and 44--each oriented to rotate about axes parallel to the axes of wheel rotation. The worm gears 34 and 44 and the respective wheel pairs 237 and 247 are mounted conaxially (that is, together on the same respective shafts 36 and 46). The gears and wheels are fixed to their corresponding axles, for rotation in common; thus each of the worm gears 34 and 44 drives a respective pair 237 or 247 of wheels.
Thus the wheels may be driven by a symmetrical power train having but two stages and yet providing very high mechanical advantage between the motor driveshaft and the axles, and occupying a narrow space along one side of the chassis 11--and thus leaving the greater width of the chassis for a "penlight" battery 21 (whose positive pole appears at 23), and the appropriate electrical connectors 22 and 24.
From the fact that the dry-cell battery 21 appearing in FIG. 1 is only a size-AA penlight type, the remarkably small overall size of the vehicle may be seen dramatically. Yet, due to the simplicity of the novel drive train, it is not necessary to use highly miniaturized or high-precision gears.
A miniature scale-model vehicle body (such as 74 in FIGS. 2 through 4) is fitted to the chassis 10, and held on by appropriate detents formed in the outsides of the chassis walls 11 and/or 12 and 13. The body 74 snaps on and off to permit easy changing of the battery 21. The body style typically is derived from a real vehicle body, with some adjustment of proportions to fit the chassis.
To obtain excellent traction on irregular surfaces and to permit locomotion of the vehicle in water, the tires 37 and 47 are made of resilient rubber or plastic, configured with extremely exaggerated or pronounced cleats such as 38 and 48.
Some details of the construction of this preferred embodiment of our invention include protective drive-gear wells, such as the rear well 73, encasing the worm gears 34 and 44 respectively; and the drive-mechanism cover 62. The cover 62 protects the motor 27, the worms 33, 43, and worm gears 34, 44, and the pinions 31, 41 against damage when the user installs or changes a battery. The cover also has a side wall which isolates the drive mechanism from the battery-mounting area, while providing an electrical connection path via a slot. It will be noted, however, that the cover 62 does not function to keep water out of the motor or mechanical parts, and does not cover the switch (to be described shortly) at all.
The forward end of the forward worm shaft 35 rests in a half-journal formed in the horizontal bottom surface 16 of the slot 15, 16. Likewise the rearward end of the rear worm shaft 45 rests in a half-journal formed in the horizontal bottom surface 18 of the rear slot 17, 18. The upper halves of these two journals are provided by portions of the drive cover 62.
Though below the chassis floor proper 19, the axles 36 and 46 are within the chassis enclosure by virtue of axle wells 19W (FIG. 6), which extend to the two sides of the chassis and serve as axle bearings.
The electrical circuitry of the toy is generally conventional: battery 21 applies power through contacts 22 and 24 (FIGS. 1, 5, 6, and 7), wire 224, and switch 222-223-324-322-323 to the motor 27. The electrical switching mechanism, however, is in part novel, as will shortly be explained.
As to the battery polarity, the motor connections, and the "handedness" or pitch direction of the worms used in our invention, it is to be understood that any two of these factors may be reversed and the toy vehicle will operate in the same direction. For instance, if the battery polarity is reversed and the handedness of the worms is also reversed, the vehicle will still move "forward" as defined by the front/rear terminology used in this document.
FIG. 5 shows (also see FIG. 7) that the first (rear battery) metal contact 22 is screwed to the floor 19, and is extended along the side of the battery into a recessed section 315 of floor 19, and is integral with a springy metallic contact portion 222. This springy portion 222 includes an outwardly flared guide section 223. The front battery contact 24, too, is screwed to the floor 19, and is connected by a wire 224 to an appropriate contact point on the motor 27. Another contact point (the ground) on the motor is connected to a second metal contact 327, which is integral with a springy contact portion 322--which includes an outwardly flared guide section 323.
The user may turn the motor 25 on and off by operating the switch handle 25 (FIGS. 5 and 6) rearward and frontward, respectively. This handle slides in and out through the rear wall 13 of the chassis 10, through a passage 425 (FIG. 6) that is formed in the rear wall 13 just above the floor 19.
Integral with the handle 25, though offset downwardly at 225, is a bridging metal contact 324 that is slidably fixed to the recessed floor section 315 by a screw 328. The screw 328 screws into a hole which is given sufficient depth for an adequate number of threads by bosses 316 formed above and below the recessed floor section 315 of the frame or chassis.
The bridging contact 324 has a slot 326 through which the screw 328 passes, thus permitting the bridging contact 324 to slide rearward and forward (through the passage 425 in the rear wall 13), while remaining fixed to the floor section of the frame or chassis.
The bridging contact 324 also has laterally extending enlargements that touch neither of the contacts 222-223 and 322-323 when the bridging contact 324 is actuated to slide into a first (forward) position--as shown in FIG. 5. In this first position the switch is "off." It can be seen that the equivalent "off" condition will be obtained as long as the bridging contact 324 is not touching at least one (either one) of the previously mentioned first and second contacts.
However, the laterally extending enlargements 325 touch both of the contact springy portions 222-223 and 322-323 when the bridging contact 324 is actuated to slide into a second (rearward) position. In this second position the switch is "on," and the springy portions 222-223 and 322-323 press firmly against the bridging contact 324.
The forward-backward direction of motion of the bridging contact 324, relative to the sideward directions in which the springy portions 222-223 and 322-323 press, is such that in the course of its sliding motion the bridging contact firmly wipes the springy portions of the first and second contacts where they touch the bridging contact. This self-wiping action, as previously explained, preserves operability of the circuit even after extended exposure to water.
Secured (as by gluing) to the underside of the chassis 10 is a flotation chamber 310, having side walls 311, a front wall 312, a rear wall 313, and a floor 419. The flotation chamber is "capped" by the bottom floor of the chassis proper--specifically, by floor section 19, recessed floor section 315, axle wells 19W, and worm-gear wells 73. Formed in the chamber floor 419 is a drain hole 420, which in use is plugged by a stopper 421.
As best shown in FIG. 5, each wheel (such as the front wheel 237) is formed as a hollow toroidal structure, preferably (for maximum volume) squared off with outboard annular planar surface 237, inboard annular planar surface 337, an interior annular generally cylindrical surface 342, and an exterior annular generally cylindrical surface 343.
Formed in the exterior surface 343 is a circumferential groove 344. Engaging this groove 344 is a mating inward-directed ridge 338 formed on the internal annular surface of the tire 37. The groove 344 and ridge 338 cooperate to retain the tire 37 in place on the wheel 237, and the ridge 338 also seals a drain hole 345 that is defined in the wheel 237 within the groove 344.
Generally equivalent results will be obtained by configuring the cross-section of the tire 37 with sufficient thickness near its center (laterally) to permit forming a groove (rather than a ridge) in the internal annular surface of the tire; and also forming a ridge (rather than a groove) in the peripheral surface of the wheel.
The toroidal wheel 38 is mounted to the axle 36 by a cylindrical wheel hub 335, which fits snugly within the wheel 38 and whose flange 336 locates the inboard surface 337 of the wheel 38. The wheel 38 is retained at its outboard surface 237 by the flange 334 of a cylindrical hub cap 333. The hub cap 333 is located relative to the hub 335 by a central pin 332 of the hub cap 333, which fits into a central hole 331 in the end face of the hub 335. The hub cap 335 is held in place by glue.
The cleated tires 37, 47 need not extend the entire width of the wheels 237, 247.
Taking the distance between axles 36 and 46 as compatible with the dimensions of the model vehicle body 74--that is to say, assuming that the axles 36 and 46 are spaced apart by a distance which is correct for the scale of the model body 74--it may now be asked how the scale of the tires 237, 247 compares with the scale of the body and wheelbase. It will be seen from FIGS. 2, 3, and 4 that the tires 237 and 247 are substantially "overscale"--that is, oversize with respect to the otherwise generally consistent model body and wheelbase.
Due to the very pronounced cleats 38 and 48, the vehicle can find a grip on all but the slipperiest surfaces, even on very steep grades; and due to the high mechanical advantage of the drive train will climb any surface it can rest on and grip. We have found that the preferred embodiment illustrated in FIG. 1 can rest on and grip surfaces of virtually any substance at grades up to about 30°, and with surfaces of high-traction substance such as styrofoam it can operate at grades up to about 40°. The limiting factor at 40° is that the weight of the vehicle is centered at a point very nearly above the rear wheel axle, so that the vehicle is subject to tipping over backward when it bounces over a small bump.
Moreover, the flotation chamber 310 and the hollow wheels 237, 247 are so sized and proportioned that when the toy vehicle is placed in water it floats generally as shown in FIG. 4--with generally the bottom half of each wheel below the surface 181 of the water 81, and with generally the top half of each wheel above the surface 181. In this condition the cleats 38 and 48 propel the vehicle forwardly, as at 157 in FIG. 4, along the water surface 181.
Overall flotation characteristics vary with mechanical details, materials, wall thicknesses, and so forth. Based on this disclosure, however, a person skilled in the art of mechanical design will perceive how to determine suitable proportions and dimensions for the flotation chamber and wheels, to obtain the flotation behavior herein described.
A toy terrain such as 83, 84 in FIGS. 2 through 4 is advantageously supplied with the toy vehicle. The ascending outer surface 84 provides an irregular climbing surface, and also supplies the necessary height for an upwardly concave inner surface 83, which as already indicated can be filled with water 81. Due to the very small size of the toy vehicle, the toy terrain may be smaller than two feet in overall diagonal dimension and yet provide sufficient "terrain" for enjoyable amphibious operation of the toy vehicle.
For the preferred embodiment of FIG. 1 we use a motor whose unloaded rotational speed is 3,000 to 10,000 revolutions per minute. The motor of course slows down when the vehicle is climbing a steep grade. We provide a 2:1 gear ratio between the pinion and spur gears 31, 32 and 41, 42; and a further step-down of 30:1 or greater between the worm and worm gear, for an overall reduction or mechanical advantage of approximately 60:1.
It will be understood that the foregoing disclosure is intended to be merely exemplary, and not to limit the scope of our invention--which is to be determined by reference to the appended claims.
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An amphibious toy vehicle about the length of a "penlight" battery can climb any grade where it will not tip over backward, and can propel itself through water. An "AA" battery powers an electric motor in the four-wheel-drive vehicle. The motor has a double-ended shaft, driving a symmetrical worm-and-worm-gear geartrain. The motor and geartrain are aligned along one side of the chassis; the battery alongside them occupies the rest of the chassis. Both climbing and water-propulsion capability are enhanced by several-times-overscale hollow (to aid flotation) wheels, with pronounced peripheral cleats. A flotation chamber extends beneath the entire chassis. To resist degradation due to dirt, the chassis is substantially sealed against dirt particles, but for economy the sealing is not watertight. To compensate for this, the entire electromechanical system has been made to operate even with the chassis full of water. In particular the on-off switch is "self wiping" and the key motor components are corrosion resistant.
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FIELD OF THE INVENTION
The present invention relates to perimeter security and more specifically to a security fence module in a delay-and-detect type system.
BACKGROUND
Physical barriers in the form of fences are used to surround various facilities ranging from private homes to government installations. One type of fence provides a physical barrier, or delay mechanism, which inhibits a potential intruder from gaining access to a protected zone. Such fences include chain link fences, and razor coil fences. Another type of fence provides both a physical barrier and an alarm, or detection, functionality. Such fences include pressure sensor taut wire fences and rigid fences in combination with vibration sensing modules. This latter type is generally referred to as part of a delay-and-detect type system since the fence provides both a delay and a detect function.
An inherent difficulty with delay-and-detect fences is the need to balance the quality of detection with adequate delay. An extreme example is a brick wall employed as a high quality delay mechanism with a vibration sensor fitted onto the wall. As may be appreciated, it would require substantial interference with the wall to trigger an alarm in such a system thus providing low detection quality. The opposite is also a problem, for example in a system which combines a flexible chain link fence with a vibrations sensor where sensitivity is increased but physical delay properties are reduced. Accordingly, present delay-and-detect systems employ reliable sensing element in a first system and then set the required delay quality by providing a physical barrier placed inward of the detection system. This allows for mounting additional fences, digging trenches, and placing other barriers which do not interfere with the detection functionality and increase delay quality. However, at times, geographic and aesthetic considerations do not allow for extending the width of the perimeter fence as far into the protected zone as is desirable for placing sufficient obstacles for a required delay. Other times, physical soil properties may inhibit the construction of separate supporting structures for a detect system and a delay system. For example, digging may be difficult by way of utility lines running under the fence perimeter. In those instances, it is very difficult to provide a delay element without compromising the sensing capability of the combined system. Accordingly, there is a need for a compact delay-and-detect system which can be deployed over restricted terrain while providing for reliable delay and detect functionality.
SUMMARY OF THE INVENTION
In accordance with the present invention, a fence section is provided. The fence section includes a rectangular shaped planer base frame having a front support beam, and a rear support beam, a first lateral support beam coupled perpendicular to the first and second support beams substantially at respective ends thereof. A second lateral support beam is coupled perpendicular to the first and second support beams substantially at respective ends thereof, at least one additional lateral support beam is coupled in perpendicular to said first and second support beams substantially at respective ends thereof at a position between the first and the second lateral support beams. A first vertical support extends perpendicular to the plane defined by the base frame. The first vertical support is coupled to the base frame substantially proximate to the first lateral support beam. A second vertical support extends perpendicular to the plane defined by the base frame and is coupled to the base frame such that the second vertical support is closer to the front support beam of the base frame than the first vertical support is to the front support beam of the base frame. A third vertical support extends perpendicular to the plane defined by the base frame and is coupled to the base frame substantially proximate to the additional lateral support beam. The third vertical support is coupled to the base frame such that the line between the first vertical support and the third vertical support is substantially perpendicular to at least the first lateral support beam. A fourth vertical support extends perpendicular to the plane defined by the base frame and is coupled to the base frame substantially proximate to the additional lateral support beam. The fourth vertical support is coupled to the base frame such that the line between the second vertical support and the fourth vertical support is substantially perpendicular to at least the first lateral support beam.
The fence section also includes a first planar fence section coupled between the first and the third vertical supports and extends from a first end of the first and the third vertical supports to a point proximate a second end of the vertical supports, whereby the first end of the first and the third vertical supports is coupled to the base frame. A second planar fence section is coupled between the second and fourth vertical supports and extends from a first end of the second and fourth vertical supports to a point proximate a second end of the vertical supports, whereby the first end of the second and fourth vertical supports is coupled to the base frame. A third fence section is coupled between the first end of the second and fourth vertical supports and also between a point along the first and third vertical supports a predefined distance from the first end of the first and third vertical supports, whereby the third fence section defines a plane that forms an acute angle with the plane defined by the base frame at the second and fourth vertical supports. A first sensing module is coupled to the first fence section to sense vibrations applied through the first fence section. Finally, a second sensing module is coupled to the third fence section to sense vibrations applied through the third fence section.
Thus, there has been summarized and outlined, generally in broad form, a plurality of the most important features of the present invention, as described with respect to the foregoing preferred and alternate embodiments, in order that the following detailed description thereof which follows may be better understood by one of ordinary skill in the art. This summary and outline is further presented so that the novelty of the present contribution to the related art may be better appreciated. It will further be apparent that additional features of the invention described hereinafter and which will form the subject matter of the claims appended hereto will further define the scope, novelty, and in certain instances the improvements upon any existing art.
Further, it is to be readily understood that the invention presented herein is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the various figures integrated and categorized herein. The scope of the disclosure is presented in broad form so that other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description.
Those skilled in the art will appreciate that the disclosure of the present invention may readily be utilized as a basis for the designing of other similar structures, methods and systems for carrying out the various purposes and objectives of the present invention. Thus, the claims as set forth shall allow for such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:
FIG. 1 illustrates a side view of a fence module of the invention;
FIG. 2 illustrates a front view of a planar base frame and upright post of a fence section of FIG. 1 ;
FIG. 3 illustrates a top view of a planar base frame of a fence section of FIG. 1 ;
FIG. 4 illustrates an alternate, anchored embodiment, of the fence module of FIG. 1 ;
FIG. 5 illustrates a compact fence module in accordance with the invention; and
FIG. 6 illustrates an alternate embodiment of a compact fence module in accordance with the invention.
DETAILED DESCRIPTION
A further understanding of the present invention and the objectives other than those set forth above can be obtained by reference to the various embodiments set forth in the illustrations of the accompanying figures. Although the illustrated embodiment is merely exemplary of systems for carrying out the present invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The figures are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention. The detailed description makes reference to the accompanying figures wherein:
FIG. 1 illustrates a fence section module 20 of a delay-and-detect system in accordance with the invention. The fence section structural support elements include a base frame 21 , a first upright post 22 , and an extension arm 23 . The first upright post 22 is coupled to a first end 24 of the base frame 21 so as to extend substantially perpendicular to the plane defined by base frame. A first end of the extension arm 23 is coupled the same first end 24 of the base frame 21 so as to extend parallel to the base frame. The extension arm 23 includes a lower portion 25 that is parallel to the base frame and a second upright post 26 extending perpendicular from an end of the lower portion. Each frame section includes at least two sets of first upright posts 22 and extension arms 23 . As may be appreciated, adjacent fence modules provide additional structural support elements.
A first semi-rigid fence section 27 is coupled between each adjacent pair of first upright posts 22 . The first fence section 27 is preferably coupled to the first upright posts 22 so as to provide a generally flat vertical fence plane extending parallel to the vertical plane defined by the first upright posts 22 . In one embodiment, the first fence section 27 extends in line with the upper edges of the first upright posts 22 , as is illustrated in FIG. 1 . In another embodiment, the first fence section 27 extends beyond the edge of the first upright posts 22 . A second semi-rigid fence section 28 is coupled between second upright posts 26 of adjacent extension arms 23 . The second fence section 28 is preferably coupled to the second upright posts 26 so as to provide a generally flat vertical plane extending parallel to the vertical plane defined by the upright supports 26 . In the embodiment illustrated in FIG. 1 , the second fence section extends beyond the edge of the second upright posts 26 . In other embodiments, the second fence section extends only to the edge of the second upright posts 26 ( FIG. 5 ) . A third semi-rigid fence section 29 is coupled between the second upright posts 26 and a point located a short distance along the first upright post 22 from the connection point of the first upright post and the base frame 21 . In one embodiment, the third fence section 29 is coupled so as to form an acute angle between the third fence section and the extension arm lower portion 25 . In one embodiment, this angle is about 30 degrees. In the illustrated embodiment, an extension portion 30 of the third section 29 is positioned parallel to the second fence section and is supported by the second upright posts 26 .
A first vibration sensing module 31 is coupled to the first fence section 27 so as to sense disturbances of the first fence section by a possible intruder. A second vibration sensing module 32 is coupled to the third fence section 29 so as to sense disturbances of the third fence section. As may be appreciated, the first vibration sensing module 31 and the second vibration sensing module 32 may each include a plurality of sensors equally spaced along the first fence section 24 and the third fence section 29 or a continuous sensing module such as a fiber optic cable.
FIG. 2 illustrates a front view of a planar base frame of fence module 20 of FIG. 1 . A pair of first upright posts 22 are shown positioned in perpendicular to the base frame 21 .
FIG. 3 illustrates a top view of a planar base frame of the fence module of FIG. 1 . In the illustrated embodiment, each base frame 21 includes three parallel longitudinal beams 40 , 41 , 42 and five parallel lateral beams 43 , 44 , 45 , 46 , 47 . Two of the longitudinal beams serve as a front beam 40 and as a rear beam 42 of the base frame. Two of the lateral beams serve as end beams 43 , 47 . As discussed with reference to FIGS. 1 and 2 , the first upright posts 22 and the extension arms 23 are coupled to the front beam 40 of the base frame. In one embodiment, these connection points proximate to the connection points 52 , 53 coupling the end lateral beam 43 and the central lateral beam 45 to the front beam 40 . In the illustrated embodiment, no support section elements are coupled to one of the two end beams 47 .
To provide a continuous perimeter fence, adjacent base frames are initially joined by connecting an end beam 47 which does not include supporting structure to an end beam 43 on an adjacent module which includes supporting structure. As may be appreciated, in some embodiments, the base from is coupled to other base frames before any supporting structure is installed.
In some embodiments, the base frame 21 is anchored to the underlying substrate by anchor elements (not shown) positioned adjacent to beams of the base frame. Accordingly, the optional anchoring elements are placed at various locations within the interior of the frame defined by the end beams 43 , 47 , and the front and rear beams 40 , 42 , as permitted by terrain conditions. This anchoring is much more flexible than prior methods which required linear anchoring, at points along the length of a fence section where supporting posts are to be situated.
As illustrated in FIG. 1 , in one embodiment, a razor coil configuration 33 is placed on the base frame 21 of the fence module, adjacent to the upright support post 22 , to provide an additional delay mechanism. In the illustrated razor coil configuration, a pair of braces 34 are used to secure razor coil elements 35 to one another so as to provide for a rigid pyramid-like coil structure 33 .
As may be appreciated, a plurality of fence modules are coupled together as discussed above to form a barrier extending from a first fence module to a final module at an opposite end of the barrier. The barrier modules are positioned such that the extension arms 23 are facing the exterior, or non-secure, side of the barrier.
Referring again to FIG. 3 , in operation, the second fence section 28 , coupled to the second upright posts 26 , serves as a delay mechanism to inhibit access to the sensor modules 31 , 32 , and prevent objects from striking the third fence section or the first fence section and thereby trigger a false alarm. If an intruder gains access through the second fence section 28 , contact will be made with the third fence section 29 , which is positioned at an angle extending from the base of the second fence section. The second vibration sensing module 32 senses such contact and reports an alarm condition. An attempt to bypass the detection provided by the third fence section 29 and directly jump onto or climb the first fence section 27 will be detected by the first vibration sensing module 31 coupled to the first fence section. The first fence section 27 also serves to delay an intruder so as to allow time for security personnel to arrive at the alarm location when an alarm is triggered by contact with the third fence section or the first fence section 27 . Additional delay is provided by the razor coil configuration 33 placed beyond the first fence section 27 in the illustrated embodiment.
As may be appreciated, the use of the angular third fence section 29 provides for an early alarm indication, prior to the time an intruder attempts to bypass the first fence section 27 . Furthermore, the rate of false alarms resulting from animal contact with the third fence section 29 is reduced by placing the third fence section behind the second fence section 28 . Moreover, the second fence section 28 prevents tampering with the sensors 31 , 32 on the first fence section 27 and the third fence section 29 . The fence section configuration of the invention provides early detection of potential intrusion at substantially lower costs than those associated with prior art configurations where independent sensing systems are placed in front of a physical barrier, such as by placing a microwave system in front of a razor wire fence. The third fence section configuration is also substantially cheaper than pressure or vibration sensing means buried in the ground in front of the physical barrier. Moreover, such buried sensing systems may not be suitable where conditions do not allow for digging. Additionally, the third fence section configuration provides a compact physical barrier that can be placed in space restricted environment.
FIG. 4 illustrates an embodiment of a fence module in accordance with the invention, where the base frame is replaced by a ground anchor, provided below the first upright posts 22 A. Where conditions allow anchoring, a fence module of the invention, as illustrated in FIG. 4 , nonetheless provides advantages over prior systems by the high delay and detection capabilities relative to the overall dimensions of the module. An anchoring extension 56 is provided from the first upright post 22 A so as to extend below the supporting surface, preferably in a underground cavity. The first upright support post 22 A is preferably anchored within a rigid anchoring substance 55 such as concrete. An optional supporting sleeve 54 is provided around the substrate cavity. As may be appreciated, various anchoring techniques may be used in other embodiments without departing from the spirit of the invention.
FIG. 5 illustrates an alternate configuration of a fence module of the invention, which is configured for use in restricted spaces. The fence module 59 is intended for use in areas where topographical or environmental conditions do not allow for placement of configurations such as those in FIG. 1 . The fence module 59 maintains the overall configuration of the invention by employing a pair of supporting posts 61 , 62 , and a base frame 21 A. The base frame 21 A is constructed substantially as discussed with reference to the base frame of FIG. 3 , with differences including different connection points to the supporting posts as may be appreciated. Sensor modules 66 , 67 , are provided on a first fence section 64 of the first supporting post 61 . A second fence section 63 is also provided on the second supporting post 62 for additional delay functionality. A pair of razor coils 68 are provided above the first and second supporting posts 61 , 62 so as to provide additional delay when an intruder attempts to climb over the fence module 59 . An advantage of the fence module 59 is that it does not require anchoring and can be installed and removed without disturbing the underlying substrate. Accordingly, the fence module 59 , as well as the fence module of FIG. 1 are suitable for installing over access roads, above sewage pipes and other utilities, and over rocky terrain.
FIG. 6 illustrates a fence module 70 in accordance with the invention, which is configured for placement adjacent to an existing fence or other structure. The fence module includes a first supporting post 22 B, a base frame 21 B, and a second supporting post 72 . The first support post 22 B and the second supporting post 72 are coupled to the base frame 21 B so as to extend perpendicular from the base frame. A first fence section 27 B is coupled between adjacent first supporting posts. A second fence section 28 B is coupled between adjacent second supporting posts 72 . A third fence section 29 B is coupled between the second supporting posts 72 , and the first supporting posts 22 B. The third fence section 29 B is coupled between the second supporting posts 72 and the first supporting posts 22 B so as to form an acute angle with the base frame 21 B as is shown in FIG. 6 . A first sensor module 31 B is coupled to the first fence section 27 B. A second sensor module 32 B is coupled to the third fence section 29 B. A plurality of razor coils 74 is provided on the base frame behind the first fence section so as to occupy a space between the first fence section and an existing fence 76 . Accordingly, the fence module of FIG. 6 provides delay and detection capabilities in a restricted space environment, without interference with the underlying substrate and in a configuration which maximizes delay while providing reliable sensing functionality (i.e., low false alarms, high detection reliability).
Although the present invention was discussed in terms of certain preferred embodiments, the invention is not limited to such embodiments. A person of ordinary skill in the art will appreciate that numerous variations and combinations of the features set forth above can be utilized without departing from the present invention as set forth in the claims. Thus, the scope of the invention should not be limited by the preceding description but should be ascertained by reference to claims that follow.
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A fence module is adapted for installation without required anchoring buy providing a base frame and a plurality of upright supporting posts extending from the base frame. At least three fence sections extend between the supporting posts. A first fence section at a first extreme end of the fence module, a second fence section at a second extreme end of the fence module, and a third fence section angularly positioned between the first and second fence sections. A pair of vibration sensing modules are used to detect intruders, one applied to the first fence section and a second applied to the third fence section, with the first fence section positioned on the secure end of the protected zone.
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The present invention relates to wireless communication links and specifically to high data rate point-to-point links. This application is a continuation-in-part application of Ser. No. 09/952,591 filed Sep. 14, 2001, now U.S. Pat. No. 6,714,800 that was a continuation-in-part of Ser. No. 09/847,629 filed May 2, 2001, now U.S. Pat. No. 6,556,836, and Ser. No. 09/882,482 filed Jun. 14, 2001, now U.S. Pat. No. 6,665,546.
BACKGROUND OF THE INVENTION
Local Wireless Radio Communication
Local wireless communication services represent a very rapidly growing industry. These services include paging and cellular telephone services. The cellular telephone industry currently is in its second generation with several types of cellular telephone systems being promoted. The cellular market in the United States grew from about 2 million subscribers and $2 million in revenue in 1988 to more than 60 million subscribers about $30 billion in revenue in 1998 and the growth is continuing in the United States and also around the world as the services become more available and prices decrease.
FIG. 1 describes a typical cellular telephone system. A cellular service provider divides its territory up into hexagonal cells as shown in FIG. 1 . These cells may be about 5 miles across, although in densely populated regions with many users these cells may be broken up into much smaller cells called micro cells. This is done because cellular providers are allocated only a limited portion of the radio spectrum. For example, one spectral range allocated for cellular communication is the spectral range: 824 MHz to 901 MHz. (Another spectral range allocated to cellular service is 1.8 GHz to 1.9 GHz) A provider operating in the 824-901 MHz range may set up its system for the cellular stations to transmit in the 824 MHz to 851 MHz range and to receive in the 869 MHz to 901 MHz range. The transmitters both at the cellular stations and in devices used by subscribers operate at very low power (just a few Watts) so signals generated in a cell do not provide interference in any other cells beyond immediate adjacent cells. By breaking its allocated transmitting spectrum and receive spectrum in seven parts (A–G) with the hexagonal cell pattern, a service provider can set up its system so that there is a two-cell separation between the same frequencies for transmit or receive, as shown in FIG. 1 . A one-cell separation can be provided by breaking the spectrum into three parts. Therefore, these three or seven spectral ranges can be used over and over again throughout the territory of the cellular service provider. In a typical cellular system each cell (with a transmit bandwidth and a receive bandwidth each at about 12 MHz wide) can handle as many as about 1200 two-way telephone communications within the cell simultaneously. With lower quality communication, up to about 9000 calls can be handled in the 12 MHz bandwidth. Several different techniques are widely used in the industry to divide up the spectrum within a given cell. These techniques include analog and digital transmission and several techniques for multiplexing the digital signals. These techniques are discussed at pages 313 to 316 in The Essential Guide to Telecommunications, Second Edition, published by Prentice Hall and many other sources. Third generation cellular communication systems promise substantial improvements with more efficient use of the communication spectra.
Other Prior Art Wireless Communication Techniques Point-to-Point and Point-to-Multi-Point
Most wireless communication, at least in terms of data tansmitted is one way, point to multi-point, which includes commercial radio and television. However, there are many examples of point-to-point wireless communication. Cellular telephone systems, discussed above, are examples of low-data-rate, point-to-point communication. Microwave transmitters on telephone system trunk lines are another example of prior art, point-to-point wireless communication at much higher data rates. The prior art includes a few examples of point-to-point laser communication at infrared and visible wavelengths.
Information Transmission
Analog techniques for transmission of information are still widely used; however, there has recently been extensive conversion to digital, and in the foreseeable future transmission of information will be mostly digital with volume measured in bits per second. To transmit a typical telephone conversation digitally utilizes about 5,000 bits per second (5 Kbits per second). Typical personal computer modems connected to the Internet operate at, for example, 56 Kbits per second. Music can be transmitted point to point in real time with good quality using MP3 technology at digital data rates of 64 Kbits per second. Video can be transmitted in real time at data rates of about 5 million bits per second (5 Mbits per second). Broadcast quality video is typically at 45 or 90 Mbps. Companies (such as line telephone, cellular telephone and cable companies) providing point-to-point communication services build trunk lines to serve as parts of communication links for their point-to-point customers. These trunk lines typically carry hundreds or thousands of messages simultaneously using multiplexing techniques. Thus, high volume trunk lines must be able to transmit in the gigabit (billion bits, Gbits, per second) range. Most modern trunk lines utilize fiber optic lines. A typical fiber optic line can carry about 2 to 10 Gbits per second and many separate fibers can be included in a trunk line so that fiber optic trunk lines can be designed and constructed to carry any volume of information desired virtually without limit. However, the construction of fiber optic trunk lines is expensive (sometimes very expensive) and the design and the construction of these lines can often take many months especially if the route is over private property or produces environmental controversy. Often the expected revenue from the potential users of a particular trunk line under consideration does not justify the cost of the fiber optic trunk line. Digital microwave communication has been available since the mid-1970's. Service in the 18–23 GHz radio spectrum is called “short-haul microwave” providing point-to-point service operating between 2 and 7 miles and supporting between four to eight T1 links (each at 1.544 Mbps). Recently, microwave systems operating in the 11 to 38 Ghz band have been designed to transmit at rates up to 155 Mbps (which is a standard transmit frequency known as “OC-3 Standard”) using high order modulation schemes.
Data Rate and Frequency
Bandwidth-efficient modulation schemes allow, as a general rule, transmission of data at rates of about 1 to 8 bits per second per Hz of available bandwidth in spectral ranges including radio wave lengths to microwave wavelengths. Data transmission requirements of 1 to tens of Gbps thus would require hundreds of MHz of available bandwidth for transmission. Equitable sharing of the frequency spectrum between radio, television, telephone, emergency services, military and other services typically limits specific frequency band allocations to about 10% fractional bandwidth (i.e., range of frequencies equal to about 10% of center frequency). AM radio, at almost 100% fractional bandwidth (550 to 1650 GHz) is an anomaly; FM radio, at 20% fractional bandwidth, is also atypical compared to more recent frequency allocations, which rarely exceed 10% fractional bandwidth.
Reliability Requirements
Reliability typically required for wireless data transmission is very high, consistent with that required for hard-wired links including fiber optics. Typical specifications for error rates are less than one bit in ten billion (10 −10 bit-error rates), and link availability of 99.999% (5 minutes of down time per year). This necessitates all-weather link operability, in fog and snow, and at rain rates up to 100 mm/hour in many areas. On the other hand cellular telephone systems do not require such high reliability. As a matter of fact cellular users (especially mobile users) are accustom to poor service in many regions.
Weather Conditions
In conjunction with the above availability requirements, weather-related attenuation limits the useful range of wireless data transmission at all wavelengths shorter than the very long radio waves. Typical ranges in a heavy rainstorm for optical links (i.e., laser communication links) are 100 meters, and for microwave links, 10,000 meters.
Atmospheric attenuation of electromagnetic radiation increases generally with frequency in the microwave and millimeter-wave bands. However, excitation of rotational modes in oxygen and water vapor molecules absorbs radiation preferentially in bands near 60 and 118 GHz (oxygen) and near 23 and 183 GHz (water vapor). Rain, which attenuates through large-angle scattering, increases monotonically with frequency from 3 to nearly 200 GHz. At the higher, millimeter-wave frequencies, (i.e., 30 GHz to 300 GHz corresponding to wavelengths of 1.0 centimeter to 1.0 millimeter) where available bandwidth is highest, rain attenuation in very bad weather limits reliable wireless link performance to distances of 1 mile or less. At microwave frequencies near and below 10 GHz, link distances to 10 miles can be achieved even in heavy rain with high reliability, but the available bandwidth is much lower.
Setting Up Additional Cells in a Telephone System is Expensive
The cost associated with setting up an additional cell in a new location or creating a micro cell within an existing cell with prior art techniques is in the range of about $650,000 to $800,000. (See page 895 Voice and Data Communication Handbook, Fourth Edition, published by McGraw Hill.) These costs must be recovered from users of the cellular system. People in the past have avoided use of their cellular equipment because the cost was higher that their line telephones. Recently, costs have become comparable.
The Need
Therefore, a great need exists for techniques for adding, at low cost, additional cells in cellular communication systems.
SUMMARY OF THE INVENTION
The present invention provides a wireless cellular communication system in which groups of cellular base stations communicate with a central office via a narrow-beam millimeter wave trunk line. The transceivers are equipped with antennas providing beam divergence small enough to ensure efficient spatial and directional partitioning of the data channels so that an almost unlimited number of point-to-point transceivers will be able to simultaneously use the same millimeter wave spectrum. In a preferred embodiment the trunk line communication link operates within the 92 to 95 GHz portion of the millimeter spectrum. A large number of base stations are each allocated a few MHz portion of a 900 MHz bandwidth of the millimeter wave trunk line. A first transceiver transmits at a first bandwidth and receives at a second bandwidth, both within the above spectral range. A second transceiver transmits at the second bandwidth and receives at the first bandwidth.
Antennas are described to maintain beam directional stability to less than one-half the half-power beam width. In a preferred embodiment the first and second spectral ranges are 92.3–93.2 GHz and 94.1–95.0 GHz and the half power beam width is about 0.36 degrees or less. Thus, in this system the low frequency bandwidth is efficiently utilized over and over again by dividing a territory into small cells and using low power antenna. The higher frequency bandwidth is efficiently utilized over and over again by using transmitting antennae that are designed to produce very narrow beams directed at receiving antennae. In a preferred embodiment cellular base stations are prepackaged for easy quick installation at convenient locations such as the tops of commercial buildings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sketch showing a prior art cellular network.
FIG. 2 is a sketch showing features of a single prior art cell.
FIG. 3 is a sketch of a preferred embodiment of the present invention.
FIG. 4 demonstrates up conversion from cell phone frequencies to trunk line frequencies.
FIG. 5 demonstrates down conversion from trunk line frequencies to cell phone frequencies.
FIG. 6 is a block diagram showing the principal components of a prepackaged cellular base station designed for roof-top installation.
FIG. 7 is a schematic diagram of a millimeter-wave transmitter of a prototype transceiver system built and tested by Applicants.
FIG. 8 is a schematic diagram of a millimeter-wave receiver of a prototype transceiver system built and tested by Applicants.
FIG. 9 is measured receiver output voltage from the prototype transceiver at a transmitted bit rate of 200 Mbps.
FIG. 10 is the same waveform as FIG. 9 , with the bit rate increased to 1.25 Gbps.
FIGS. 11A and 11B are schematic diagrams of a millimeter-wave transmitter and receiver in one transceiver of a preferred embodiment of the present invention.
FIGS. 12A and 12B are schematic diagrams of a millimeter-wave transmitter and receiver in a complementary transceiver of a preferred embodiment of the present invention.
FIGS. 13A and 13B show the spectral diagrams for a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A first preferred embodiment of the present invention comprises a system of linked millimeter-wave radios which take the place of wire or fiber optic links between the cells of a cellular network. The use of the millimeter-wave links can eliminates the need to lay cable or fiber, can be installed relatively quickly, and can provide high bandwidth normally at a lower cost than standard telecom-provided wires or cable. Since the millimeter-wave links simply up and down convert the signal for point-to-point transmission, the data and protocols used by the original signals are preserved, making the link ‘transparent’ to the user. This embodiment supports a conventional system operating at standard cellular telephone frequencies, but it is equally applicable to other, newer technologies such as 1.8 GHz to 1.9 GHz PCS systems.
A typical prior art cell phone base station transmits in the 824–851 MHz band and receives in the 869–901 MHz band and is connected mobile telephone switching office by wire connections which is in turn connected to a central office via a high speed wired connection. The central office performs call switching and routing. It is possible to replace both wired links with a millimeter-wave link, capable of carrying the signals from several cellular base stations to the central office for switching and routing, and then back out again to the cellular base stations for transmission to the users' cellular phones and other communication devices. A millimeter-wave link with 1 GHz of bandwidth will be capable of handling approximately 30 to 90 cellular base stations, depending on the bandwidth of the base stations. Since the cellular base stations are typically within a few miles (or less for micro cells) of each other, the millimeter-wave link would form a chain from base station to base station, then back to the central office. FIG. 3 illustrates the basic concept.
Most wireless computer networking equipment on the market today is designed according to IEEE standards 802.11a and 802.11b that describe a format and technique for packet data interchange between computers. In this equipment the 802.11b formatted data is transmitted and received on one of eleven channels in the 2.4–2.5 GHz band and uses the same frequencies for transmit and receive. Therefore, in this preferred embodiment the cellular stations all operate on a slice of the 2.4 to 2.5 GHz band using equipment built in accordance with the above IEEE standards. An up/down converter is provided to up and down convert the information for transmittal on the millimeter wave links. The up/down converter is described below. Typically, base stations are organized in generally hexagonal cells in groups of 7 cells as shown in FIG. 1 . In order to avoid interference, each of the 7 cells operate at a different slice of the available bandwidth in which case each frequency slice is separated by two cells. If 3 different frequencies are used in the group of 7 cells, there is a one-cell separation of frequencies.
Cellular Base Station Transmission Back to Central Office
Cell phone calls are received in the 824–851 MHz band at each group of base stations, and up-converted to a 27 MHz slot of frequencies in the 91–93 GHz band for transmission over the link back to the central office. Each group of base stations is allocated a 27 MHz slice of spectrum in the 91–93 GHz band as follows:
Base Station
Group Number
Base Station Frequency
Trunk Line Frequency
1
824–851 MHz
91.000–91.027 GHz
2
824–851 MHz
91.027–91.054 GHz
3
824–851 MHz
91.054–91.081 GHz
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.
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.
.
30
824–851 MHz
91.783–91.810 GHz
31
824–851 MHz
91.810–91.837 GHz
32
824–851 MHz
91.837–91.864 GHz
FIG. 4 shows a block diagram of a system that converts the cellular base station frequencies up to the millimeter-wave band for transmission back to the central office. Each base station receives both the cell phone frequencies within its cell, and the millimeter-wave frequencies from the earlier base station in the chain. The cell-phone frequencies are up-converted to a slot (of spectrum) in the 91–93 GHz band and added to the 91–93 GHz signals from the earlier base station up the chain. The combined signals are then retransmitted to the next base station in the chain. Each base station has a local oscillator set to a slightly different frequency, which determines the up-converted frequency slot for that base station. The local oscillator may be multiplied by a known pseudo-random bit stream to spread its spectrum and to provide additional security to the millimeter-wave link.
At the telephone company central switching office, each 27 MHz slot of frequencies in the 91–93 GHz band is downconverted to the cellular telephone band. If a spread-spectrum local oscillator was used on the millimeter-wave link, the appropriate pseudo random code must be used again in the downconverter's local oscillator to recover the original information. Once the millimeter-wave signals are downconverted to the cell phone band, standard cellular equipment is used to detect, switch, and route the calls.
Central Office Transmission to Cellular Base Stations
Cell phone calls leave the central office on a millimeter-wave link and each group of cellular base stations downconverts a 32 MHz slice of the spectrum to the cell phone band for transmission to the individual phones. The cellular base stations transmit (to the phones) in the 869–901 MHz band so each group of base stations requires a 32 MHz slice of the spectrum in the 91–93 GHz range on the millimeter wave link. The 1.024 GHz will support 32 base stations. Each group of base stations is allocated a 32 MHz slice of spectrum in the 91–93 GHz band as follows:
Base station # Trunk Line Frequencies (link RX)
converts to Base Station (cell TX)
Base Station
Group Number
Trunk Line Frequency
Base Station Frequency
1
92.000–92.032 GHz
869–901 MHz
2
92.032–92.064 GHz
869–901 MHz
3
92.064–92.096 GHz
869–901 MHz
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30
92.928–92.960 GHz
869–901 MHz
31
92.960–92.992 GHz
869–901 MHz
32
92.992–92.024 GHz
869–901 MHz
FIG. 5 shows a block diagram of a system that receives millimeter-wave signals from the central office and converts them to the cellular band for transmission by a cell base station. Each base station receives picks off the signals in its 32 MHz slice of the 91–93 GHz spectrum, down-converts this band to the cell phone band, and broadcasts it. The 91–93 GHz band is also retransmitted to the next base station in the chain. Each base station has a local oscillator set to a slightly different frequency, which determines the 32 MHz wide slot (in the 91–93 GHz band) that is assigned to that base station. If a spread-spectrum local oscillator was used on the up-conversion at the central office, then the appropriate pseudo random code must be used again in the down-converter's local oscillator (at each base station) to recover the original information.
At the telephone company central switching office calls are detected, switched, and routed between the various cellular base stations and the landline network. Each group of cellular base stations at the central office is represented by a 32 MHz wide slot of spectrum, which is up-converted to the 91–93 GHz band and sent out over a point-to-point link to the chain of several base stations. The local oscillator used to up-convert the signals may be spread-spectrum to provide additional'security to the millimeter-wave link.
Prototype Demonstration of MM Wave T/R
A prototype demonstration of the millimeter-wave transmitter and receiver useful for the present invention is described by reference to FIGS. 1 to 4 . With this embodiment the Applicants have demonstrated digital data transmission in the 93 to 97 GHz range at 1.25 Gbps with a bit error rate below 10 −12 .
The circuit diagram for the millimeter-wave transmitter is shown in FIG. 7 . Voltage-controlled microwave oscillator 1 , Westec Model VTS133/V4, is tuned to transmit at 10 GHz, attenuated by 16 dB with coaxial attenuators 2 and 3 , and divided into two channels in two-way power divider 4 . A digital modulation signal is pre-amplified in amplifier 7 , and mixed with the microwave source power in triple-balanced mixer 5 , Pacific Microwave Model M3001HA. The modulated source power is combined with the un-modulated source power through a two-way power combiner 6 . A line stretcher 12 in the path of the un-modulated source power controls the depth of modulation of the combined output by adjusting for constructive or destructive phase summation. The amplitude-modulated 10 GHz signal is mixed with a signal from an 85-GHz source oscillator 8 in mixer 9 and high-pass filtered in waveguide filter 13 to reject the 75 GHz image band. The resultant, amplitude-modulated 95 GHz signal contains spectral components between 93 and 97 GHz, assuming unfiltered 1.25 Gbps modulation. A rectangular WR-10 wave guide output of the high pass filter is converted to a circular wave guide 14 and fed to a circular horn 15 of 4 inches diameter, where it is transmitted into free space. The horn projects a half-power beam width of 2.2 degrees.
The circuit diagram for the receiver is shown in FIG. 8 . The antenna is a circular horn 1 of 6 inches in diameter, fed from a waveguide unit 14 R consisting of a circular W-band wave-guide and a circular-to-rectangular wave-guide converter which translates the antenna feed to WR-10 wave-guide which in turn feeds heterodyne receiver module 2 R.
This module consists of a monolithic millimeter-wave integrated circuit (MMIC) low-noise amplifier spanning 89–99 GHz, a mixer with a two-times frequency multiplier at the LO port, and an IF amplifier covering 5–15 GHz. These receivers are available from suppliers such as Lockheed Martin. The local oscillator 8 R is a cavity-tuned Gunn oscillator operating at 42.0 GHz (Spacek Model GQ410K), feeding the mixer in module R 2 through a 6 dB attenuator 7 . A bias tee 6 at the local oscillator input supplies DC power to receiver module 2 R. A voltage regulator circuit using a National Semiconductor LM317 integrated circuit regulator supplies +3.3V through bias tee 6 . An IF output of the heterodyne receiver module 2 R is filtered at 6–12 GHz using bandpass filter 3 from K&L Microwave. Receiver 4 R which is an HP Herotek Model DTM 180AA diode detector, measures total received power. The voltage output from the diode detector is amplified in two-cascaded microwave amplifiers 5 R from MiniCircuits, Model 2FL2000. The baseband output is carried on coax cable to a media converter for conversion to optical fiber, or to a Bit Error-Rate Tester (BERT) 10 R.
In the laboratory, this embodiment has demonstrated a bit-error rate of less than 10 −12 for digital data transmission at 1.25 Gbps. The BERT measurement unit was a Microwave Logic, Model gigaBERT. The oscilloscope signal for digital data received at 200 Mbps is shown in FIG. 9 . At 1.25 Gbps, oscilloscope bandwidth limitations lead to the rounded bit edges seen in FIG. 10 . Digital levels sustained for more than one bit period comprise lower fundamental frequency components (less than 312 MHz) than those which toggle each period (622 MHz), so the modulation transfer function of the oscilloscope, which falls off above 500 MHz, attenuates them less. These measurement artifacts are not reflected in the bit error-rate measurements, which yield <10 −12 bit error rate at 1.25 Gbps.
Transceiver System
A preferred embodiment of the present invention is described by reference to FIGS. 11A to 13B . The link hardware consists of a millimeter-wave transceiver pair including a pair of millimeter-wave antennas and a microwave transceiver pair including a pair of microwave antennas. The millimeter wave transmitter signal is amplitude modulated and single-sideband filtered, and includes a reduced-level carrier. The receiver includes a heterodyne mixer, phase-locked intermediate frequency (IF) tuner, and IF power detector.
Millimeter-wave transceiver A ( FIGS. 11A and 11B ) transmits at 92.3–93.2 GHz as shown at 60 in FIG. 13A and receives at 94.1–95.0 GHz as shown at 62 , while millimeter-wave transmitter B ( FIGS. 12A and 12B ) transmits at 94.1–95.0 GHz as shown at 64 in FIG. 13B and receives at 92.3–93.2 GHz as shown at 66 .
Millimeter Wave Transceiver A
As shown in FIG. 11A in millimeter-wave transceiver A, transmit power is generated with a cavity-tuned Gunn diode 21 resonating at 93.15 GHz. This power is amplitude modulated using two balanced mixers in an image reject configuration 22 , selecting the lower sideband only. The source 21 is modulated at 1.25 Gbps in conjunction with Gigabit-Ethernet standards. The modulating signal is brought in on optical fiber, converted to an electrical signal in media converter 19 (which in this case is an Agilent model HFCT-5912E) and amplified in preamplifier 20 . The amplitude-modulated source is filtered in a 900 MHz-wide passband between 92.3 and 93.2 GHz, using a bandpass filter 23 on microstrip. A portion of the source oscillator signal is picked off with coupler 38 and combined with the lower sideband in power combiner 39 , resulting in the transmitted spectrum shown at 60 in FIG. 13A . The combined signal propagates with horizontal polarization through a waveguide 24 to one port of an orthomode transducer 25 , and on to a two-foot diameter Cassegrain dish antenna 26 , where it is transmitted into free space with horizontal polarization.
The receiver unit at Station A as shown on FIGS. 11 B 1 and 11 B 2 is fed from the same Cassegrain antenna 26 as is used by the transmitter, at vertical polarization (orthogonal to that of the transmitter), through the other port of the orthomode transducer 25 . The received signal is pre-filtered with bandpass filter 28 A in a passband from 94.1 to 95.0 GHz, to reject back scattered return from the local transmitter. The filtered signal is then amplified with a monolithic MMW integrated-circuit amplifier 29 on indium phosphide, and filtered again in the same passband with bandpass filter 28 B. This twice filtered signal is mixed with the transmitter source oscillator 21 using a heterodyne mixer-downconverter 30 , to an IF frequency of 1.00–1.85 GHz, giving the spectrum shown at 39 A in FIG. 13A . A portion of the IF signal, picked off with coupler 40 , is detected with integrating power detector 35 and fed to an automatic gain control circuit 36 . The fixed-level IF output is passed to the next stage as shown in FIG. 11 B 2 . Here a quadrature-based (I/Q) phase-locked synchronous detector circuit 31 is incorporated, locking on the carrier frequency of the remote source oscillator. The loop is controlled with a microprocessor 32 to minimize power in the “Q” channel while verifying power above a set threshold in the “I” channel. Both “I” and “Q” channels are lowpass-filtered at 200 MHz using lowpass filters 33 A and 33 B, and power is measured in both the “I” and Q channels using square-law diode detectors 34 . The baseband mixer 38 output is pre-amplified and fed through a media converter 37 , which modulates a laser diode source into a fiber-optic coupler for transition to optical fiber transmission media.
Transceiver B
As shown in FIG. 12A in millimeter-wave transceiver B, transmit power is generated with a cavity-tuned Gunn diode 41 resonating at 94.15 GHz. This power is amplitude modulated using two balanced mixers in an image reject configuration 42 , selecting the upper sideband only. The source 41 is modulated at 1.25 Gbps in conjunction with Gigabit-Ethernet standards. The modulating signal is brought in on optical fiber as shown at 80 , converted to an electrical signal in media converter 60 , and amplified in preamplifier 61 . The amplitude-modulated source is filtered in a 900 MHz-wide passband between 94.1 and 95.0 GHz, using a bandpass filter 43 on microstrip. A portion of the source oscillator signal is picked off with coupler 48 and combined with the higher sideband in power combiner 49 , resulting in the transmitted spectrum shown at 64 in FIG. 13B . The combined signal propagates with vertical polarization through a waveguide 44 to one port of an orthomode transducer 45 , and on to a Cassegrain dish antenna 46 , where it is transmitted into free space with vertical polarization.
The receiver is fed from the same Cassegrain antenna 46 as the transmitter, at horizontal polarization (orthogonal to that of the transmitter), through the other port of the orthomode transducer 45 . The received signal is filtered with bandpass filter 47 A in a passband from 92.3 to 93.2 GHz, to reject backscattered return from the local transmitter. The filtered signal is then amplified with a monolithic MMW integrated-circuit amplifier on indium phosphide 48 , and filtered again in the same passband with bandpass filter 47 B. This twice filtered signal is mixed with the transmitter source oscillator 41 using a heterodyne mixer-downconverter 50 , to an IF frequency of 1.00–1.85 GHz, giving the spectrum shown at 39 B in FIG. 13B . A portion of the IF signal, picked off with coupler 62 , is detected with integrating power detector 55 and fed to an automatic gain control circuit 56 . The fixed-level IF output is passed to the next stage as shown on FIG. 12 B 2 . Here a quadrature-based (I/Q) phase-locked synchronous detector circuit 51 is incorporated, locking on the carrier frequency of the remote source oscillator. The loop is controlled with a microprocessor 52 to minimize power in the “Q” channel while verifying power above a set threshold in the “I” channel. Both “I” and “Q” channels are lowpass-filtered at 200 MHz using a bandpass filters 53 A and 53 B, and power is measured in each channel using a square-law diode detector 54 . The baseband mixer 58 output is pre-amplified and fed through a media converter 57 , which modulates a laser diode source into a fiber-optic coupler for transition to optical fiber transmission media.
Very Narrow Beam Width
A dish antenna of two-foot diameter projects a half-power beam width of about 0.36 degrees at 94 GHz. The full-power beamwidth (to first nulls in antenna pattern) is narrower than 0.9 degrees. This suggests that up to 400 independent beams could be projected azimuthally around an equator from a single transmitter location, without mutual interference, from an array of 2-foot dishes. At a distance of five miles, two receivers placed 400 feet apart can receive independent data channels from the same transmitter location. Conversely, two receivers in a single location can discriminate independent data channels from two transmitters ten miles away, even when the transmitters are as close as 400 feet apart. Larger dishes can be used for even more directivity.
Backup Microwave Transceiver Pair
During severe weather conditions data transmission quality will deteriorate at millimeter wave frequencies. Therefore, in preferred embodiments of the present invention a backup communication link is provided which automatically goes into action whenever a predetermined drop-off in quality transmission is detected. A preferred backup system is a microwave transceiver pair operating in the 10.7–11.7 GHz band. This frequency band is already allocated by the FCC for fixed point-to-point operation. FCC service rules parcel the band into channels of 40-MHz maximum bandwidth, limiting the maximum data rate for digital transmissions to 45 Mbps full duplex. Transceivers offering this data rate within this band are available: off-the-shelf from vendors such as Western Multiplex Corporation (Models Lynx DS-3, Tsunami 100BaseT), and DMC Stratex Networks (Model DXR700 and Altium 155). The digital radios are licensed under FCC Part 101 regulations. The microwave antennas are Cassegrain dish antennas of 24-inch diameter. At this diameter, the half-power beamwidth of the dish antenna is 3.0 degrees, and the full-power beamwidth is 7.4 degrees, so the risk of interference is higher than for MMW antennas. To compensate this, the FCC allocates twelve separate transmit and twelve separate receive channels for spectrum coordination within the 10.7–11.7 GHz band. Sensing of a millimeter wave link failure and switching to redundant microwave channel is an existing automated feature of the network routing switching hardware available off-the-shelf from vendors such as Cisco, Foundry Networks and Juniper Networks.
The reader should understand that in many installations the provision of a backup system will not be justified from a cost-benefit analysis depending on factors such as costs, distance between transmitters, quality of service expected and the willingness of customers to pay for continuing service in the worse weather conditions.
Narrow Beam Width Antennas
The narrow antenna beam widths afforded at millimeter-wave frequencies allow for geographical portioning of the airwaves, which is impossible at lower frequencies. This fact eliminates the need for band parceling (frequency sharing), and so enables wireless communications over a much larger total bandwidth, and thus at much higher data rates, than were ever previously possible at lower RF frequencies.
The ability to manufacture and deploy antennas with beam widths narrow enough to ensure non-interference, requires mechanical tolerances, pointing accuracies, and electronic beam steering/tracking capabilities, which exceed the capabilities of the prior art in communications antennas. A preferred antenna for long-range communication at frequencies above 70 GHz has gain in excess of 50 dB, 100 times higher than direct-broadcast satellite dishes for the home, and 30 times higher than high-resolution weather radar antennas on aircraft. However, where interference is not a potential problem, antennas with dB gains of 40 to 45 may be preferred.
Most antennas used for high-gain applications utilize a large parabolic primary collector in one of a variety of geometries. The prime-focus antenna places the receiver directly at the focus of the parabola The Cassegrain antenna places a convex hyperboloidal secondary reflector in front of the focus to reflect the focus back through an aperture in the primary to allow mounting the receiver behind the dish. (This is convenient since the dish is typically supported from behind as well.) The Gregorian antenna is similar to the Cassegrain antenna, except that the secondary mirror is a concave ellipsoid placed in back of the parabola's focus. An offset parabola rotates the focus away from the center of the dish for less aperture blockage and improved mounting geometry. Cassegrain, prime focus, and offset parabolic antennas are the preferred dish geometries for the MMW communication system.
A preferred primary dish reflector is a conductive parabola. The preferred surface tolerance on the dish is about 15 thousandths of an inch (15 mils) for applications below 40 GHz, but closer to 5 mils for use at 94 GHz. Typical hydroformed aluminum dishes give 15-mil surface tolerances, although double-skinned laminates (using two aluminum layers surrounding a spacer layer) could improve this to 5 mils. The secondary reflector in the Cassegrainian geometry is a small, machined aluminum “lollipop” which can be made to mil tolerance without difficulty. Mounts for secondary reflectors and receiver waveguide horns preferably comprise mechanical fine-tuning adjustment for in-situ alignment on an antenna test range.
Flat Panel Antenna
Another preferred antenna for long-range MMW communication is a flat-panel slot array antenna such as that described by one of the present inventors and others in U.S. Pat. No. 6,037,908, issued 14 Mar. 2000, which is hereby incorporated herein by reference. That antenna is a planar phased array antenna propagating a traveling wave through the radiating aperture in a transverse electromagnetic (TEM) mode. A communications antenna would comprise a variant of that antenna incorporating the planar phased array, but eliminating the frequency-scanning characteristics of the antenna in the prior art by adding a hybrid traveling-wave/corporate feed. Flat plates holding a 5-mil surface tolerance are substantially cheaper and easier to fabricate than parabolic surfaces. Planar slot arrays utilize circuit-board processing techniques (e.g. photolithography), which are inherently very precise, rather than expensive high-precision machining.
Coarse and Fine Pointing
Pointing a high-gain antenna requires coarse and fine positioning. Coarse positioning can be accomplished initially using a visual sight such as a bore-sighted rifle scope or laser pointer. The antenna is locked in its final coarse position prior to fine-tuning. The fine adjustment is performed with the remote transmitter turned on. A power meter connected to the receiver is monitored for maximum power as the fine positioner is adjusted and locked down.
At gain levels above 50 dB, wind loading and tower or building flexure can cause an unacceptable level of beam wander. A flimsy antenna mount could not only result in loss of service to a wireless customer; it could inadvertently cause interference with other licensed beam paths. In order to maintain transmission only within a specific “pipe,” some method for electronic beam steering may be required.
Beam Steering
Phased-array beam combining from several ports in the flat-panel phased array could steer the beam over many antenna beam widths without mechanically rotating the antenna itself. Sum-and-difference phase combining in a mono-pulse receiver configuration locates and locks on the proper “pipe.” In a Cassegrain antenna, a rotating, slightly unbalanced secondary (“conical scan”) could mechanically steer the beam without moving the large primary dish. For prime focus and offset parabolas, a multi-aperture (e.g. quad-cell) floating focus could be used with a selectable switching array. In these dish architectures, beam tracking is based upon maximizing signal power into the receiver. In all cases, the common aperture for the receiver and transmitter ensures that the transmitter, as well as the receiver, is correctly pointed.
The microwave backup links operate at approximately eight times lower frequency (8 times longer wavelength) than the millimeter wave link. Thus, at a given size, the microwave antennas have broader beam widths than the millimeter-wave antennas, again wider by about 8 times. A typical beam width from a 2-foot antenna is about 7.5 degrees. This angle is wider than the angular separation of four service customers from the relay tower and it is wider than the angular separation of the beam between the relay station and the radio antenna. Specifically, the minimum angular separation between sites serviced from the relay station is 1.9 degrees. The angular separation between receivers at radio antenna tower 79 and relay station 76 is 4.7 degrees as seen from a transmitter at facility 70 . Thus, these microwave beams cannot be separated spatially; however, the FCC Part 101 licensing rules mandate the use of twelve separate transmit and twelve separate receive channels within the microwave 10.7 to 11.7 GHz band, so these microwave beams can be separated spectrally. Thus, the FCC sponsored frequency coordination between the links to individual sites and between the links to the relay station and the radio antenna will guarantee non-interference, but at a much reduced data rate. The FCC has appointed a Band Manager, who oversees the combined spatial and frequency coordination during the licensing process.
Other Wireless Techniques
Any millimeter-wave carrier frequency consistent with U.S. Federal Communications Commission spectrum allocations and service rules, including MMW bands currently allocated for fixed point-to-point services at 57–64 GHz, 71–76 GHz, 81–86 GHz, and 92–100 GHz, can be utilized in the practice of this invention. Likewise any of the several currently-allocated microwave bands, including 5.2–5.9 GHz, 5.9–6.9 GHz, 10.7–11.7 GHz, 17.7–19.7 GHz, and 21.2–23.6 GHz can be utilized for the backup link. The modulation bandwidth and modulation technique of both the MMW and microwave channels can be increased, limited again only by FCC spectrum allocations. Also, any flat, conformal, or shaped antenna capable of transmitting the modulated carrier over the link distance in a means consistent with FCC emissions regulations can be used. Horns, prime focus and offset parabolic dishes, and planar slot arrays are all included.
Transmit power may be generated with a Gunn diode source, an injection-locked amplifier or a MMW tube source resonating at the chosen carrier frequency or at any sub-harmonic of that frequency. Source power can be amplitude, frequency or phase modulated using a PIN switch, a mixer or a bi-phase or continuous phase modulator. Modulation can take the form of simple bi-state AM modulation, or can involve more than two symbol states; e.g. using quantized amplitude modulation (QAM). Double-sideband (DSB), single-sideband (SSB) or vestigial sideband (VSB) techniques can be used to pass, suppress or reduce one AM sideband and thereby affect bandwidth efficiency. Phase or frequency modulation schemes can also be used, including simple FM, bi-phase, or quadrature phase-shift keying (QPSK). Transmission with a full or suppressed carrier can be used. Digital source modulation can be performed at any date rate in bits per second up to eight times the modulation bandwidth in Hertz, using suitable symbol transmission schemes. Analog modulation can also be performed. A monolithic or discrete-component power amplifier can be incorporated after the modulator to boost the output power. Linear or circular polarization can be used in any combination with carrier frequencies to provide polarization and frequency diversity between transmitter and receiver channels. A pair of dishes can be used instead of a single dish to provide spatial diversity in a single transceiver as well.
The MMW Gunn diode and MMW amplifier can be made on indium phosphide, gallium arsenide, or metamorphic InP-on-GaAs. The MMW amplifier can be eliminated completely for short-range links. The mixer/downconverter can be made on a monolithic integrated circuit or fabricated from discrete mixer diodes on doped silicon, gallium arsenide, or indium phosphide. The phase lock loop can use a microprocessor-controlled quadrature (I/Q) comparator or a scanning filter. The detector can be fabricated on silicon or gallium arsenide, or can comprise a heterostructure diode using indium antimonide.
The backup transceivers can use alternative bands 5.9–6.9 GHz, 17.7–19.7 GHz, or 21.2–23.6 GHz; all of which are covered under FCC Part 101 licensing regulations. The antennas can be Cassegrainian, offset or prime focus dishes, or flat panel slot array antennas, of any size appropriate to achieve suitable gain.
Prefabricated Cellular Base Station
In a preferred embodiment a prefabricated base station is provided for quick and easy installation on commercial building roof-tops. All of the components of the base station as described above are pre-assembled in the prefabricated station. These components include the cellular transceiver for communication with users and the millimeter wave transceiver for operation as a part of the trunk line as described above.
While the above description contains many specifications, the reader should not construe these as a limitation on the scope of the invention, but merely as exemplifications of preferred embodiments thereof. For example, the 71.0–76 GHz and 81.0 to 86 GHz bands utilized for point to point trunk lines would work very well in the above applications. The present invention is especially useful in those locations where fiber optics communication is not available and the distances between communications sites are less than about 15 miles but longer than the distances that could be reasonably served with free space laser communication devices. Ranges of about 1 mile to about 10 miles are ideal for the application of the present invention. However, in regions with mostly clear weather the system could provide good service to distances of 20 miles or more. Accordingly, the reader is requested to determine the scope of the invention by the appended claims and their legal equivalents, and not by the examples given above.
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A wireless cellular communication system in which groups of cellular base stations communicate with a central office via a narrow-band millimeter wave trunk line. The transceivers are equipped with antennas providing beam divergence small enough to ensure efficient spatial and directional partitioning of the data channels so that an almost unlimited number of transceivers will be able to simultaneously use the same millimeter wave spectrum. In a preferred embodiment the trunk line communication link operates within the 92 to 95 GHz portion of the millimeter spectrum. A large number of base stations are each allocated a few MHz portion of a 900 MHz bandwidth of the millimeter wave trunk line. A first transceiver transmits at a first bandwidth and receives at a second bandwidth both within the above spectral range. A second transceiver transmits at the second bandwidth and receives at the first bandwidth. Antennas are described to maintain beam directional stability to less than one-half the half-power beam width. In a preferred embodiment the first and second spectral ranges are 92.3–93.2 GHz and 94.1–95.0 GHz and the half power beam width is about 0.36 degrees or less. Thus, in this system the low frequency band width is efficiently utilized over and over again by dividing a territory into small cells and using low power antenna. And a higher frequency bandwidth is efficiently utilized over and over again by using transmitting antennae that are designed to produce very narrow beams directed at receiving antennae. In a preferred embodiment cellular base stations are prepackaged for easy quick installation at convenient locations such as the tops of commercial buildings.
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RELATED U.S. APPLICATIONS
[0001] not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO MICROFICHE APPENDIX
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] This invention refers to an integrating device to detect, recover and compensate the deformation of shoulders, in a press-bending machine.
[0005] The innovation finds particular even if not exclusive application in the field of machine tools.
BACKGROUND OF THE INVENTION
[0006] Press-bending machines, as known, are widely used in the engineering industry, and particularly in the working of metal sheets, to obtain, for example, differently shaped longitudinal sections, sometimes with the possibility of being each re-taken and subjected again to a cycle of press-bending.
[0007] Operatively, a press-bending cycle consists in the vertical descent of a tool, until it presses on the underlying metal sheet rested on the matrix, in carrying out the bending, and then, at the end, in proceeding with the ascent, up to a primary position. For carrying out the mentioned steps, the machine consists of two parts, respectively a first one, dynamic, generally engaging the upper part, and a substantially static part, constituting the underside of the machine placed perpendicular to the dynamic part. As far as the first dynamic part is concerned, in the execution of a press-bending cycle, a tool is provided for, made up of a differently shaped punch, also of the interchangeable type, which, supported by a beater or upper cross-piece, makes just one movement, along a vertical axis, of to and fro. The said movement is ensured by at least two oil-dynamic end-cylinders, which determine the descent, the possible stop and ascent of the beater that supports the tool longitudinally. Every cylinder group, in a traditional forming press, is joined and made integral with the frame or static body of the machine, and, in this case, to a corresponding side or side-shoulder of the frame of the press.
[0008] These characteristics give origin, during the pressing phase, to a multitude of rather strong forces, which develop in various known directions to engage the different parts of the machine, deforming them temporarily. Furthermore, some of these forces above all, end up modifying the shape of each shoulder even in a non-uniform way. It follows that during the execution phase of a press-bending cycle, a widespread deformation takes place, which affects in a negative way the qualitative result of the working required.
[0009] Tests carried out on the test stand, have evidenced that this characteristic temporary deformation of each shoulder, has its own logical progression the more the punch presses down on the sheet, and it is always proportional to the thickness of the sheet and to the type of material.
[0010] It therefore follows that it is necessary to have a control system that allows to detect the deflection of the shoulders, in order to intervene in the first stages of the working process. Then it is a question of correctly prearranging the forming press, in order that it can carry out a manufacturing cycle that will allow to achieve the predetermined bending angle with precision.
[0011] Actually, two techniques are known for solving the problem, which however do not seem completely satisfactory.
[0012] In one case, see for example TABLE 1, the movement of the beater G or punch carrying cap of the synchronized bending presses is given by two hydraulic cylinders, placed to the sides of the first and integral with the shoulders R, which assume the name of the two axes YI and Y2. These axes, Y1 and Y2, are checked sideways by optical rulers H where a small reading trolley I slides. The reading trolley I is hinged, through a L rod, to the upper end of a flexion recovery shoulder or false shoulder D, superimposed to the shoulder R, which is made integral, only on the underside, with the cross-piece F, with the platform M and with the matrix N (FIG. 1. 1 ).
[0013] Considering the fact that the false shoulder D is integral with the cross-piece F, with the platform M and with the matrix N, the punch O should, both when under pressure and when load-less, maintain a locating spot in correspondence with the bottom dead center 0 (see FIG. 1. 2 ). Intuitively, this should take place because the false shoulder D is not engaged to the shoulder R.
[0014] A second system, not shown, but just as common, is the solution originally suggested by the Beyler Company. It refers to an electronic card consisting of a data base, cooperating with the logical unit of the machine, where a great number of data relative to the known deformations is stored, therefore including the deformation of shoulders, in relation to an entire series of parameters, namely: extension of the carpentry, extension of optical lines, changes on the viscosity of the oil, electric de-compensations, de-compensations in the control of the valves. This data have been previously acquired on the basis of a series of tests and subsequently transferred to the database. The processing and the comparing of these by a logical unit with others values, allows to define, in a manufacturing cycle of the sheet, ascribable theoretic values foreseeable in the localized deformation of the shoulders that therefore will be conveniently recovered.
[0015] As regards the first of the mentioned solutions, the use of the traditional optical ruler does not seem to be at all sufficient to allow a precise recovery of the deflection of the false shoulder and consequently obtain the predetermined angle. In fact (see FIG. 1. 3 ) even reaching the planned value of the trolley on the optical ruler H, under pressure the point 0 is not held as happens instead in the load-less condition (see FIG. 1. 2 ). This difference is due in part to the crushing of some parts of the machine, as for example in the underside the cross-piece F, the platform M and the matrix N, which, altering the value in reference to height B, cause a variation in the value of the dimension A. In the same way, in the upper part of the machine the same crush is created between punch 0 and beater G causing a variation of dimension Δ. Furthermore, with the deformation of shoulder R, a displacement C of the upper part of the false shoulder D takes place and therefore of the hinging point of the lower extremity of lever L of the trolley I, which in this hypothesis advances. During the working process, the displacement of the false shoulder D opposite to that of shoulder R concurs in emphasizing the phenomenon, as indicated by letters P and Q. Finally, one detects that value C is proportional to arm E that is placed between the anchorage point of the lever L to the trolley I.
[0016] The consequence, therefore, is that the reaching of spot 0 by the machine Δ in a load-less condition, is different from when the system is under pressure, Δ1, for the total diversity of points A, B and C.
[0017] As regards the solution suggested by Beyler, one observes, as in the previous proposal, the basic impossibility of achieving a correct recovery of the deflection of the shoulders, that would allow to carry-out with precision the predetermined bending angle. This is substantially due to the fact that the values of points A, B and C, are presumed and do not correspond to the ones actually measured, or real, obtainable from the single measuring of phenomena during the execution of the press-bending cycle of a sheet.
[0018] Therefore there is the need for companies to find alternative and more effective systems than the ones described above.
[0019] A purpose of the present proposal is also to avoid the abovementioned drawbacks.
BRIEF SUMMARY OF THE INVENTION
[0020] This and other purposes are achieved with this innovation according to the characteristics as in the included claims, solving the mentioned problems, with an integrating device to detect and recover the deformation of shoulders, in a press-bending machine, including an optical rulerjoined to the beater and a reading trolley, pulled back elastically, stressed by the false shoulder; said device provided for above the false shoulder, being made up of a rod placed perpendicular to the beater, which is hinged to the shoulder of the machine on one side, while the opposite end, oscillating and directed towards said beater, is stressed by the arm joined to the reading trolley of the optical ruler, and furthermore in which said rod provides a sliding device in correspondence with an underlying plane plate that is part of the false shoulder.
[0021] The considerable creative contribution, found in the proposal now described, determines an immediate technical progress, allowing to obtain various advantages.
[0022] First of all, the system gives the user the possibility of finding the desired angle in a fast way, with intuitable and extremely simple operations. More particularly, first it carries out tests on a small piece to then take it on to a definite piece, even along the total length of the machine or differently placed along the fold-line (right, left and center). All this independently of the bending force, that, as known, varies according to what piece has to be bent.
[0023] Secondly, this system has the advantage of correcting automatically the different flexions noticeable from one shoulder to the other, caused by variations in the thickness of the material with which the shoulders are obtained, by the diversity of the materials, as well as by continuous variations in the temperature of the environment where the said machine is made operative.
[0024] Amongst the peculiarities of this invention, we also point out the fact that, under the executive point of view, having two metal-sheets of the same length but with a different bending section, the result between the two pieces is maintained constant.
[0025] An additional advantageous point refers to the lack of particular complications in the device; this implies almost an absence of maintenance with rather low costs, relatively to the construction and to installation. The particularity of the device, additionally, also allows installations on already existing machines, favoring an increase in quality and, as a whole, in the works in progress.
[0026] These advantages have the all but negligible value of obtaining a product with a good technological content, functional and extremely reliable, even if submitted to particular working conditions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] Other advantages will appear from the following specific description of some preferred embodiments, with the aid of the included schematic drawings, whose details of execution are not to be considered limitative, but only illustrative.
[0028] [0028]FIG. 1, represents a side view of a portion of the press-bending machine, to which a device for the control of the deflection of the shoulder is joined, taken in correspondence with the working area.
[0029] [0029]FIG. 2, is always a side view of a portion of a press-bending machine as in the previous figure, comprehensive of the device for the control of the deflection of the shoulder, represented in a load-less working condition.
[0030] [0030]FIG. 3, is again a side view of a portion of a press-bending machine as in FIG. 1, but represented in an effective working condition.
[0031] [0031]FIG. 4, illustrates sideways a portion of a press-bending machine, with a different version of the device for the control of the deflection of the shoulder.
[0032] [0032]FIG. 5, is a side view of a portion of a press-bending machine as in the previous figure, represented in a load-less working condition.
[0033] [0033]FIG. 6, is again a side view of a portion of a press-bending machine as in FIG. 4, but represented in an effective working condition.
[0034] [0034]FIG. 7 is an enlarged side view of the detail as in FIG. 1, of a portion of the press-bending machine, to which a device for the control of the deflection of the shoulder is joined, taken in correspondence with the working area.
[0035] [0035]FIG. 8 is an enlarged side view of the portion of press-bending machine of FIG. 4, which represents the different version of the device for the control of the deflection of the shoulder.
[0036] [0036]FIG. 9 is an additional enlargement of a detail of the portion of press-bending machine of FIG. 4.
[0037] Finally, FIG. 10, is an overall and frontal view of a press-bending machine.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Also with reference to the figures, one can detect that a press-bending machine (A), provided with a device for the control of the deflection of the shoulder, includes an upper beater ( 1 ), vertically mobile with respect to the frame, to the lower end of which an interchangeable type tool is associated longitudinally, realizing the punch ( 2 ). Always the machine (A), provides at the two ends a cylinder group for each side ( 3 , 4 ), which being synchronous, determine the downward and upward vertical movement of the beater ( 1 ) towards the underlying cross-piece ( 5 ), which supports a platform ( 6 ) which supports the matrix ( 7 ), also of the interchangeable type.
[0039] With the purpose of detecting and later on allowing the recovery of the deflections that both the shoulders ( 8 ) undergo, during the execution of a press-bending cycle, for example of a metal sheet (Z) interposed between the matrix ( 7 ) and the punch ( 2 ), false shoulders or flexion recovery shoulders ( 9 a , 9 b ) are provided for each of said shoulders ( 8 ), set on the side facing towards the exterior.
[0040] Every false shoulder ( 9 a , 9 b ), composed of a robust metallic body plate on both the sides, presents a characteristic “C” shape where the empty part faces towards the tool ( 2 ) and the underlying matrix ( 7 ). As regards the fixing of the false shoulder ( 9 a , 9 b ), it is provided for only in correspondence with the lower end ( 91 a, 91 b ), in such a way as to make it integral with the lower cross-piece ( 5 ), as it is directly joined to the latter, and integral with the bed ( 6 ) and the matrix ( 7 ).
[0041] There is also an optical ruler ( 10 ) joined to the beater ( 1 ), cooperating with a reading trolley ( 100 ). This reading trolley ( 100 ), instead of being directly fixed to the false shoulder ( 9 a , 9 b ), as seen in previous solutions, is now equipped with a small cantilevered arm ( 101 ), with a bearing ( 102 ) at the end which insists in correspondence with the extremity ( 111 , 141 ) of a rod ( 11 , 14 ) for the neutralization of horizontal end plays hinged in ( 112 , 143 ) to the shoulder ( 8 ). The necessary and constant contact of the bearing ( 102 ) along the rod ( 11 , 14 ), that in this case is of the type made of harmonic steel, is ensured by the action of an underlying elastic means ( 12 ), which on one side is engaged to the shoulder ( 8 ) and on the other to the reading trolley ( 100 ).
[0042] In a first proposition of the invention, with the purpose of controlling the oscillation of the rod that neutralizes the end play ( 11 ), along the latter a movable body ( 13 ) is provided for. This movable body ( 13 ), which is nothing less than a trolley, in the underside is provided with a point of support ( 131 ), for example a bearing, which slides along the flat edge of the upper end ( 921 ) of the false shoulder ( 9 a ). In this way, the rod ( 11 ) takes on the function of a second-degree lever, so that when the position of the movable body ( 13 ) varies, the width of the movement of the rod varies proportionally to the deformation of the shoulder due to the pressure exerted by the cylinders for the bending.
[0043] Operatively, to make sure that the point 0 does not change when the pressure varies, one will have to act on the movable body ( 13 ). This action determines the variation of the value (K) until point 0 is not maintained constant even when variations of the pressure take place.
[0044] The described condition, in such a case, is reached thanks to the movement in opposite directions (P, Q) of the shoulder ( 8 ) and of the false shoulder ( 9 a ), which contextually determines the movement of the movable body ( 13 ) along the plane ( 921 ). Thanks to the sliding of the movable body ( 13 ) with respect to the plane ( 921 ) of the extremity ( 92 a ) of the false shoulder ( 9 a ), it is possible to maintain the value of the optical ruler ( 10 ) and to get the beater ( 1 ) down until it reaches the position 0 (value reached in a load-less condition) proportionally to the pressure exerted on the beater ( 1 ).
[0045] A different version of the mentioned device is represented in the following FIGS. 4, 5 and 6 . Also in this hypothesis, with the purpose of detecting and recovering the flexions that both the shoulders ( 8 ) undergo, during the execution of a press-bending cycle, for example of a metal sheet (Z) interposed between the matrix ( 7 ) and the punch ( 2 ), false shoulders or flexion recovery shoulders ( 9 b ) are provided, for each of the shoulders ( 8 ), set on the side facing towards the exterior.
[0046] Each of the two false shoulders ( 9 b ), is composed by a robust metallic body, flat on both sides, with a characteristic “C” shape where the hollow part faces towards the tool ( 2 ) and the underlying matrix ( 7 ). Also in such case, the fixing of the false soulder ( 9 b ) is provided for only in correspondence with the lower end ( 91 b ), in such a way to make it integral with the cross-piece ( 5 ), as it is directly-joined to it, and integral with the bed ( 6 ) and the matrix ( 7 ).
[0047] An optical ruler ( 10 ) is always present, joined to the beater ( 1 ), cooperating with a reading trolley ( 100 ). The said reading trolley ( 100 ), is equipped with a small arm ( 101 ), with at the end a bearing ( 102 ) which insists in correspondence of the extremity ( 141 ) of a steel rod ( 14 ) for neutralizing horizontal end games. The necessary and constant contact of the bearing ( 102 ) along the top-side of the rod ( 14 ) is ensured by the action of an elastic means ( 12 ) which, on one side, is engaged to the shoulder ( 8 ), on the other to the reading trolley ( 100 ).
[0048] Furthermore, one detects that above the extremity ( 92 b ) of the false shoulder ( 9 b ), the said end game neutralizing rod ( 14 ) is hinged in correspondence with point ( 143 ) to the shoulder ( 8 ). This rod is provided, along the bottom side in correspondence with the extremity ( 141 ), with a bearing ( 142 ), which engages along an adjustable plane ( 15 ), provided with reference graduations with relation to the measuring of degrees allowing to establish a more or less stronger inclination. In more detail, said adjustable plane ( 15 ) is hinged in correspondence with the higher extremity ( 92 b ) of the false shoulder ( 9 b ), which has a short extension section directed vertically, for the support of said adjustable plane ( 15 ).
[0049] Operatively, during pressing, the false shoulder ( 9 b ) moves in direction (P) and the shoulder ( 8 ) in the opposite direction (Q), so that, as the rod ( 14 ) is anchored to the shoulder ( 8 ), the bearing ( 142 ) runs along the adjustable plane ( 15 ) creating therefore a movement along a vertical direction (K) proportional to the power at work.
[0050] The plane ( 15 ), is inclined until the maintenance of point 0 of the punch ( 2 ) is achieved, in a practical way, at any working pressure. This is thanks to the movement in opposite directions of (P) and (Q) which makes the bearing ( 142 ) run along the inclined plane ( 15 ). Thanks to the sliding of the bearing ( 142 ) with respect to the plane ( 15 ) it is possible to maintain the value of the optical ruler and get the beater ( 1 ) down until it reaches the position 0 [value reached when load-less] proportionally to the pressure exerted on the beater ( 1 ).
[0051] After accurately setting-up the angle, the system recovers the anomalies of deformations and flexions of the shoulders ( 8 ) due to movements (P, Q) and of compressions therefore maintaining point 0 (value reaching point) constant whatever the pressure, both in a load-less condition and under maximum load.
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Integrating device to detect and recover the deformation of shoulders in a press-bending machine, including an optical ruler joined to the beater and reading trolley, pulled back elastically, and stressed by the false shoulder. The device provided for the false shoulder is made up of a rod perpendicular to the beater, which on one side is hinged to the shoulder of the machine, while on the opposite end, oscillating and facing the beater. It is stressed by the arm joined to the reading trolley of the optical ruler, and further in which the rod provides a slider in connection with an underlying plane plate that is part of the false shoulder.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the levitation of magnetic materials by magnetic fields, and more particularly to the suspension of such materials in a state of stable or indifferent equilibrium relative to gravitational attraction. The invention may be incorporated and used for measurement and control in a wide range of instruments such as accelerometers, flow meters, gravity meters, gyroscopes, magnetometers, micrometers, and tilt meters, as well as in nonmeasurement devices such as bearings and other apparatus.
2. Description of the Related Art
There are many applications where it would be desirable to levitate a magnet or a magnetic member. A levitated magnet can be acted on magnetically, and its position can be sensed magnetically. There are significant limitations that must be overcome to levitate a magnet. Magnetostatic or stationary electromagnetic fields will not levitate magnets or magnetic materials unless the field is modified to have a relative magnetic permeability that is less than one at one or more positions. Otherwise, the magnetic material to be suspended will either be expelled from the field or drawn into contact with a magnet providing the field. This phenomenon is referred to as instability. Magnetic fields with stable or indifferent equilibrium can be created by interaction between a permanent magnet and a material having a relative magnetic permeability less than one. The stabilizing magnetic force of such a field is inversely proportional to the relative magnetic permeability.
There are substantial drawbacks to all prior approaches for providing a magnetic permeability that is less than one in order to achieve levitation.
Diamagnetic materials have relative magnetic permeabilities that are lower than one and can be used to provide stable levitation. But the permeabilities are only slightly lower than one and provide low lift force. Large permanent magnets have been used to levitate diamagnetic members. But that is very different from levitating a magnet. One prior reference suggests that the interaction between a magnet and a diamagnetic material could levitate a few microns of the magnetic material. That is not a sufficient volume for use in a practical device. A stronger magnetic field capable of levitating a greater mass of magnetic material would not be attained simply by increasing the mass or quantity of diamagnetic material. Another reference uses a diamagnetic material to provide stability and a second fixed magnet located above a first magnet in order to provide sufficient lift force to levitate the first magnet. Some of the drawbacks of this design are that the second magnet creates substantial magnetic spring constants or forces that distort the motion and limit the stability of the first magnet. The lift magnet also increases size, weight, and cost.
Superconductors have a magnetic permeability of zero and produce higher lift force than diamagnetics. The lift force of the magnetic field produced by the interaction between a magnet and a superconductor is sufficiently large to suspend a magnet in the magnetic field. A permanent magnet of about one gram has been reported suspended above a concave superconducting disk. But applications involving materials in the superconductive state have the limitation of requiring very low temperatures, i.e. around -200° C. or lower. Another approach to levitation is to use a variable electromagnetic field and feedback control to suspend magnetic materials. Drawbacks of electromagnetic devices are that they require power consumption, active control, and increase cost.
SUMMARY OF THE INVENTION
This invention provides a configuration for levitating magnets by a magnetic field that is free of undesirable spring constants and instability. The invention comprises a first member that is defined by an array of magnets or magnetic dipoles which are arranged to provide a high strength, high gradient magnetic field adjacent one surface of the array. More specifically, the magnets are arranged in a side by side sequence with each consecutive magnet having opposite magnetic polarity. This arrangement provides closed loop magnetic flux paths for each two consecutive magnets that intercept both magnetic poles of the two magnets. A second member that is formed from a diamagnetic or other material having a relative magnetic permeability that is less than one interacts with the magnetic field to levitate the magnetic first member. This second member defines a base or area over which the levitated magnetic array may be moved by external forces. Levitation over this area is free of even small undesirable forces because the diamagnetic or other material can be formed without surface irregularities and without magnetic or other impurities that would affect levitation.
The magnetic field provided by the array of magnets has a higher field strength and a higher field gradient than a magnetic field provided by a single magnetic of similar size and shape. The magnetic field from one or more magnets always forms closed loop flux paths. The strength of the field for a given magnetic material is determined by the portion of the closed loop flux paths through air compared with the portion that passes through the magnets. The shorter the portion through air compared to the portion through the magnets, the stronger the magnetic field. For a lone magnet or single magnetic dipole not in an array or near other magnets, the closed loop flux path near the center of the magnet must pass all the way around the edge of the magnet before returning through the other side. This distance is particularly long for thin magnets having only a short distance separating the two magnetic poles, such as are desirable for levitation in order to minimize weight. By comparison, in an array of alternating polarity magnets having the same overall shape as the single thin magnet, a closed loop flux path originating at one magnet to travels only a short distance through air before it re-enters a magnet of opposite polarity. Thus, the array has shorter flux paths through air compared to the path segments through magnetic material, and hence stronger magnetic fields than a single magnet. Similarly with respect to the field gradient, the magnetic field from a lone magnet projects through air over a large area. In an array of alternating polarity magnets, the field from each magnet is drawn to the next consecutive magnet. This limits the range and causes the strength of the magnetic field to change rapidly with displacement along the direction of magnetization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, plan view of an array of magnets levitated above a diamagnetic material.
FIG. 2 is a schematic, plan view of a modification of the levitation apparatus of FIG. 1 that includes a layer of ferromagnetic material.
FIG. 3 is a schematic, plan view of a modification of the levitation apparatus of FIG. 1 that includes nonmagnetic spacers between the magnets.
FIG. 4 is a schematic, perspective view of a two-dimensional array of magnets levitated above a diamagnetic material.
FIG. 5 is a schematic, perspective view of a sequence of concentric ring magnets levitated above a diamagnetic material.
FIG. 6a is a cutaway cross sectional view of a level having a magnetic array levitated above a diamagnetic material. FIG. 6b is a top view of of the level shown in FIG. 6a.
FIG. 7 is a cutaway cross sectional side view of a bearing having cylindrical magnetic arrays that project from a central shaft interleaved between layers of a diamagnetic material.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows levitation apparatus 10 comprised of a two-dimensional array 12 of permanent magnets 14 levitated over a layer 16 of pyrolytic graphite. Array 12 comprises an arrangement of alternate polarity magnets. Viewed from above, the alternating north and south poles form a checkerboard pattern. The permanent magnets 14 are formed from neodymium-iron-boron of grade 35 megagauss-oersted or higher. This material is a strongly magnetic rare earth composition. The pyrolytic graphite 16 is a diamagnetic material. It has the lowest relative magnetic permeability or value closest to zero of the common diamagnetics. Pyrolytic graphite has an oriented structure of graphite crystal layers. The crystal layers (not shown) of the rectangular block 16 are oriented parallel to the bottom face of array 12. With respect to dimensions, each magnet 14 is of rectangular box shape and measures 0.5×0.5×0.25 mm. The 0.25 mm is the thickness dimension, which is also the direction of magnetization or direction along which the magnetic poles are spaced. These dimensions are typical optimum dimensions. They provide a ratio of thickness divided by width that is 0.5 for each magnet 14. The range of variation for practical dimensions of the apparatus 10 encompasses a thickness to width ratio of 0.3-0.8, and thickness for each individual magnet 14 less than about 2.0 mm.
In operation, the arrangement of magnets in array 12 shown in FIG. 1 produces a magnetic field 20 in the gap or area 18 between the array 12 and surface 16 that has both a high magnetic strength and a high gradient along the direction of magnetization. The pyrolytic graphite 16 interacts with this magnetic field to produce a lift force that levitates the magnetic array 12 above surface 16 in a state of indifferent equilibrium. The array floats above surface 16 with no spring constant or force attracting it to a particular position or accelerating it in any particular direction. The magnetic strength of the field 20 changes rapidly as a function of distance from the array 12. For the specific dimensions noted above, the gap 18 will be about 25 to 50 μm or 0.001" to 0.002".
FIGS. 2 through 7 illustrate various modifications of the levitation apparatus 10 shown in FIG. 1. Common components are designated with the same numerals in all figures. FIG. 2 shows levitation apparatus 22 having a layer 24 of ferromagnetic material placed across the top of array 12. Ferromagnetic layer 24 provides a low resistance magnetic path above array 20 that increases the flux density of field 20 in the gap 18 between the array 12 and surface 16. This increased flux density provides a higher lift force that will levitate a greater mass of material.
FIG. 3 shows levitation apparatus 26 comprised of an array 28 in which the magnets 14 are spaced apart rather than adjacent to each other as shown in FIGS. 1 and 2. The array 28 includes spacer elements 30 formed from a material that is substantially nonmagnetic placed between consecutive magnets 14. Such spacers 30 increase the distance between the magnetic poles of consecutive magnets, which in turn decreases the gradient of the magnetic field 20 in gap 18. This lower gradient field provides a lower lift force and will not support as large a mass as the apparatus shown in FIGS. 1 and 2. But the size of the gap 18 is increased as shown in FIG. 3, and the position of material that will be supported is at a greater distance from surface 16 than provided by the other illustrated embodiments.
FIG. 4 shows levitation apparatus 32 comprised of a two-dimensional array 34 floating above a layer of diamagnetic material 36. A shallow bowl shape 38 is machined into the top surface of layer 36. The array 34 includes four magnets 14 arranged in a square configuration. Array 34 is a small version of array 12. Array 34 has no net magnetic dipole moment because the two magnets with vertically upward polarizations are balanced by the two magnets with vertically downward polarizations. Arrays such as array 34 with zero net dipole moment are preferred for many applications because they are less sensitive to being twisted or turned about an axis parallel to surface 38 by magnetic interaction with either the earth's magnetic field or with the diamagnetic material. This sensitivity to twisting can be avoided with rectangular arrays having a different number of consecutive magnets along one dimension than another, as well as with square configurations. The shallow bowl-shaped surface 38 in the top of diamagnetic layer 36 provides the magnetic array 34 with stable equilibrium rather than the indifferent equilibrium provided by the flat surfaces shown in FIGS. 1, 2, and 3. The bowl shape of surface 38, and corresponding configuration of magnetic interaction between that surface and the array 34 causes array 34 to be drawn by gravity toward the center of layer 36. Array 34 is thereby kept from floating off the diamagnetic member 36.
FIG. 5 shows an array 40 of magnets comprised of a small central cylinder 42 encircled by a concentric ring 44 of opposite magnetization. The radius of the central cylinder 42 is chosen to be 1/√2 times the outer radius of the ring 44. Other dimensions can be used, but with this choice the central cylinder 42 will be magnetically balanced by the outer ring 44. The two-magnet array 40 has no net magnetic dipole moment. Levitated over a piece of pyrolytic graphite 36 with a gap 18 of 0.025 mm (0.001"), the two-magnet array 40 has approximately 75 percent greater levitation force than a single magnet disc formed from the same magnetic material with the same overall dimensions as the two-magnet array 40. Arrays with more than two concentric magnets will have even greater levitation force.
FIG. 6 shows a two-dimensional level 46 for detecting tilt. The level is comprised of a transparent cover 48 with visual alignment marks 50. Cover 48 encloses an array 34 of magnets levitated above a layer of diamagnetic material 36 similar to that shown in FIG. 4. Operation of the two-dimensional level 46 is similar to that of a more conventional two-dimensional bubble type level. The alignment marks 50 indicate the position of array 34, and thereby the tilt of level 46. But compared to a conventional bubble level, the diamagnetic level 46 is more sensitive, lighter weight because of no need for a liquid, and free from liquid leaks. When the level 46 is placed on a horizontal surface, the levitated array 34 will line up with the alignment marks 50. If the surface is tilted, the array 34 will stabilize over the portion of the bowl 38 that is locally horizontal relative to the earth. Since that horizontal portion will be away from the alignment marks 50, the array will stabilize off to the side of the marks. Thus, tilted surfaces are detected by the position of the array 34 relative to the marks 50.
FIG. 7 shows a bearing 52 comprised of a shaft assembly 54 suspended in a housing 56. A plurality of discs 58 which are comprised of concentric magnetic rings 44 that are similar to the ring 44 shown in FIG. 5 are spaced along shaft 54. The discs 58 are interleaved between discs 60 of diamagnetic material that are attached to and project inwardly from the outer shell of housing 56. Magnetic interaction between the magnets 44 and multiple layers of diamagnetic material 60 produce a large lift force and low spring constant in the circumferential direction for shaft rotation.
There are many modifications and variations that can be made to the levitation apparatus of this invention in addition to the variations shown in FIGS. 1 through 7. For example, levitation can be achieved with materials other than those specifically noted. This includes materials that provide lower lift forces. The magnets 14 may be either other rare earth magnets or also lower strength magnets not formed from rare earth materials. The layer 16 may be comprised of other diamagnetic materials having higher relative magnetic permeability such as bismuth. Or, the diamagnetic layer can be replaced by a superconductive material which has a lower relative magnetic permeability, namely zero. The interaction with the superconductor will provide a higher lift force that can levitate a larger mass. But there will also be the requirement to cool the superconductor. As another variation, there are a number of alternatives to the shallow-machined surface 38 shown in FIG. 4 that can be used to urge or draw the magnetic array toward a desired location. For example, a small force that will attract an array to a preferred location can be provided by forming a small indentation at a selected location in an otherwise flat diamagnetic surface. Or, particles of magnetic material could be embedded in the diamagnetic material at a preselected location to provide a small magnetic attraction to the magnetic array.
With respect to modifications of the level 46 shown in FIG. 6 and other instruments, a one-dimensional diamagnetic level can be provided by making the bowl 38 long and narrow. In such configurations alignment would be taken only along one axis. The level 46 can also be made into a tiltmeter by putting gradations on the transparent cover 46 rather than simple alignment marks 50. Or, electronic sensing apparatus using either optical or magnetic sensors could be used to identify the position of the levitated array 34. Electronic versions will be more sophisticated than the visual embodiment shown in FIG. 6 and increase accuracy. There is an increased cost, but it is moderate as the electronics are within the state of the art and fairly simple. As another variation, other measuring devices can include three-dimensional levitated members that project high strength, high gradient magnetic fields in all directions. Examples include cubes with each side formed from a flat array as shown in FIG. 4 and spheres with magnets displaced radially. Such members can be enclosed in larger cubes, spheres, or other housings of diamagnetic material, with sensors placed to detect motion relative to different axes.
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Various levitation devices are disclosed in which an array of permanent magnets is levitated by magnetic interaction with a diamagnetic material. Levitation is achieved without using a fixed permanent magnet or other device to supplement the magnetic field of the array. The cost and design constraints resulting from undesirable spring constants produced by such permanent magnets are thereby avoided.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of, and incorporates herein by reference in its entirety, U.S. Provisional Patent Application No. 61/604,421, filed Feb. 28, 2012.
TECHNICAL FIELD
[0002] This invention relates generally to articles and methods for separating emulsions. More particularly, in certain embodiments, a hierarchical porous membrane is provided for separating oil and water.
BACKGROUND
[0003] Separation of oil and water mixtures is of great importance across a wide range of technologies and industries. For example, oil and water separation problems gained national attention during the 2010 Gulf oil spill and subsequent cleanup efforts. The petroleum industry faces similar water and oil separation challenges as it attempts to extract oil from beneath the sea.
[0004] Existing separation devices and methods are either environmentally unfriendly, extremely energy intensive, or incapable of performing the desired separations. For example, in deep sea oil extraction, one energy-intensive approach is to pump oil emulsified in water from the ocean floor to the surface where it is stored it in gravity separation tanks. Unfortunately, once much of the water has been removed from the oil, existing techniques (e.g., ultracentrifugation) are incapable of removing additional, trace amounts of water that remain. These trace amounts of water in oil may cause problems for end users, process equipment, and machinery. Current separation techniques are therefore inefficient and incapable of performing the wide range of oil and water separations of interest.
[0005] There is a need for more efficient devices and methods for separating oil and water mixtures. In particular, a need exists for separating trace amounts of water from oil and water mixtures.
SUMMARY OF THE INVENTION
[0006] Various embodiments of the invention provide a hierarchical porous membrane for separating emulsions of oil and water. In principle, the membrane may be applied to the separation of any two immiscible liquids. Unlike existing separation techniques, the membrane and methods described herein may be used to separate trace amounts of water (e.g., no greater than 3 wt % water content, no greater than 1 wt % water content, or 50-1000 ppm water) from oil. By altering properties of the membrane (such as pore size, hydrophobicity, and layer length), parameters critical to operation can be controlled, such as the breakthrough pressure and permeability. The membrane has a wide range of applications, including deep seep oil exploration, oil purification, and oil spill cleanup.
[0007] In one aspect, the invention relates to a hierarchical porous membrane suitable for use in oil/water separation processes. The membrane: (i) includes a polymer; (ii) is oleophilic; (iii) is hydrophobic; (iv) has a first layer with small pores; and (v) has a second layer, wherein the second layer is a support layer that is substantially thicker than the first layer and that has substantially larger pores than the first layer.
[0008] In certain embodiments, the first layer has thickness from about 0.3 micron to about 2 microns or from about 0.5 to about 2.0 microns. In one embodiment, the first layer has average pore size from about 25 nm to about 300 nm, from about 50 nm to about 200 nm, or from about 100 nm to about 150 nm. The support layer preferably has thickness from about 55 microns to about 370 microns. The support layer may have average pore size from about 10 microns to about 25 microns.
[0009] In certain embodiments, the first layer include a coating. The coating may be a silane coating. The silane coating may include at least one member selected from the group consisting of octadecyltrichlorosilane (OTS), methylsilane, phenylsilane, isobutylsilane, dimethylsilane, tetramethyldisilane, hexylsilane, octadecylsilane, and fluorosilane.
[0010] In certain embodiments, the polymer is selected from the group consisting of polycarbonate, polysulfone (PSf), polyacrylonitrile (PAN), polyethersulfone (PES), and any combination thereof. In certain embodiments, the membrane includes polycarbonate and wherein the membrane has a coating comprising octadecyltrichlorosilane (OTS).
[0011] In another aspect, the invention relates to a method of performing an oil/water separation. The method includes: (a) providing an initial liquid stream or volume including oil and water; (b) passing the initial liquid stream or volume through the membrane, described above, thereby allowing the passage of the oil from the initial stream or volume through the membrane and inhibiting the flow of the water from the initial stream or volume through the membrane; and (c) collecting fluid passing through the membrane, wherein the fluid that has passed through the membrane has water concentration less than the initial liquid stream or volume.
[0012] In certain embodiments, initial liquid stream or volume has water concentration no greater than 3 wt % or no greater than 1 wt %. In certain embodiments, initial liquid stream or volume has water concentration from about 50 ppm to about 1000 ppm. In one embodiment, the fluid that has passed through the membrane has water concentration no greater than about 30 ppm.
[0013] In another aspect, the invention relates to a method of preparing a hierarchical porous membrane (e.g., the membrane described above) suitable for use in an oil/water separation process (e.g., the method described above). The method includes: (a) combining a polymer, a pore former, and a solvent to make a polymer solution; (b) casting the polymer solution on a plate (e.g., glass plate); (c) following step (b), immersing the plate in a non-solvent to allow release of air bubbles; and (d) optionally, cutting a layer of the membrane resulting from step (c) to undergo coagulation, thereby forming the hierarchical porous membrane.
[0014] In certain embodiments, the polymer is selected from the group consisting of polycarbonate, polysulfone (PSf), polyacrylonitrile (PAN), polyethersulfone (PES), and any combination thereof. The solvent preferably includes dimethyl acetamide (DMAc) and/or n-methyl-2-pyrrolidone (NMP). In one embodiment, the pore former includes poly(vinylpyrrolidone) (PVP), polyethylene glycol (PEG), or a mixture thereof. The non-solvent may be DI water or a mixture of water and an alcohol. For example, the non-solvent may be a mixture of water and ethanol. In various embodiments, the non-solvent is a mixture of no less than about 50 wt. % water and no greater than about 50 wt. % alcohol (e.g., ethanol). In one embodiment, the non-solvent is a mixture of about 90 wt. % water and about 10 wt. % alcohol (e.g., ethanol). The method may also include the step of performing plasma etching to remove at least a portion of a first layer of the membrane.
[0015] Elements of embodiments described with respect to a given aspect of the invention may be used in various embodiments of another aspect of the invention. For example, it is contemplated that features of dependent claims depending from one independent claim can be used in apparatus and/or methods of any of the other independent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The objects and features of the invention can be better understood with reference to the drawing described below, and the claims.
[0017] FIG. 1 is a photograph of an oil film on a membrane surface, in accordance with an illustrative embodiment of the invention.
[0018] FIG. 2 is a schematic cross-sectional view of a membrane, in accordance with an illustrative embodiment of the invention.
[0019] FIG. 3 a is an SEM image of a top surface of a membrane, in accordance with an illustrative embodiment of the invention.
[0020] FIG. 3 b is an SEM image of a cross-section of a membrane, in accordance with an illustrative embodiment of the invention.
[0021] FIG. 4 includes a schematic front view of a plasma etching process, in accordance with an illustrative embodiment of the invention.
[0022] FIG. 5 includes photographs of a dry membrane and a membrane wetted by oil, in accordance with an illustrative embodiment of the invention.
[0023] FIG. 6 includes a schematic diagram and a photograph of a device for performing oil and water separation experiments.
[0024] FIG. 7 includes a schematic illustration and a series of photographs of a coated polycarbonate membrane, in accordance with an illustrative embodiment of the invention.
[0025] FIG. 8 includes SEM images and photographs of a coated polycarbonate membrane, in accordance with an illustrative embodiment of the invention.
[0026] FIG. 9 includes a macroscopic photo and a microscopic photo demonstrating filtration of emulsions through coated polycarbonate membranes, in accordance with an illustrative embodiment of the invention.
[0027] FIG. 10 includes diagrams showing distribution of water droplets on membranes used in accordance with an illustrative embodiment of the invention.
[0028] FIG. 11 are SEM images of a 100% PSf membrane in accordance with an illustrative embodiment of the invention.
[0029] FIG. 12 are SEM images of a 95% PSf, 5% PEG membrane in accordance with an illustrative embodiment of the invention.
[0030] FIG. 13 are SEM images of a 90% PSf, 10% PEG membrane in accordance with an illustrative embodiment of the invention.
DESCRIPTION
[0031] It is contemplated that articles, apparatus, methods, and processes of the claimed invention encompass variations and adaptations developed using information from the embodiments described herein. Adaptation and/or modification of the articles, apparatus, methods, and processes described herein may be performed by those of ordinary skill in the relevant art.
[0032] Throughout the description, where articles and apparatus are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are articles and apparatus of the present invention that consist essentially of, or consist of, the recited components, and that there are processes and methods according to the present invention that consist essentially of, or consist of, the recited processing steps.
[0033] It should be understood that the order of steps or order for performing certain actions is immaterial so long as the invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
[0034] The mention herein of any publication, for example, in the Background section, is not an admission that the publication serves as prior art with respect to any of the claims presented herein. The Background section is presented for purposes of clarity and is not meant as a description of prior art with respect to any claim.
[0035] Referring to FIG. 1 , in certain embodiments, a membrane is provided that is naturally oleophilic (e.g., it is spontaneously wetted by oil) and hydrophobic (e.g., it repels water droplets). This useful property allows oil to pass through the membrane and water to be blocked or stopped. In one embodiment, the ability of the membrane to separate oil and water is due at least in part to the membrane's structure. As depicted, oil wets the membrane to form a barely visible thin film.
[0036] Referring to FIGS. 2 , 3 a , and 3 b , in certain embodiments, the membrane is about 120 μm thick and includes a top layer and a bottom layer. The top layer has a thickness l 1 and includes a plurality of small pores having a diameter from about 300 nm to about 500 nm. The bottom layer has a thickness l 2 and includes a plurality of large pores having a diameter from about 10 μm to about 50 μm. As depicted in FIG. 2 , the membrane is designed for an emulsion to flow down through it, from the top layer to the bottom layer. The SEM images in FIGS. 3 a and 3 b show the nanoscale or small pores on a top surface of the top layer and the microscale or large pores just below the surface (in the bottom layer).
[0037] While not wishing to be bound by a particular theory, to understand how the membrane operates, consider water in contact with the top surface of the membrane. The Young-Laplace equation states that the pressure difference p c across the surface in question in given by
[0000]
p
c
=
2
γ
cos
θ
r
,
(
1
)
[0000] where γ is the surface tension of water, θ is the contact angle for water, and r is the pore radius. For the hydrophobic membrane, θ for water is greater than 90° and, accordingly, there is a positive pressure difference p c across the top surface that prevents the water from entering the pores. If this pressure difference is overcome, water may spontaneously enter the pores. In certain embodiments, the pressure necessary to force water to enter the pores of the membrane is referred to as the breakthrough pressure.
[0038] In various embodiments, the breakthrough pressure is controlled by varying the pore radius r. For example, a smaller pore radius r results in a higher breakthrough pressure. In addition, in one embodiment, the membrane is chemically treated to alter the contact angle for water θ.
[0039] While the hydrophobic properties of the membrane prevent the passage of water, in various embodiments, the oleophilic properties of the membrane cause oil to wet the membrane and enter the pores of the membrane spontaneously. While again not wishing to be bound by a particular theory, Darcy's law is a phenomenologically derived equation that describes fluid flow through porous media:
[0000]
Q
=
-
kA
μ
Δ
p
L
.
(
2
)
[0000] In this equation, Q is the volumetric flowrate of the fluid, k is the permeability of the membrane, A is the surface area of the membrane, μ is the viscosity of the fluid, L is the thickness of the membrane, and Δp is the pressure difference across the membrane.
[0040] In certain embodiments, to maximize the flowrate of oil through the membrane, the permeability k and/or the pressure difference Δp are kept high, and/or the thickness L is kept low. To prevent the flow of water through the membrane, the pressure preferably does not exceed the breakthrough pressure.
[0041] In various embodiments, the membrane allows for the key parameters (e.g., breakthrough pressure and flowrate) to be systematically controlled. The methodology for controlling these parameters is summarized in Table 1.
[0000]
TABLE 1
Key parameters for membrane.
Positive
Negative
Property
Modify by
Effects On
Effects On
Decrease r
Controlling pore size
Breakthrough
Permeability,
pressure
flow rate
Increase θ
Chemical treatment
Breakthrough
pressure
Decrease l 1
Membrane fabrication
Permeability
Increase l 2
Membrane fabrication
Stability
[0042] In some embodiments, membrane fabrication is bound by certain physical limits. For example, from a permeability standpoint, it would be preferable to make l 1 infinitely thin. In general, the easiest parameter of the membrane to influence or control is the pore radius r. Pore radius r, however, is coupled to both breakthrough pressure and permeability k. For example, in certain embodiments, the breakthrough pressure is inversely proportional to the radius r of the pores. At the same time, changing the radius r changes the permeability k. Fine-tuning the membrane may therefore be a delicate process.
[0043] Both breakthrough pressure and flowrate Q influence the separation efficiency of the membrane. In certain embodiments, the separation efficiency is defined as the flow of oil through the membrane divided by the total flow through the membrane. It is desirable to fine-tune the membrane to achieve the best flowrate possible.
[0044] In certain embodiments, a hierarchical porous polysulfone (PSf) membrane is manufactured using a phase inversion process (e.g., immersion precipitation). The method uses the following ingredients: a polymer (e.g., polysulfone (PSf) or polyacrylonitrile (PAN)); a solvent (e.g., organic, such as Dimethyl acetamide (DMAc) or n-methyl-2-pyrrolidone (NMP)); a non-solvent (e.g., DI water or a mixture of water/ethanol:90/10); and a pore former (e.g., poly(vinylpyrrolidone) (PVP) or Poly ethylene glycol (PEG) or a mixture of PVP/PEG (50/50)). The method includes dissolving the polymer in the solvent to produce a mixture, casting the mixture on a glass plate, and immersing the glass plate and mixture in a water bath to initiate phase inversion (also called immersion precipitation) to get the membrane films. During the phase inversion process, PVP and/or PEG creates macro pores. In general, a lower polymer concentration or addition of PEG creates bigger pores in the top layer.
[0045] In one embodiment, a porous polysulfone (PSf) membrane is prepared using a phase inversion technique based on a non-solvent induced phase separation method. A mixture of 7 g PSF and 3 g poly(vinylpyrrolidone) (PVP) is dissolved in 40 mL DMAc at 80° C. to form a homogeneous solution, which is then left at 50° C. for 12 h to allow air bubbles to be released. Using a doctor blade knife or other cutting instrument, a thin layer (0.28 mm) of polymer solution is then casted on a glass plate which is then immersed into non-solvent water at room temperature (22° C.), to undergo coagulation. Phase separation of the polymer-solvent system takes place during this process, which creates an asymmetric microporous membrane matrix. To wash away the PVP additive completely, the porous membrane is then rinsed with running tap water for 24 h, followed by immersion in a glycerol-water solution (volume ratio of 1:1) for another 24 h, before being dried at ambient conditions.
[0046] In various embodiments, polyacrylonitrile (PAN) porous membranes are prepared in a similar fashion. Compared to PSf, PAN is generally less hydrophobic (contact angle with water is 71°, compared to 84° for PSI) and usually results in bigger pores on the surface.
[0047] In various embodiments, PVP and/or PEG are used as pore forming chemicals to create uniform arrays of macropores. Without PVP and/or PEG, the formation of macropores may be random, and the quality of the membrane microstructure may be poor.
[0048] In certain embodiments, the addition of a water and alcohol (e.g., ethanol) mixture in the bath makes the non-solvent less polar and can delay the mixing of solvent (DMAc) and the non-solvent (water and ethanol). In one embodiment, this creates a membrane where the top layer pore sizes are in the scale of 50 to 300 nm, due to delayed mixing.
[0049] In certain embodiments, the top layer of the membrane has a thickness l 1 from about 0.3 microns to about 1 micron (e.g., as determined from cross-sectional scanning electron microscopy of the membrane film). In one embodiment, the top layer (also referred to as the active layer) provides the separation efficiency or selectivity of the membrane. As mentioned, the top layer includes the small pores (e.g., nanopores). In one embodiment, a pore diameter of the top layer is from about 25 nm to about 300 nm. The pore size may increase gradually from the top surface of the membrane to the inner structure.
[0050] In various embodiments, the bottom layer has a thickness l 2 from about 55 microns to about 370 microns (e.g., as determined from cross-sectional scanning electron microscopy of the membrane film). In one embodiment, the bottom layer provides mechanical support and gives negligible resistance to permeability, due to the large pores (e.g., macropores). In one embodiment, a pore diameter in the bottom layer is from about 10 microns to about 25 microns. The pore size may increase gradually toward the inner structure.
[0051] To form the top and bottom layers, in certain embodiments, the PSf polymer solution is cast as a film on a glass plate with a casting knife. The film is then immersed into a coagulation bath containing water. At the moment of immersion, DMAc diffuses out of the film, while water diffuses into the film. Because PSf is immiscible with the water, and has a relatively high molecular weight and a low diffusion coefficient, a relative velocity of the PSf molecules is very low. Diffusion therefore takes place in a polymer frame of reference. As a result of instantaneous or near-instantaneous demixing, two phases result in the glass plate. In one embodiment, a first phase that is poor (lean) in polymer creates macropores for the bottom layer, and a phase that is rich in polymer creates nanopores for the top layer, for selective separation.
[0052] In certain embodiments, to improve the permeability of the PSf and/or PAN hierarchical membranes, selective or plasma etching of the top layer (e.g., where the pore sizes are 30-300 nm) is performed. The plasma etching is preferably performed in an O 2 (oxygen) plasma chamber in a vacuum (200 mbar), for a controlled etching time of 3 to 10 seconds. FIG. 4 is a schematic of a plasma etching process, in accordance with certain embodiments of the invention. The plasma etching removes part of polymer material from the top layer surface, thereby decreasing an effective thickness of the top layer and opening up bigger pores (e.g., with size greater than 80 nm) beneath the original surface. The plasma etching process may be helpful to increase the overall permeability of the membrane.
[0053] In certain embodiments, the membranes and methods described herein are used to remove water from oil when the water concentrations are too low to be separated with conventional devices. For example, when the water concentration is higher than 0.5% by volume in the oil-water mixture, traditional separation devices (e.g., an ultracentrifuge) may be used. However, for trace amount of water (e.g., no greater than 3 wt % water content, no greater than 1 wt % water content, or 50-1000 ppm water), these traditional separation devices may be incapable of separating the water from the oil. Advantageously, for these trace amounts, the hierarchical porous membranes described herein may be used to perform the separation. In one embodiment, these membranes have a have high affinity for oil (contact angle less than 10°) and a low affinity for water (contact angle of about 84°). In various embodiments, PSf is the polymer used to form the hierarchical porous structure suitable for the separation of low concentrations (e.g., on the order of ppm) of water from oil.
[0054] The membranes and methods have several applications in the petroleum industry. For example, the membranes and methods may be used to remove trace amounts of water from oil to obtain higher oil concentrations and improve the performance of machines that use the oil (e.g., combustion engines). The petroleum industry faces similar difficulties as it turns to the sea floor for oil extraction. Previous separation methods used for these purpose are either environmentally unfriendly or extremely energy intensive. For example, one separation method includes pumping oil emulsified in water from the sea floor to the sea surface and storing the emulsion in gravity separation tanks. Pumping the complete emulsion to the surface requires substantially more power than pumping the oil alone. Hence, the methods and membranes described herein may be used to separate oil and water more effectively at the source. Once separated, the oil can be pumped to the surface for further purification.
[0055] The membranes and methods have additional applications, across many different industries. For example, the membranes and methods may be used to collect oil following an oil spill, such as the 2010 Gulf oil spill. The membranes and methods may also be used to clean water contaminated with oil before the water is released to the environment or reused. For example, the membranes and methods may be used to separate oil from the bilge water accumulated in ships, as required by the international MARPOL Convention.
Example 1
[0056] A porous polysulfone (PSf) membrane was prepared using a phase inversion technique based on a non-solvent induced phase separation method. A mixture of 7 g PSF and 3 g poly(vinylpyrrolidone) (PVP) was dissolved in 40 mL DMAc at 80° C. to form a homogeneous solution, which was then left at 50° C. for 12 h in order for air bubbles to be released. Using a doctor blade knife, a thin layer (0.28 mm) of polymer solution was then casted on a glass plate which was then immersed into non-solvent water at room temperature (22° C.), to undergo coagulation. During this process, phase separation of the polymer-solvent system took place, which created an asymmetric microporous membrane matrix. To wash away the PVP additive completely, the porous membrane was then rinsed with running tap water for 24 h, followed by immersion in a glycerol-water solution (volume ratio of 1:1) for another 24 h, before being dried at ambient conditions.
[0057] A micrometer was used to determine the composite membrane thickness by measuring at least 10 different locations, including the center. The thicknesses of the selective layers were determined from a cross-sectional SEM image analysis. The thickness (dry) of the membrane was 120±10 μm, as measured by a micrometer and later verified by SEM image analysis.
[0058] Referring again to the SEM images of FIGS. 3 a and 3 b , the phase inversion process created a porous polysulfone structure. As depicted, the PSf membrane includes pores of different sizes, ranging from about 100 nm to about 10 μm in diameter. The asymmetric membrane shows hierarchical porous morphology, with interconnected small pores on the surface that span a thickness of 300-500 nm, and large pores (10-50 μm) below. The dissolving of PVP in water accelerates the initial separation of polymer and solvent to form the large pores.
[0059] To demonstrate the membrane's ability to readily wet with oil, mineral oil dyed with nile red was applied to the membrane. Referring to FIG. 5 , it is clear that the oil easily wets the membrane.
[0060] In general, the stability of an oil-in-water emulsions is strongly affected by the chain length of the oil (hexadecane is better than decane). Emulsions may be prepared using a variety of methods including but not limited to sonication, freeze-pump-thaw cycles, or mechanical mixing.
[0061] Separation experiments were performed with an emulsion of water (e.g., MILLI-Q water) and oil (hexadecane). To form the emulsion, a mixture of water and hexadecane (2:1, by volume) was mechanically nebulized using a 26 gauge needle. The emulsion was allowed to settle for about 30 minutes so that macroscopic hexadecane could physically separate and rise to the top of the emulsion. The stability of the emulsion was monitored visually over a 24 hour period, enough time needed to run the membrane experiments. In general, the mixture should maintain a cloudy, turbid appearance, indicating that the emulsion remains intact. An optical microscope may be used to quantify the mechanically dispersed emulsions (hexadecane particles may be on the order of 10 microns in diameter). To determine a weight percent of dispersed hexadecane, 1 ml aliquots of the emulsion may be placed on a thin microscope slide and the water may be allowed to evaporate from the microscope slide. The weight percent is then determined from the difference between the initial mass (with water) and the final mass (no water). The final volume ratio (water to hexadecane) of the emulsions may be reported for separation testing based on the residual mass measurements. Surfactant free hexadecane-in-water emulsions have been shown to be stable for longer than 24 hours, as compared to similar suspensions of decane-in-water (e.g., stable only for about 3 hours).
[0062] FIG. 6 depicts a device for performing laboratory separations of oil/water emulsions, in accordance with one embodiment of the invention. The device includes a membrane holder having a Teflon holder along with a vito o-ring, to ensure good sealing of the membrane against any pressure loss. The holder is connected to a vacuum flask with a rubber adapter. The vacuum flask is connected to a vacuum line. To perform a separation experiment, a vacuum of 10 to 14 psi may be applied and the time for a fixed volume of liquid to transport across the membrane may be recorded.
[0063] The device may be used to determine membrane permeability. For example, the time for 20 ml of water to pass through a known membrane area may be recorded. For bulk fluid flow measurements, a filtration setup is used with the membrane and sealed (e.g., using adhesive). The membranes and tubes are checked for leaks around the seal, ensuring that all fluid flow occurs only through the membrane. A pressure gauge or vacuum may be used to regulate the pressure across the membrane. In general, the pressure/vacuum is chosen such that 5-20 ml (depending on filtration setup, membrane) of water passes through a membrane during 2 to 10 minutes. Next, flow rates for water are measured. The tubes and membranes are then dried under vacuum, and the flow rate for hexadecane is measured.
[0064] In certain embodiments, membranes are tested for selectivity to determine their ability to separate water-hexadecane. Using the device, the emulsions are gravity fed through the membrane. The emulsions are injected directly into the membrane-tube setup. The fluid that passed through the membrane is then collected in a pre-weighed vial. The residual hexadecane in the vial is isolated by allowing the water to evaporate overnight. Next, the mass of the residual hexadecane is measured to determine the percentage of hexadecane that had been retained by the membrane.
Example 2
[0065] Without wishing to be bound by a particular theory, provided a the droplet radius is larger than the pore diamater, a droplet will breakthrough the membrane at pressures exceeding the breakthroguh pressure, P B , which may be expressed as follows:
[0000]
P
B
=
2
γ
WO
cos
θ
OW
r
p
(
3
)
[0000] where P B is the breakthrough pressure, γ OW is the interfacial energy between water and oil, θ WO is the contact angle of a water droplet on the membrane surface in a background of oil, and r p is the Pore radius of the membrane.
[0066] Accordingly, in order to achieve maximum rejection of water droplets, the transmembrane pressure P t must be kept below the breakthrough pressure. The relavant interface here is the interface between oil and water. The membrane should be more wetting to oil than water in order to achieve permeation of the oil phase.
[0067] Without wishing to be bound by any particular theory, when considering two immiscible phases 1 and 2, it is found that complete rejection of phase 2 and permeation of phase 1 results if two conditions are met. First, the minimum droplet size of phase 2 must be larger than the maximum pore size of the membrane. Second, phase 1 must wet the membrane more than phase 2.
[0000] (i)
[0000] r 2,min >r pore,max (4)
[0000] (ii)
[0000] γ 2 (√{square root over (γ S LW γ 1 LW )}+√{square root over (γ S + γ 1 − )}+√{square root over (γ S − γ 1 + )})>γ 1 (√{square root over (γ S LW γ 2 LW )}+√{square root over (γ S + γ 2 − )}+√{square root over (γ S − γ 2 + )}) (5)
[0000] wherein r 2,min is the minimum drop radius of dispersed phase 2, r p,max is the maximum pore radius of the membrane, γ 1 is surface tension of phase 1, γ 2 is surface tension of phase 2, γ S LW is Lifshitz-van der Waals parameter of the surface free energy of the membrane, γ 1 LW is Lifshitz-van der Waals parameter of the surface free energy of phase 1, γ 2 LW is Lifshitz-van der Waals parameter of the surface free energy of phase 2, γ S + is Lewis acid parameter of surface free energy of the membrane, γ 1 + is Lewis acid parameter of surface free energy of phase 1, γ 2 + Lewis acid parameter of surface free energy of phase 2, γ S − is Lewis base parameter of surface free energy of the membrane, γ 1 − is Lewis base parameter of surface free energy of phase 1, and γ 2 − is Lewis base parameter of surface free energy of phase 2.
[0068] FIG. 7 shows a) a schematic of a water/oil (w/o) emulsion being filtered through a membrane; b) a close-up diagram of a rejected droplet on the surface of the membrane; and c) frames from a video showing a 2 mm diameter droplet breakthrough a 600 nm OTS coated polycarbonate membrane.
[0069] In FIG. 8 , SEM images of an OTS-coated 600 nm polycarbonate membrane show a) the coated top side and b) the cross section. FIG. 8 c shows that in air, the membrane is oleophilic (hexadecane dyed red) and hydrophobic (water dyed red). FIG. 8 d shows that when submerged in hexadecane, the membrane surface is much more hydrophobic.
[0070] To demonstrate the operation of membranes capable of filtering w/o emulsions, two polycarbonate membranes of pore sizes 600 nm and 100 nm were coated with octadecyltrichlorosilane (OTS). These membranes were prepared via the track-etch method. The membranes are prepared by exposing polycarbonate films to ion bombardment followed by a chemical etch. The pores sizes are tightly distributed around the reported values. Furthermore, the pores have regular cylindrical geometries.
[0071] FIG. 9 shows a macroscopic photo and a microscopic photo of a 3 wt % w/o emulsion stabilized by Span 80 a, before filtration and b, filtered through a 600 nm OTS coated PC membrane at a transmembrane pressure below the breakthrough pressure. FIG. 9 c shows DSC data for the emulsion before filtration, filtered through a 600 nm OTS coated PC membrane, filtered through a 100 nm OTS coated PC membrane, as well as data for pure water and hexadecane with Span 80.
[0072] The membranes were tested by applying a transmembrane pressure below the calculated breakthrough pressure. With both membranes, the permeate was visually clear. Microscopy revealed that water droplets (mean size ˜1.5 μm) were not in the permeate. The differential scanning calorimetry (DSC) results demonstrate that the permeate samples had very low water content.
[0073] FIG. 10 shows a, Distribution of droplets in the pre-filtered emulsion and b, DLS data for the pre-filtered emulsion and permeates. Image analysis gives the distribution of water droplets in the pre-filtered emulsion. Dynamic light scattering (DLS) is used to characterize the distribution of droplets smaller than 1 μm. The pre-filtered emulsion has droplets around 100 nm while the size of droplets in both permeate samples is on average less than 10 nm.
[0074] While the 600 nm membrane and 100 nm membrane seem to perform similarly, the distribution data (particularly the DLS) should demonstrate that the 100 nm membrane filters out even the particles<600 nm.
Example 3
[0075] This Example demonstrates decreasing the skin layer thickness of the membrane while retaining its pore sizes. This results in a membrane exhibiting the same rejection characteristics but better permeabilities. Table 2 summarizes that membranes we have synthesized.
[0000]
TABLE 2
Skin thickness for membranes.
PSf concentration
PEG concentration
Skin thickness (μm)
100%
0%
1.7
95%
5%
1.6
90%
10%
0.8
[0076] FIG. 11 shows SEM images of the 100% PSf membrane, FIG. 12 shows SEM images of the 95% PSf, 5% PEG membrane, and FIG. 13 shows SEM images of the 90% PSf, 10% PEG membrane.
EQUIVALENTS
[0077] While the invention has been particularly shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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Hierarchical porous membranes suitable for use in oil/water separation processes are provided. The membranes described herein are particularly well suited for separating trace amounts of water (e.g., no greater than 3 wt % water content, no greater than 1 wt % water content, or 50-1000 ppm water) from oil. The membranes have a wide range of applications, including deep seep oil exploration, oil purification, and oil spill cleanup.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention, in general, relates to a method of and an apparatus for purifying and maintaining the purity of water and, more particularly, to a novel method and apparatus of the kind in which a substance is utilized to purify water in swimming pools and the like.
2. The State of the Art
It has been common practice to add chemical additives such as, but not limited to, softeners, disinfectants, pH control agents, flocculants, etc. to the water in swimming pools is well known in the art. Such compounds are added to the water either simultaneously or in a predetermined sequence in order to prevent clouding and bacterial contamination as well as to soften the water. Chlorine compounds, in particular, are used for such purposes.
The inherent disadvantage of treatments of this kind is that the purchase and storage of the chemicals are expensive, and that to use them properly is unduly difficult and complex. Moreover, their concentration usually renders them toxic and physiologically unsafe, and, for children in particular, such chemicals can even be dangerous. Once added to water, they remain therein until their effective-ness is reduced to the point at which more such chemicals are added to increase their concentration. At any event, the chemicals remain in the water permanently, and they require regular supervision or monitoring by their user. Not only are the chemicals in and of themselves environment-ally hazardous, but they also pollute the environment beginn-ing with their manufacture and ending with their final disposal. Nor is their application free of unpleasant side effects in terms of the health and well being of their user. The best-known or most common side effects are conjunctivi-tis of the eyes induced by chlorinated water and the unpleasant odor and taste of such water.
OBJECTS OF THE INVENTION
It is, therefore, a primary object of the invention to provide an apparatus for purifying water in swimming pools in an easy and efficient manner.
A more specific object of the invention is to provide an apparatus capable of purifying water in swimming pools and the like without recourse to any of the usual and potentially hazardous chemical additives.
Another object of the invention is to provide an appa-ratus for purifying water in swimming pools by natural, phy-siologically harmless and environmentally safe substances.
Yet another object of the invention is to provide an apparatus for purifying water in swimming pools by such substances as limestone, calcium carbonate or calcite (hereinafter sometimes called lime), carbon dioxide, carbonic acid and air.
Still further, it is an object of the invention to provide an apparatus for purifying water in swimming pools and the like by establishing therein a lime-carbonic acid equilibrium.
Yet another object of the invention is to provide an apparatus for purifying water in swimming pools suitable for cost-efficient retro-fitting in existing filtering circuits.
Moreover, it is an object of the invention to provide a novel method of treating water in swimming pools for the purification thereof by utilizing environmentally safe and physiologically harmless substances.
Another object of the invention is to provide a method of maintaining the purity of water in swimming pools by simple and effective environmentally safe and physiological-ly harmless means.
BRIEF SUMMARY OF THE INVENTION
In the accomplishment of these and other objects, the invention, in a preferred embodiment thereof, provides for a novel apparatus for filtering, purifying and softening water in swimming pools or the like where it is substantially constantly recirculated by pumps and conduits, by initially filling a swimming pool with water rendered acidic and hardness-free (softened) by treatment in an ion exchanger, by thereafter adding to the swimming pool water lime water, i.e., a clear saturated solution of one of white lime or hydrate of white lime in an amount yielding a lime-carbonic acid equilibrium, whereby all free carbon dioxide in the water is associated with the carbonate hardness thereof, lime is precipitated when phosphate and sulfate in the water are converted into poorly soluble calcium salts, whereby exogenous matter, such as squamae, cosmetic creams and bath oils are precipitated as lime soap, and inorganic oxidation products are precipitated by calcium ions under the influence of sun light, and whereby calcite adsorbs minute suspended and precipitated particles which defy filtering out by conventional methods into larger surface structures; by circulating at least some of the water thus treated over a bed of crushed limestone by means of conduits, pumps, valves and filters, and by maintaining the water at a pH value not less than 7 by adding further lime water as required to render the water-specific concentration ratios of the lime-carbonic acid equilibrium adjustable along its equilibrium curve, without destroying the equilibrium; and by replenishing water lost as a result of bathing, evaporation or back-flushing of the filter plant by adding acidic and hardness-free water to prevent increases in the level of salt in the water.
Other objects and advantages of the invention will in part be obvious and will in part appear hereinafter.
DESCRIPTION OF THE DRAWING
The novel features which are considered to be charac-teristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its operating steps and the sequence thereof, and the structure, construction and lay-out as well as manufac-turing techniques involved in apparatus for practicing the invention, together with other objects and advantages there-of, will be best understood from the following description of preferred embodiments when read with reference to the appended sole drawing which schematically depicts a swimming pool provided with an apparatus in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein, lime in general is understood to mean limestone, calcium carbonate or calcite, but at any rate compounds other than calcium oxide.
A receptacle such as a swimming pool measuring about 7×2×4 m is filled with 50 m 3 of fresh water fed from a conduit 4 through an ion exchanger 6 for softening by removing both its temporary and its permanent hardness. By its natural absorption of carbon dioxide from the ambient air and supplemental charging with carbon dioxide by the turbulent mixing of air with the water 1 as, for instance, by a strong water jet 21, or by direct feeding of carbon dioxide, and by feeding lime water 8 from a solution and sedimentation tank 7, a pH value not less than 7, preferably between 7.9 and 8.1, is established for the water. In the context of the present invention, lime water is understood to mean a clear and saturated aqueous solution of either white lime or white lime hydrate.
The output of the solution and sedimentation tank 7 is connected to the swimming pool by way of a conduit provided with a valve 11 and a feed pump 10 and feeding into a conduit 22 connected to the swimming pool. The pump 10 and the valve 11 are controlled by a control unit 5 in a manner to be described. The contents of the solution and sedimentation tank 7 are replenished as needed the need arises by way of a branch conduit and valve connected to the fresh water conduit 4, excess lime precipitating as lime sludge 9 on the bottom of the tank 7.
Preferably, the water jet 21 is connected to the output of a filter 15 and is force-fed by a pump 16. It will be understood by those skilled in the art that the suffusion of carbon dioxide into the water 1 by the jet 21 may be period-ic or constant, and that direct feeding of carbon dioxide into the water 1 may be accomplished by pressurized air or by any other means known in the art. While not shown in the drawing, the pump 16 feeding the jet 21 may be connected to the control unit 5 to be activated for selective suffusion of carbon dioxide into the water. Alternatively, carbon dioxide could be infused into the water under the control of the control unit as pressurized gas by means selectively actuated by the control means in a manner well known in the art. Preferably, the water 1 is continuously recirculated by recirculation pumps 16, 17. In this manner, a lime-carbonic acid equilibrium is established as well.
To maintain the equilibrium, the water 1 treated as aforesaid is recirculated by a conduit or pipe 19, recirculation pump 17, filter 15, the valve 14, first conduit 13, a container 12 filled with, for example, 30 dm 3 of crushed 30 mm grain size limestone and thence returned to the swimming pool through second conduit 22. Such a flow pattern would feed all of the water through the container 12. As may be seen, however, the output of filter 15 is connected to the junction of valve 14 connecting to the container 12 and another valve 18 connecting to the swimming pool. Therefore, depending upon the state of the valves 14 and 18, either all, none, or a predetermined portion of the water discharged from the filter 15 is fed to the swimming pool through the container 12 so that precipitated calcium ions may be replaced, and the lime-carbonic acid equili-brium may be maintained. Thus, if valve 18 is open and valve 14 is closed the entire output of the pump 17 is fed to the swimming pool through the filter 15. On the other hand, if the valve 18 is closed and valve 14 is open, the entire output of the pump 17 will be transmitted to the swimming pool through the filter 15 and the container 12. If both valves 14 and 18 are partially open, some of the output of the pump 17 will pass through the container 12, the remainder flowing to the swimming pool directly. The relative opening sizes of the valves 14, 18 will determine the proportion of the two water flows. A similar effect could be achieved by a system using a variable output pump 17 instead of two valves 14 and 18.
Preferably, the container 12 filled with crushed limestone is an open container disposed such that its overflow is positioned at a higher level than the level of the water in the swimming pool.
Furthermore, while not shown, those skilled in the art will understand that means may be provided for permanently or temporarily exposing the water to one or more metallic oxidizing catalysts. Catalysts useful in this connection are, among others, platinum, palladium, silver and copper.
The condition of the water 1 in the swimming pool is monitored by a pH value measuring transducer or sensor 2. Measurement signals emitted by the sensor 2 are fed to a control unit 5 which on the basis of the signals controls the flow rate through the valves 11, 14, and 18 and the output of the pumps 10 and 17 in such a way that the condition or quality of the water 1 in the swimming pool remains substantially uniform. In particular, the pump 10 may be intermittently driven whenever significant deviations of the pH value from a desired value have been detected by the sensor 2.
Preferably, the valves 11, 14 and 18 are motorized or solenoid valves. While, as shown, the pumps 16 and 17 are not connected to the control unit 5, it is within the scope of the invention to drive these pumps by the control unit 5 in response to an evaluation of the aforesaid signals. The control unit 5 is of a kind well-known in the art and may, for instance, be provided with look-up tables or computer memories in which water-specific equilibrium curves are stored.
ADVANTAGES OF THE INVENTION
Treatment of the water by adding to it lime water of a certain dosage results in a lime-carbonic acid equilibrium therein so that all free carbon dioxide in the water is associated with its carbonate hardness. In this manner, any algae otherwise providing nutrients for bacteria and germs, are deprived of their own nutrients.
As a result of phosphate and sulfate conversion into poorly soluble calcium salts lime precipitates in the water, thus further diminishing the metabolism and growth of micro-organisms.
Exogenous substances, such as cosmetic creams, bath oils and the like are precipitated as substantially insoluble lime soaps and may thus be mechanically filtered out. The water is softened and rendered acidic by removing cations during treatment of the water in the ion exchanger. By adding lime water, calcium will dominate at a pH value in excess of 7. Sunlight refracted by the water imparts to it a beautiful greenish blue color. Thus, the quality of the water may be judged by its visual appearance, as contamina-tions result in altered light refraction. By feeding oxygen from the air into the water by means of a forceful water jet or by pressurized air, the oxidation process eliminating residual organic matter is substantially enhanced.
The resultant discharge of carbon dioxide leads to the formation of calcite which adsorbs minute suspended and precipitated particles into flakes which may be filtered out.
By using lime of a special quality which contains cer-tain additives such a tracer elements, for instance, spa-like properties may be imparted to the water.
The method in accordance with the invention may be practiced with little technical investment, and it allows the utilization of modern control technology for a substantially automatic operation beyond the mere automatic chemical mechanism.
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The invention relates to a method and apparatus for purifying and maintaining the purity of water in a swimming pool by initially feeding into the pool water treated in an ion exchanger to render it acidic and hardness-free, lime water consisting of a clear and saturated aqueous solution of white lime or white lime hydrate being thereafter added to provide a lime-carbonic acid equilibrium, at least some of the acidic and hardness-free water being recirculated over a body of crushed limestone to establish a pH of not less than 7. Carbon dioxide and oxygen may also be added.
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This is a divisional of U.S. patent application Ser. No. 09/685,908, filed Oct. 10, 2000, now U.S. Pat. No. 6,589,446.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ceramic slurry compositions and methods for producing ceramic green sheets and multilayer ceramic electronic devices, and more particularly, relates to a ceramic slurry composition for use in production of ceramic electronic devices, such as multilayer ceramic capacitors and multilayer ceramic substrates, and to methods for producing a ceramic green sheet using the ceramic slurry composition and for producing a multilayer ceramic electronic device using the ceramic green sheets.
2. Description of the Related Art
Multilayer ceramic electronic devices, such as multilayer ceramic capacitors, and multilayer ceramic substrates, are generally produced by the steps of laminating ceramic green sheets, compressing the laminate and heating for sintering the ceramics and electrodes.
For example, when a multilayer ceramic capacitor as shown in FIG. 1 is produced in which internal electrodes 2 are formed in a ceramic element 1 , and a pair of external electrodes 3 a and 3 b are formed at two side surfaces of the ceramic element 1 so as to be connected with the internal electrodes which alternately extend to one side surface and to the other side surface of the ceramic element 1 , the method described below is generally used.
(1) Electrode-provided sheets 11 (see FIG. 2 ) are formed by disposing internal electrodes to be used as electrodes for a capacitor on the green sheets produced by the method mentioned above.
(2) A predetermined number of the electrode-provided sheets 11 are laminated as shown in FIG. 2 , ceramic green sheets having no internal electrodes thereon (sheets used as outer layers) are disposed on the top and the bottom of the laminated sheets, and they are compressed, whereby a laminate (a compressed laminate) is formed in which ends of the internal electrodes 2 alternately extend to one side surface and to the other side surface of the laminate.
(3) The laminate is baked under predetermined conditions so as to be sintered, and an electroconductive paste is coated on two side surfaces of the baked laminate (the ceramic element 1 ) (see FIG. 1 ) and is baked, whereby the external electrodes 3 a and 3 b which are connected with the internal electrodes 2 are formed.
Accordingly, a multilayer ceramic capacitor as shown in FIG. 1 is produced.
Other multilayer ceramic electronic devices, such as multilayer ceramic substrates, are also produced by the step of laminating ceramic green sheets.
Ceramic green sheets for use in the production of multilayer ceramic electronic devices are generally formed by steps of preparing starting materials, such as a powdered ceramic, a dispersing medium (e.g., a solvent), a dispersing agent, a binder, and a plasticizer, so as to produce a predetermined composition; mixing and pulverizing the starting materials thus prepared by using a media-type mill, such as a bead mill, a ball mill, an attritor, a paint shaker and a sand mill, so as to form a ceramic slurry; molding the ceramic slurry into sheets having a predetermined thickness by methods such as the doctor blade method; and subsequently, drying the sheets thus formed. In this connection, the media-type mill mentioned above is an apparatus for dispersing a powdered ceramic between media by mixing and stirring the powdered ceramic with the media.
However, recently, miniaturization and improved performance have been required for various multilayer ceramic electronic devices, such as multilayer ceramic capacitors, as is the case with other electronic devices.
Accordingly, ceramic green sheets for use in the production of multilayer ceramic electronic devices must be thinner, and recently, use of extremely thin ceramic green sheets of 10 μm or less thick is increasingly necessary.
When the extremely thin ceramic green sheets described above are produced, a ceramic slurry used for production of ceramic green sheets must be used in which the starting powdered ceramic is sufficiently dispersed. Hence, as a starting powdered ceramic, a fine powdered ceramic having an average particle diameter of 0.01 to 1 μm must be used.
However, in a ceramic slurry used for the production of the ceramic green sheet as described above, in general, a dispersing agent is conventionally used which is a lower molecular compound of a binder in consideration of the compatibility with the binder.
That is, as a binder, polyvinyl butyral resins, cellulose resins, acrylic resins, vinyl acetate resins, polyvinyl alcohol resins and the like are often used, and hence, lower molecular compounds of the binder mentioned above are generally used as a dispersing agent.
In this connection, most of the resins used as binders, such as polyvinyl butyral resins, cellulose resins, acrylic resins, vinyl acetate resins and polyvinyl alcohol resins, are nonionic compounds, and as a result, the low molecular resins thereof used as dispersing agents are also nonionic compounds.
The nonionic dispersing agents mentioned above have low adsorbing rates on powdered ceramics, and hence, a fine powdered ceramic having particles of 1 μm or less in diameter, which has strong cohesive force, cannot be rapidly and efficiently dispersed. Consequently, there are problems in that serious damage is done to the powdered ceramic and the productivity is decreased due to the longer time required in the dispersing step.
SUMMARY OF THE INVENTION
Accordingly, taking into consideration the problems described above, an object of the present invention is to provide a ceramic slurry composition having superior productivity in which a powdered ceramic can be efficiently dispersed without causing serious damage thereto, and to provide methods for producing ceramic green sheets using the ceramic slurry composition and for producing a ceramic electronic devices using the ceramic green sheets.
To these ends, a ceramic slurry composition of the present invention comprises a powdered ceramic, a dispersing agent, a binder and a solvent, wherein the dispersing agent is an anionic dispersing agent, and the content of the anionic dispersing agent is so that the total acid amount thereof corresponds to about 10 to 150% of the total base amount of the powdered ceramic.
As an anionic dispersing agent which is preferably used for the present invention, an anionic dispersing agent having intermolecular carboxyl groups, maleate groups, sulfonic groups, phosphate groups or the like is mentioned as an example. In addition, polycarboxylic compounds and polymaleate compounds containing no metal ions are mentioned as more preferable anionic dispersing agents.
The anionic dispersing agent is preferably added so that the total acid amount thereof corresponds to about 10 to 150% of the total base amount of the powdered ceramic. The reason for this is that when the dispersing agent is added so that the total acid amount thereof is less than about 10% of the total base amount of the powdered ceramic, satisfactory dispersing effects cannot be obtained, and on the other hand, when the total acid amount is more than about 150%, significant further improvement in the dispersing effects cannot be observed.
In this connection, the total acid amount of the anionic dispersing agent and the total base amount of the powdered ceramic can be determined by a titration method or the like.
In the present invention, a binder containing a plasticizer, and/or an anti-statistic agent may be used. In addition, a binder containing other additives may also be used.
In the present invention, the dispersing method for dispersing a powdered ceramic is not specifically limited. Various dispersing methods may be used, for example, a method of using a media-type mill, such as a bead mill, a ball mill, an attritor, a paint shaker and a sand mill; a method of kneading a powdered ceramic, a dispersing medium, a dispersing agent, a binder, a plasticizer and the like; and a method of using a three-roll mill. In this connection, the method of using a three-roll mill is a method for dispersing a powdered ceramic in a mixture thereof with a dispersing medium, a dispersing agent, a binder, a plasticizer, and the like. In the method described above, the mixture is passed through a small gap between a first roller and a second roller, which roll independently from each other and are adjacent to each other with the small gap therebetween, so as to be compressed and kneaded, and subsequently, the mixture is passed between the second roller and a third roller, which rolls and is adjacent to the second roller with a smaller gap therebetween than the gap between the first and the second rollers, so as to be further compressed and kneaded.
In addition, when the ceramic slurry composition of the present invention is formed, the sequence of addition of dispersing agent and binder is not specifically limited. However, it is generally preferable that powdered ceramic, dispersing agent, and solvent be mixed and dispersed so that the dispersing agent is adsorbed on the powdered ceramic beforehand; a binder is then added to the mixture thus formed, and subsequently, mixing and dispersing is performed again.
In the ceramic slurry composition according to the present invention, the average particle diameter of the powdered ceramic is preferably about 0.01 to 1 μm.
According to the present invention, a ceramic slurry composition provided with superior dispersibility of a powdered ceramic having diameters of about 0.01 to 1 μm (the average particle diameter measured by an electron microscope), which is generally difficult to disperse by a conventional dispersing method, can be obtained. Hence, the present invention is particularly significant.
In addition, the present invention can be used when the particle diameter of a powdered ceramic is out of the range of about 0.01 to 1 μm.
A method for producing a ceramic green sheet of the present invention comprises the step of molding the ceramic slurry composition described above into a sheet on a predetermined substrate so as to form the green sheet.
Since the powdered ceramic is sufficiently dispersed in the ceramic slurry composition according to the present invention described above, the thin ceramic green sheets having high quality can be reliably produced by molding the ceramic slurry composition into sheets. That is, a ceramic green sheet preferably used for production of multilayer ceramic electronic devices can be produced, in which the ceramic green sheet has superior smooth surfaces, a high density and a high tensile strength, and in which resins, such as a binder and a plasticizer, are uniformly distributed therein. Furthermore, when a multilayer ceramic electronic device is produced by using the ceramic green sheets described above, a highly reliable multilayer ceramic electronic device having desired characteristics and high quality can be obtained.
In the method for producing the ceramic green sheet according to the present invention, the thickness of the ceramic green sheet is preferably about 0.1 to 10 μm.
According to the present invention, even when the ceramic green sheet is formed to be thin from about 0.1 to 10 μm, a ceramic green sheet having high quality can be reliably produced, and hence, ceramic green sheets preferably used for production of multilayer ceramic electronic devices can be obtained.
A method for producing a multilayer ceramic electronic device, according to the present invention, comprises a step of laminating the ceramic green sheets produced by the method for producing the ceramic green sheets described above together with internal electrodes composed of a base metal, a step of cutting the laminated ceramic green sheets, a step of baking the laminated ceramic green sheets and a step of forming external electrodes.
A highly reliable multilayer ceramic electronic device having desired characteristics and high quality can be formed by the steps of producing ceramic green sheets using the ceramic slurry formed by the method according to the present invention described above, laminating the ceramic green sheets together with the internal electrodes composed of a base metal, cutting, baking, and forming the external electrodes.
A method for producing multilayer ceramic electronic devices of the present invention, comprises steps of laminating the ceramic green sheets, which are produced by the method for producing the green sheets described above, together with the internal electrodes composed of a base metal; cutting; baking; and forming the external electrodes. Since the ceramic green sheets having a higher density and superior smooth surfaces are used, the rate of occurrence of short-circuiting can be decreased, and hence, the reliability thereof can be improved. In addition, since serious damage is not done to a powdered ceramic, the reproducibility of the target characteristics can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a multilayer ceramic capacitor produced by laminating ceramic green sheets; and
FIG. 2 is a schematic view showing a method for producing a multilayer ceramic capacitor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described in detail with reference to the embodiments.
According to the present invention, the type of powdered ceramic and the composition thereof are not specifically limited, and the present invention can be broadly applied to ceramic slurries using various powdered ceramics composed of dielectric powdered ceramics, such as barium titanates, strontium titanate and lead titanate; magnetic powdered ceramics, such as ferrite; piezoelectric powdered ceramics; and insulating powdered ceramics, such as alumina and silica.
The particle diameter of the powdered ceramic is not specifically limited; however, when a powdered ceramic having an average particle diameter of about 0.01 to 1 μm, measured by using an electron microscope, is used, which is difficult to disperse by a conventional dispersing method as described above, the advantages of the present invention can be fully utilized.
The powdered ceramic may contain additives and the like. For example, when a powdered ceramic is primarily composed of barium titanate, the powdered ceramic may contain glass, magnesium oxide, manganese oxide, barium oxide, rare-earth oxides, calcium oxide and the like.
In the present invention, the type of solvent (dispersing medium) is not specifically limited. Various solvents may be used, for example, aromatic compounds, such as toluene and xylene, and alcohol compounds, such as ethyl alcohol, isopropyl alcohol and butyl alcohol. In addition, the solvents mentioned above may be used alone or combination thereof.
As a dispersing medium, solvents other than these mentioned above may be used, and water may also be used.
As a binder, polyvinyl butyral resins, cellulose resins, acrylic resins, vinyl acetate resins, polyvinyl alcohol resins and the like may be used. According to the ceramic green sheet to be formed, the type and the amount of the binder is optionally determined.
The ceramic slurry composition of the present invention may also contain a plasticizer, and various plasticizers, such as polyethylene glycol or phthalic esters, may be appropriately used. The amount thereof is optionally determined in accordance with the ceramic green sheet to be formed.
The specifications thus described for powdered ceramics, dispersing media, plasticizers, and the like can be applied to every aspect of the present invention.
Hereinafter, examples of the present invention will be described in detail.
EXAMPLE 1
(1) A powdered ceramic, a dispersing agent, a binder, a plasticizer and a solvent were mixed together so as to produce the composition described below.
(a) A commercially available dielectric material (a powdered ceramic containing additives) having an average particle diameter of 0.2 μm and an average base amount of 40 μmol/g: 100 parts by weight (b) An anionic dispersing agent having an average acid amount of 960 μmol/g: 2 parts by weight (the total acid amount of the anionic dispersing agent corresponded to 48% of the total base amount of the powdered ceramic) (c) A binder (an acrylic binder): 10 parts by weight (d) A plasticizer (dioctyl phthalate (hereinafter referred to as “DOP”): 1.4 parts by weight (e) A solvent: 70 parts by weight of toluene and 70 parts by weight of ethyl alcohol
(2) Next, the starting materials thus prepared were mixed and pulverized for 5 hours by a ball mill using 500 parts by weight of balls 2 mm in diameter composed of zirconia, thereby yielding a finished dispersed slurry (a ceramic slurry composition) for forming ceramic green sheets.
The dispersibility of the ceramic slurry composition thus formed was measured using a measurement apparatus of particle size distribution made by Microtrack.
The 90% average particle diameter (D90) of the particle size distribution was 0.60 μm.
The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was measured. The rate of increase in the specific surface area from the original specific surface area was 8%.
The ceramic slurry composition was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness (Ra) of the ceramic green sheet thus formed was measured by an atomic force microscope, and as a ratio of density of the ceramic green sheet, the ratio of the measured density to the theoretical density (density ratio=the measured density/the theoretical density) was measured. The results were that the Ra was 81 nm and the density ratio was 0.81.
Next, a multilayer ceramic capacitor was produced by using the ceramic green sheets, in which, as shown in FIG. 1 , internal electrodes 2 alternately extended to one side surface and the other side surface of a ceramic element 1 were formed therein, and a pair of external electrodes 3 a and 3 b were formed so as to be connected with the internal electrodes 2 .
A method for producing the multilayer ceramic capacitor will be described below.
(1) Screen printing of a nickel (Ni) paste was performed on the ceramic green sheets thus formed, thereby yielding electrode-provided sheets having internal electrodes thereon to be used as capacitor electrodes.
(2) Next, as shown in FIG. 2 , a predetermined number of the electrode-provided sheets 11 were laminated, ceramic green sheets having no electrodes thereon (sheets for the outer layers) were laminated on the top and the bottom of the laminate of the electrode-provided sheets 11 , and they were compressed, thereby yielding a laminate (a compressed laminate) in which the ends of the individual internal electrodes 2 alternately extended to one side surface and to the other side surface of the laminate.
(3) The compressed laminate thus formed was cut into a predetermined size by using a dicer, the binder therein was removed, and the laminate thus obtained was then baked.
The binder was removed by heating in a nitrogen atmosphere.
The baking was performed by heating to a predetermined temperature in a weakly reducing atmosphere.
(4) Next, an electroconductive past having silver as an electroconductive component was coated on two side surfaces of the baked laminate (the ceramic element 1 ) and was baked, thereby forming the external electrodes 3 a and 3 b (see FIG. 1 ) which were connected with the internal electrodes 2 .
As described above, a multilayer ceramic capacitor having the internal electrodes 2 composed of Ni as shown in FIG. 1 was obtained.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was measured, and the result was superior, such as 13%. In addition, the temperature coefficient of static capacitance met the X7R specification.
EXAMPLE 2
(1) A powdered ceramic, a dispersing agent, a binder, a plasticizer and a solvent were mixed together so as to produce the composition described below.
(a) A commercially available dielectric material (a powdered ceramic containing additives) having an average particle diameter of 0.2 μm and an average base amount of 40 μmol/g: 100 parts by weight (b) An anionic dispersing agent having an average acid amount of 960 μmol/g: 2 parts by weight (the total acid amount of the anionic dispersing agent corresponded to 48% of the total base amount of the powdered ceramic) (c) A solvent: 35 parts by weight of toluene and 35 parts by weight of ethyl alcohol
(2) Next, the starting materials thus prepared were mixed and pulverized by a ball mill using 500 parts by weight of balls 2 μm in diameter composed of zirconia for 5 hours, thereby yielding a slurry.
(3) A binder solution composed of 10 parts by weight of an acrylic resin as a binder, 1.4 parts by weight of dioctyl phthalate as a plasticizer, and a solvent comprised of 35 parts by weight of toluene and 35 parts by weight of ethyl alcohol was prepared beforehand by stirring and dissolving. The binder solution was then added to the mixed and pulverized slurry described above.
(4) Subsequently, the slurry containing the binder solution was mixed and pulverized by a ball mill for 5 hours, thereby yielding a finished dispersed slurry for forming ceramic green sheets.
The dispersibility of the ceramic slurry composition thus formed was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.50 μm.
The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was measured. The rate of increase in the specific surface area from the original specific surface area was 12%.
The ceramic slurry composition was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness (Ra) of the ceramic green sheet thus formed was measured by an atomic force microscope, and as the ratio of density of the ceramic green sheet, the ratio of the measured density to the theoretical density (the measured density/the theoretical density) was measured. The results were that the Ra was 72 nm and the density ratio was 0.94.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets.
Since the multilayer ceramic capacitor was formed in a manner equivalent to that described in Example 1, the description thereof is omitted to avoid duplication.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was superior, such as 9%, and the temperature coefficient of the static capacitance met the X7R specification.
EXAMPLE 3
A ceramic slurry composition was formed in a manner equivalent to that described in Example 2, except that the binder was instead a polyvinyl butyral resin.
The dispersibility of the ceramic slurry composition formed in Example 3 was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.50 μm.
The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was measured. The rate of increase in the specific surface area from the original specific surface area was 12%.
The ceramic slurry composition of Example 3 was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness (Ra) of the ceramic green sheet thus formed was measured by an atomic force microscope, and as the ratio of density of the ceramic green sheet, the ratio of the measured density to the theoretical density (the measured density/the theoretical density) was measured. The results were that the Ra was 71 nm and the ratio of density was 0.93.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets.
The multilayer ceramic capacitor was formed in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was superior, such as 8%, and the temperature coefficient of the static capacitance met the X7R specification.
EXAMPLE 4
A ceramic slurry composition was formed in a manner equivalent to that described in Example 2 except that the amount of the anionic dispersing agent was changed from 2 parts by weight to 6 parts by weight (the total acid amount of the anionic dispersing agent corresponded to 144% of the total base amount of the powdered ceramic).
The dispersibility of the ceramic slurry composition thus formed was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.58 μm. In addition, the ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was measured. The rate of increase in the specific surface area from the original specific surface area was 8%.
The ceramic slurry composition was formed into sheets in a manner equivalent to that described in Example 1, thereby yielding ceramic green sheets. The Ra and the density ratio of the ceramic green sheet thus obtained were 74 nm and 0.91, respectively.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was superior, such as 13%. In addition, the temperature coefficient of the static capacitance met the X7R specification.
EXAMPLE 5
A ceramic slurry composition was formed in a manner equivalent to that described in Example 1, except that the amount of the anionic dispersing agent was changed from 2 parts by weight to 0.4 part by weight (the total acid amount of the anionic dispersing agent corresponded to 9.6% of the total base amount of the powdered ceramic).
The dispersibility of the ceramic slurry thus formed was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.62 μm. The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was then measured. The rate of increase in the specific surface area from the original specific surface area was 8%.
The ceramic slurry composition was formed into sheets in a manner equivalent to that described in Example 1, thereby yielding ceramic green sheets. The Ra and the density ratio of the ceramic green sheet thus obtained were 85 nm and 0.83, respectively.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was superior, such as 15%. In addition, the temperature coefficient of the static capacitance met the X7R specification.
Comparative Example 1
A ceramic slurry composition was formed in a manner equivalent to that described in Example 1, except that the dispersing agent was changed to a low molecular acrylic resin.
The dispersibility of the ceramic slurry composition formed in Comparative Example 1 was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.70 μm.
The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was then measured. The rate of increase in the specific surface area from the original specific surface area was 8%.
The ceramic slurry composition of Comparative Example 1 was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness Ra, and as the ratio of density of the ceramic green sheet thus obtained, the ratio of the measured density to the theoretical density (the measured density/the theoretical density) of the ceramic green sheet thus obtained were measured. The Ra was 112 nm, and the density ratio was 0.74.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was high, such as 51%. In addition, the temperature coefficient of the static capacitance met the X7R specification.
Comparative Example 2
A ceramic slurry composition was formed in a manner equivalent to that described in Example 1, except that the amount of the anionic dispersing agent was changed from 2 parts by weight to 0.2 part by weight (the total acid amount of the anionic dispersing agent corresponded to 5% of the total base amount of the powdered ceramic).
The dispersibility of the ceramic slurry thus formed was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.70 μm. The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was then measured. The rate of increase in the specific surface area from the original specific surface area was 8%.
The ceramic slurry composition of Comparative Example 2 was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness Ra of the ceramic green sheet thus obtained was measured by an atomic force microscope, and as the ratio of density of the ceramic green sheet, the ratio of the measured density to the theoretical density (the measured density/the theoretical density) thereof was measured. The Ra was 111 nm, and the density ratio was 0.74.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was high, such as 49%, and the temperature coefficient of the static capacitance met the X7R specification.
Comparative Example 3
A ceramic slurry composition was formed in a manner equivalent to that described in Example 1 except that the dispersing agent was changed to a low molecular acrylic resin and that the time for mixing and pulverizing by a ball mill was changed to 24 hours.
The dispersibility of the ceramic slurry composition thus formed according to the method in Comparative Example 3 was measured using a measurement apparatus of particle size distribution made by Microtrack. The D90 was 0.60 μm.
The ceramic slurry composition was dehydrated and was heated to 500° C. to remove the binder, and the specific surface area thereof was then measured. The rate of increase in the specific surface area from the original specific surface area was 30%.
The ceramic slurry composition of Comparative Example 3 was formed into sheets by a doctor blade method, thereby yielding ceramic green sheets.
The surface roughness Ra of the ceramic green sheet thus formed was measured by an atomic force microscope, and as the ratio of density of the ceramic green sheet, the ratio of the measured density to the theoretical density (the measured density/the theoretical density) was measured. The Ra was 75 nm, and the density ratio was 0.90.
Next, a multilayer ceramic capacitor was formed by using the ceramic green sheets in a manner equivalent to that described in Example 1.
The rate of occurrence of short-circuiting of the multilayer ceramic capacitor thus formed was 13%, and the temperature coefficient of the static capacitance did not meet the X7R specification.
The data of Examples 1 to 5 and the data of Comparative Examples 1 to 3 are shown in Table 1, in which the data are of the dispersibility and the rate of increase in the specific surface area after the removal of the binder of the ceramic slurry composition; the surface roughness and the density ratio of the ceramic green sheet; and the rate of occurrence of short-circuiting and the temperature coefficient of the static capacitance of the multilayer ceramic capacitor formed by using the ceramic green sheets.
The present invention is not limited to the embodiments and the examples described above, and the powdered ceramics, solvents, specific dispersing methods, and the conditions thereof may be varied or may be modified within the scope of the present invention.
As described above, since the ceramic slurry composition of the present invention uses an anionic dispersing agent, the dispersibility of the powdered ceramic is superior. In addition, as an anionic dispersing agent is used, the powdered ceramic can be efficiently dispersed in a short period, and hence, an economical ceramic slurry composition provided with desired dispersibility can be obtained.
Since the powdered ceramic can be dispersed in a short period, a ceramic slurry composition having desired characteristics can be provided, in which excessively large specific surface area will not occur, and in which the crystallinity of the powdered ceramic is not degraded.
TABLE 1
Rate of Increase
Surface
Temperature
in Specific
Roughness of
Ratio of
Rate of Occurrence
Coefficient of
Dispersibility
Surface Area
Sheet
Sheet
of Short-Circuiting
Static
(D90(μm))
(%)
(Ra(nm))
Density
(%)
Capacitance
Example 1
0.60
8
81
0.81
13
X7R
Example 2
0.50
12
72
0.94
9
X7R
Example 3
0.50
12
71
0.93
8
X7R
Example 4
0.58
8
74
0.91
13
X7R
Example 5
0.62
8
85
0.83
15
X7R
Comparative
0.70
8
112
0.74
51
X7R
Example 1
Comparative
0.70
8
111
0.74
49
X7R
Example 2
Comparative
0.60
30
76
0.89
13
B
Example 3
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A ceramic slurry composition has a powdered ceramic uniformly dispersed therein without excessive damage thereto. A method for producing a ceramic green sheet using the ceramic slurry composition and a method for producing multilayer ceramic electronic devices are also disclosed. The ceramic slurry composition contains the powdered ceramic, a dispersing agent, a binder and a solvent, in which an anionic dispersing agent is used as the dispersing agent, and the content of the anionic dispersing agent is set to be such that the total acid content thereof corresponds to about 10 to 150% of the total base content of the powdered ceramic. In addition, the powdered ceramic having an average particle diameter of about 0.01 to 1 μm is used.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Provisional Application Serial No. 60/435,854, filed Dec. 20, 2002, titled WETTING AGENT/MOISTURE CONTROL FORMULATION, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] It is known in the construction arts that water must be applied to base materials and/or soils when preparing foundations for buildings, roads, and similar construction projects. Often, especially during hot, dry weather, materials require substantial amounts of water to adsorb and absorb sufficient moisture for compaction to specified densities. Sorbed moisture levels specified for a given project depend upon the nature of the base material and the degree of compaction needed to make a stable base, whereas the amount of water applied to achieve the required amount sorbed depends on the rate at which liquid migrates through pore spaces among particles, the rate at which water penetrates into particles, and the evaporation rate.
[0003] Water is normally distributed by a water truck, being sprayed on the material from a trailer pulled by a tractor rig. Base materials and soils must be kept at appropriate moisture levels for periods as long as several days, until the base material is thoroughly wetted and settled and/or in condition for compaction. Costs of water, as well as the equipment and labor costs for distributing the water are significant.
[0004] It is useful to provide a method of treatment that reduces the amount of water and time required for conditioning roadbeds and foundation materials and for stabilizing soils. It is further desirable that such product and method decrease the frequency of applications in order to decrease the rate of fugitive water loss by the application process itself.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, water used to prepare a roadbed, building or other foundation, or for soil stabilization is mixed with a hydrotropic wetting agent having desired properties. The hydrotropic wetting agent enhances the activity of water for earthy materials by lowering surface tension to promote surface-to-surface contact, to neutralize the electric double layer, to destroy protective colloids, to neutralize other charged particles, and to bind water to the materials, thus, significantly reducing the evaporation rate and, concomitantly, reducing the amount of water that must be applied and the energy and time used to prepare the material. A wetting agent suitable for the present invention includes an alkylphenol ethoxylate (APE), such as, for example Tergitol, and a polyglycol, such as, for example, glycerin or propylene glycol (when toxicity is not an issue), and an antifoaming agent, such as for example, a polysiloxane polymer. These chemicals combined in the concentration ranges of the present invention produce wetting agent/hydrotropic formulations that may be used to provide the advantages of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0006] Many factors affect the water-demand of foundation base materials and/or soils. This water demand is due in large part to the rate of particle hydration and, once hydrated, the ability of base particles to retain moisture and agglomerate. The mineralogy, particle-size-distribution, degree of hydration prior to delivery to the site, and ambient weather conditions are among the important factors involved in water demand for base preparation.
[0007] One form of the present invention uses a combination of surfactants and hygroscopic compounds mixed with water to stabilize and prepare a roadbed, building foundation, or soil to be settled for whatever purpose. Use of this “hydrotrope”, or hydrotropic wetting agent, allows for significantly less water to be used in the preparation process, less time required to condition the material, thus saving costs for the water itself, the labor, energy, environmental control and equipment costs required to apply it.
[0008] Methods of the present invention may increase the sorption rates and holding capacities of earthy materials for water and thus decrease the amount of water that must be applied, and the time required to achieve a given level of sorbed moisture, when compared with treatment by water alone.
[0009] The use of a hydrotropic wetting agent as described by the present application typically includes an APE surfactant combined with other agents, such as glycerin or propylene glycol, and an antifoaming agent that induce rapid migration of the water/hydrotrope by virtue of the combined effect of lowered surface tension and hygroscopicity. A specific surfactant suitable for use in the present invention is Tergitol™ TMN-10. The surfactant concentration range is typically from about 10% to about 50% by volume in deionized water containing, a glycol, such as, for example, glycerin in the range from about 0.1% to about 10% by volume, and an anti-foaming agent, such as for example, a polysiloxane polymer, in the range of about 0.5 to about 5% by volume.
[0010] This formulation results in a hydrotropic concentrate that when added to water in a wide range of use dilutions, provides the water for conditioning the roadbed or foundation. The resultant hydrotrope may be mixed with water in a ratio of between approximately 10-1000 ppm to give a product that can be applied directly to the roadbed, foundation, or soil. The water is applied in the same manner as is presently done in the art, but the difference in effect is that the bed attains its desired conditioning faster than normal and retains its adsorbed and absorbed water longer. Thereby, less water must be applied to achieve moisture levels sought faster, and remaining moist longer. Thus, water is applied less often. Field tests indicate that approximately half as much water is required in tight, clayey soils as is usually applied without the hydrotrope. As little as one-third the water is required using the present invention in water applied to a crushed concrete flexible base.
[0011] A formulation useful with the present invention uses a non-toxic polyglycol or glycerin in addition to the Tergitol. The active components of this invention in its concentrated form are (1) Tergitol™ TMN-10, 10-40% v/v (2) glycerin (or polyglycols), 10-40%, (3) water, 17-77% v/v, and a silicone-based anti-foaming agent, 0.1-3%. This concentrate is mixed at a ratio of between 10-1000 ppm with the water sprayed on the roadbed, foundation, or soil bed in order to provide the benefits described. A ratio in this range can be achieved, for example, by mixing the described formulation, as available from EnviroSpecialists as the product EWO, in the ratio of between 1.5 fl ozs and 10 gals of concentrate to 10,000 gals water, dependent on the type of roadbed material, temperature, and humidity. A typical hydrotrope—water formulation for most roadbed materials is 1.5 gals of EnviroSpecialists' Enviro RoadMoisture™ per 3400 gallons of water in a tank truck.
[0012] This formulation may be provided in a concentrate that can be conveniently transported to a site where a road or foundation bed is to be prepared, then diluted with large amounts of water, often by adding the concentrate to a water tank truck, to provide the described properties, which are far superior to those of water alone.
[0013] The present invention utilizes a combination of wetting agents, surfactants and anti-foaming agent, and a hygroscopic agent carried in water to produce a hydrotropic agent that activates water and small particles by interfering with water-to-water hydrogen bonding and neutralizing electric double-layers, thus destroying protective colloids, and spreading over particles, increasing their ability to agglomerate.
[0014] In use, treated water is spread on a roadbed, foundation bed, or the like using the same techniques currently used with plain water. Additional water will not need to be added as often as is currently the case, so the operator will need to check on the moisture content remaining in the soil from time to time, or modify application schedules used for plain water application. Treated water can be applied using water trucks, various types of sprayers, or hoses as desired. Typically, the same application technique is used with the present invention as with untreated water, except that lesser amounts of water are required over the course of the bed preparation stage.
[0015] Once the treated water has been applied, the bed can be allowed to settle naturally, or be compacted mechanically, as desired. Often, both techniques will be employed. Treated water can continue to be applied during and after mechanical compaction as known in the art, with the difference that less water is required. In general, the operator should monitor the moisture levels in the soil of the bed being prepared so as to avoid over wetting, with its attendant additional costs and delays.
[0016] While the invention has been particularly shown and described with reference to the above-described example, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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The present invention provides an improved method of treating and stabilizing base materials for the preparation of foundations and roadways.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the production of polyaspartic acid homo- and copolymers by biotechnological processes and to the use of the resulting products (for influencing the crystallization or agglomeration behavior of sparingly soluble salts or solids in aqueous systems).
2. Description of the Related Art
Crystallization and agglomeration processes are, as biological mineralization, among the fundamental processes of animate nature. Thus, they are involved, for example, in the structure of skeletons or shells in living organisms. In nature, these mineralization processes are controlled by naturally occurring proteins and polysaccharides. (S. Weiner, Biochem. 22, (1983), 4139-45; C. S. Sikes, A. P. Wheeler, in Chemical Aspects of Regulation of Mineralisation., Eds. C. S. Sikes , A. P. Wheeler University of South Alabama Publ. Services (1988), 15-20).
Unfortunately, both in nature and in the industrial sector, unwanted mineralization processes also occur and result in tenacious, troublesome deposits and encrustations such as, for example, dental plaque, organ concretions or, in the industrial sector, encrustations on heat exchanger surfaces or cooling towers particle agglomerations in pigment dispersions, encrustations on hard (for example glass metal) and soft (textile) surfaces. In the past, various proposals have been made for exploiting this natural action principle for industrial problems. Thus, the U.S. Pat. Nos. 4,534,881, 4,585,560, 4,587,021 describe the inhibition of calcium carbonate deposits by protein fractions, polysaccharide fractions or polyamino acid fractions from calcium carbonate-forming organisms such as crustaceans etc.
In addition, the inhibition of mineral deposits by polyanionic hydrophobic polypeptides with a block copolymer structure and related phosphorylated polypeptides is claimed in the literature (U.S. Pat. No. 4,868,287). The polypeptides used are prepared by methods of peptide chemistry. WO 92/17194 states that an improved synthesis of these polypeptides is provided.
Since the proteins described above acquire their polyanionic characteristics through a high aspartic acid content, aspartic acid homo- and copolymers are also claimed for this purpose. These polyaspartic acids are, however, all obtained by chemical synthesis. Thus, for example, a polyaspartic acid sodium salt can be prepared by thermal polycondensation of aspartic acid to polysuccinimide and subsequent basic hydrolysis. (Kovacs et al. J. Org. Chem, 26 (1961)1084-1091). Further applications claim the preparation and use of polyaspartic acids by thermal polycondensation of aspartic acid in the presence of acidic catalysts such as phosphoric acid. In addition, polyaspartic acids are also prepared by thermal polymerization starting from aspartic acid precursors such as maleic acid ammonium salt (EP 0 256 366), maleic amide (EP 0604 813) and maleic anhydride, and ammonia-releasing compounds.
BRIEF SUMMARY OF THE INVENTION
The present invention now describes biological methods for producing aspartic acid homo- and copolymers and the use of the resulting polymers for inhibiting mineral deposits and dispersing solid particles.
To date, three different polyamino acids have been found in nature, poly-γ-glutamate, poly-Σ-lysine and poly-α-arginylaspartate (cyanophycin).
Poly-γ-glutamate is produced by various Gram-positive bacteria such as, for example, Bacillus licheniformis, Bacillus subtilis natto or Bacillus anthracis. poly-Σ-Lysine is produced by Streptomyces albulus.
Poly-α-arginylaspartate is produced by many cyanobacteria such as, for example, Spirulina platensis, Aphanocapsa PCC 6308 or Anabena cylindrica. Synthesis takes place by the non-ribosomal pathway, resulting in a polypeptide which has a polydisperse molecular weight distribution and is stored in the form of cyanophycin granules inside cells.
To date, only the biotechnological production of poly-γ-glutamate using Bacillus subtilis or Bacillus licheniformis is disclosed in the patent literature. (JP 1-174397 (1989), JP 43-24472 (1969) and U.S. Pat. No. 2,895,882).
DETAILED DESCRIPTION OF THE INVENTION
We have now found that aspartic acid homo- and copolymers can be produced using various cyanobacteria via the intermediate cyanophycin. The resulting polymers have the following structures.
R 1 : ≡OH or arginyl
n: 5-400
If the total of all the R 1 radicals corresponds to 100%, then the proportion of R 1 ═OH is between 5% and 100%, preferably 30%-100% and particularly preferably 70% to 100%. The molecular weight of the polymers is generally between 1000 and 100,000, preferably between 2000 and 50,000, particularly preferably between 2000 and 30,000.
The total n of all repeating units depends on the cleavage conditions to which the intermediate cyanophycin is subjected. Arginine elimination can take place both with acid and with base. If an acidic hydrolysis is carried out, stoichiometric amounts of acid in relation to the incorporated arginine are necessary because the acid is trapped as arginine salt. It is possible to employ as acid all mineral acids such as, for example, hydrochloric acid, sulfuric acids, phosphoric acids and lower fatty acids of C 1 -C 5 . The hydrolytic cleavage can moreover take place under pressure using carbonic acid or CO 2 . Depending on the concentration of the acid employed and on the reaction conditions, depolymerization by hydrolytic cleavage of the polyaspartate chain may also take place, in addition to the arginine elimination. However, the unwanted depolymerization can be minimized by suitable choice of the reaction conditions, such as dilute acid, moderate reaction times, temperatures not exceeding 100° C.
However, the hydrolysis can also advantageously be carried out under basic conditions, because the polyaspartate chain is more stable under these conditions. The reaction is carried out at a pH≧8.5, preferably 9-12, and at temperatures between 20° C. and 150° C., preferably 50° C.-120° C. After the hydrolysis, the reaction product is removed by filtration from the unreacted cyanophycin and the alkali-insoluble arginine. Suitable as base for the alkaline hydrolysis are all metal hydroxides or carbonates which make pH values>8.5 possible in aqueous medium. Alkali metal and alkaline earth metal hydroxides are preferred.
The cyanophycin employed for the hydrolytic formation of the aspartic acid homo- and copolymers is obtained by fermentation of cyanobacteria such as, for example, Aphanocapsa PCC 6308, Anabena cylindrica or Spirulina platensis. A possible biosynthetic pathway is described in the experimental part.
The aspartic acid homo- and copolymers obtained as products were characterized by elemental analysis, amino acid analysis and NMR spectroscopy. The molecular weight was determined with the aid of aqueous GPC. In addition, for industrial applications, the products were tested for their ability to inhibit mineral deposits such as calcium carbonate, calcium sulfate, calcium phosphate, calcium oxalate and barium sulfate, and for their dispersing capacity for solid particles. The calcium carbonate inhibiting capacity was carried out inter alia by a method of C. S. Sikes, A. P. Wheeler in Chemical Aspects of Regulation of Mineralisation, pp. 53-57, University of South Alabama Publication Series (1988). The products are completely biodegradable owing to their natural polypeptide structure based on α-linked L-aspartic acid.
They can be employed, for example, as cobuilders in detergents and cleaners, for inhibiting and dispersing deposits in cooling and heating circulations for diminishing and dispersing deposits, and for reducing corrosion and inhibiting gas hydrates in petroleum and natural gas production.
EXAMPLE 1
Culture conditions, extraction and purification of cyanophycin:
The cyanobacterium Aphanocapsa PCC6308 is incubated in a 10 l fermenter (batch culture) with 9 l of BGII medium under phototrophic conditions (6000 lux, l/d cycle 12/12) at 30° C. and supplied with air (200 ml/min). Before the cells reach the stationary phase (after 14 days with an optical density OD 665 of about 1.6), 10 mg/l L-arginine and/or 200 mg/l NaNO 3 and 5 mg/ml chloramphenicol are added to the medium, and then the cell suspension is incubated for a further 48 h with reduced light (600 lux) and at lower temperature (20° C.). The cells are harvested by centrifugation at 10 000 xg and washed twice in distilled water. The cell pellet (about 25 g wet weight, about 3 g dry matter) is taken up in 100 ml of an aqueous buffer solution (pH 7.2). The cells are disrupted by ultrasound treatment and then stirred at 4° C. for 15 h. The crude cyanophycin is pelleted by centrifugation at 30 000 xg. The crude cyanophycin is resuspended in 60 ml of H 2 O. The supernatant (S 1000) obtained by three fractional centrifugations at 1 000 xg is subjected to a centrifugation at 30 000 xg, and the pellet obtained in this way is dissolved in 0.1N HCl (yield: about 1000 mg of native cyanophycin). The native cyanophycin dissolved in 0.1N HCl is finally purified by retritration three times in 1N NaOH (yield: about 150 mg of cyanophycin).
The strain Aphanocapsa (=Synechocystis) PCC6308 was originally isolated in 1949 and G. C. Gerloff from a lake in Wisconsin (USA) and was described for the first time by Gerloff et al. in 1950 (Gerloff, G. C., Fitzgerald, G. P. & Skoog, F. 1950. The isolation, purification and nutrient solution requirements of blue-green algae. In Proceedings of the Symposium on the Culturing of Algae, pp. 27-44. Dayton, Ohio, U.S.A.: Charles F. Kettering Foundation).
The strain Synechocystis PCC 6308 used in the present application was deposited in the name of Bayer AG, 51368 Leverkusen, on Feb. 19, 1998 at the DSMZ-Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Mascheroder Weg 16, D-38124 Brunswick with the number DSM 12037.
EXAMPLE 2
Basic hydrolysis of cyanophycin
500 mg of cyanophycin from Example 1 are suspended [lacuna] 5 ml of water. 75 mg of NaOH (100%) are added, and the mixture is heated at 90° C. with stirring for 12 h. The mixture is then cooled to room temperature and filtered. The residue remaining is a mixture of arginine and unreacted cyanophycin. The filtrate contains the sodium salts of the aspartic acid homo- and copolymers.
Determination of the calcium carbonate inhibiting capacity by modification of the NACE 1) method: TM 0374-90
1) NACE: National Association of Corrosion engeneers
Starting materials:
Solution 1:
12.15 g of calcium chloride dihydrate, analytical grade
3.68 g of magnesium chloride hexahydrate, analytical grade made up to 1000 ml of solution with distilled water.
Solution 2:
7.36 g of sodium bicarbonate, analytical grade made up to 1000 ml of solution with distilled water.
Solutions 1. and 2. must each be made up freshly and saturated with CO 2 before use thereof.
100 ml of solution 1. are mixed with 1,2,3,5,10 ppm inhibitor (active substance) based on the complete test mixture. Then 100 ml of solution 2. are added.
The test mixture is then mixed by shaking in a closed vessel and stored in a waterbath preheated to 70° C. for 16 h. (For comparison, a sample without added inhibitor is included in the test series.) After this time, all the samples are removed simultaneously from the waterbath and cooled to 30° C. 5 ml portions are taken from all the samples, filtered through a 0.45 μm filter and acidified with hydrochloric acid for stabilization.
The calcium content in the filtrate is determined by titration with an indicator or by atomic absorption spectroscopy.
The inhibiting capacity is calculated as follows: a - b c - b * 100 = % inhibition
a: amount of calcium in the sample
b: amount of calcium in the blank after heat treatment
c: amount of calcium in the blank before heat treatment
Inhibition [%]
Inhibitor [ppm]
Example 2
Polyaspartic acid chemical synthesis
1
20
44
2
39
59
3
66
72
5
83
85
10
90
94
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The invention relates to the production of polyaspartic acid homo- and copolymers by biotechnological processes and to the use of the resulting products (for influencing the crystallization or agglomeration behavior of sparingly soluble salts or solids in aqueous systems).
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FIELD OF THE INVENTION
The present invention generally relates to tubing that is used to produce hydrocarbons in a subterranean environment and specifically to an improved tubing having an insert with electrical wiring.
BACKGROUND OF THE INVENTION
Basic artificial lift methods to produce oil and water from a well have improved and changed in recent years. Nearly all methods of artificial lift still employ the connection of a plurality of pipes to form a conduit within a well that has been drilled and cased to allow oil and water to be pumped from the bottom of the well to production tanks at the surface. The production string usually has a pumping device at its lower end that is positioned near the bottom of the well bore that has been prepared for production. Pumping mechanisms such as electrical submersible pumps (ESP) and progressive cavity pumps (PCP) provide the energy needed to bring fluids to the surface through a string of jointed tubing. These pumps normally require an electric motor in order to make them work. Although a multitude of improvements have been made to these pumps over the years, there has been little done to reposition the wires that provide power to the pump from the outside of the tubing to the inside of the tubing.
For various reasons, those who are skilled in the science of producing fluids from a well have sought out a reliable method of supplying power to the bottom of a well bore. The previously proposed solutions to this problem have been unreliable, expensive, and complicated to install and remove. For example, the currently preferred method of power transmission to the bottom of the well bore is to secure a cable, that contains one or more wires by means of bands that secure the cable to the outside of the production string of tubing. The bands keep the wire adjacent to the tubing so that it does not snag on the production casing or on any objects which might be in the well bore. The bands also support the weight of the cable by securing the cable to the tubing. However, this method is problematic because it exposes the cable and bands to the corrosive elements of the well bore. Furthermore, installing (running) or removing (pulling) the tubing string creates opportunities to separate the cable from the tubing because inclined well bores (the most common type of well bores) increase the chance of the band to hanging up and failing at the gap where two joints of casing have been screwed together. Failure of one or more bands can prevent the removal of the pump or tubing because the annular space between the outside of the production tubing and the inside of the production casing is small and the cable, if not secured to the tubing, can wedge between the casing and the tubing causing the tubing to become stuck. Even if the cable does not break, the insulation on the wire inside the cable can be damaged which can create a short circuit in the electrical circuit, rendering the wire essentially useless. The tubing string then has to be pulled back up to the surface, and the short found and repaired, before the pump can be run back to bottom of the well bore. The problems created by banded external cables are costly and time consuming. Therefore, a need exists for an alternative method of power transmission from the surface to the bottom of the well bore that is both reliable and cost effective.
One solution to the above stated problem is to employ a plurality of tubing with multiple wires attached to the inside of the tubing instead of the outside of the drill pipe. While this solution alleviates the problem of snagging the wire, it does not solve the problem of exposing the wire to the harsh environment of the produced fluids that are contained within the production tubing. Simply hanging the cable on the inside of the tubing is also problematic because there is no way to support the weight of the cable and the pressure requirements of the pump will be higher due to the added friction between the fluid that is being pumped and the rough exterior of the cable.
Another solution to the above stated problem is to concentrically position the wires on the exterior of a tube that is inserted and attached to the actual production tubing itself. This solution avoids the problems presented by simply attaching the wire to either the interior or the exterior of the tubing. An example of this technique can be found in U.S. Pat. No. 4,683,944 (the '944 patent) entitled “Drill Pipes and Casings Utilizing Multi-Conduit Tubulars.” The '944 patent discloses a drill pipe with electrical wires positioned inside conduits in the drill pipe wall. However, positioning the wire inside the drill pipe wall significantly decreases the overall pipe wall thickness. In order to overcome the decreased wall thickness, significantly thicker drill pipes will have to be used. Furthermore, the multiple conduits create weak points in the drill pipe in between the conduits. The high rotational stress which the drill pipe encounters in the drilling operations can cause stress fractures in the pipe wall between the multiple conduit tubulars. In an extreme case, high rotational stress can lead to an internal fracture in the drill pipe that disengages the interior wall of the drill pipe from the exterior wall of the drill pipe.
Furthermore, the manufacture of the multiple conduit drill pipe is a complicated process which is unlike the manufacturing process for conventional drill pipe. Conventional drill pipe is manufactured by attaching male and female pipe connections to opposite ends of a conventional piece of pipe. The two connections are usually welded to the pipe. Multiple conduit pipes must be either extruded with the multiple conduits in place, or the multiple conduits must be drilled or cut out of a conventional drill pipe. In either case, the costs associated with manufacture of multiple conduit drill pipe are high.
Another problem encountered in the addition of wires to drill pipe, which is not unique to multiple conduits, is the problem associated with creating reliable, secure electrical connections. In conventional drill pipe the individual pipe segments screw together, creating a problem for connecting the wires during the screwing or unscrewing process. This problem can be overcome by using drill pipe that plugs together and that is secured with a threaded coupler. This type of connection is known in the art. The '944 patent discloses a similar type of coupling connection, but requires a planer conduit seal in between the individual pipe segments in order to assure the integrity of the conduit connection. The removable conduit seal is crucial to the method in the '944 patent because a permanently installed conduit seal would be susceptible to damage during manufacture, transportation, storage, and installation of the multiple conduit drill pipe during drilling operations. Installing these conduit seals during the drilling process is also a cumbersome and a time consuming process. Therefore, a need exists for a method of transmitting electrical power to the bottom of a well bore in which the electrical connections are adequately protected from damage and the process of connecting the individual pipe segments is relatively simple and fast.
The needs identified above exist for production tubing, drill pipe, casing, and/or for any cylindrical pipe used to produce hydrocarbons in a subterranean environment. Therefore, as used herein, the term “tubing” shall mean production tubing, drill pipe, casing, and/or any other cylindrical pipe that is used to produce hydrocarbons in a subterranean environment.
Since, the previous solutions to the power transmission problem are lacking, a need still exists for an apparatus and method of transmitting power to a well bore in which the wire is not exposed to either the interior or the exterior of the tubing and is operable with any conventional tubing, including without limitation production, casing or drill pipe. Furthermore, a need exists for an apparatus and method for connecting the individual tubing segments together in which the electrical connections are well protected and the connection process is quick and easy.
SUMMARY OF THE INVENTION
The present invention, which meets the needs stated above, is an improved tubing which overcomes the problems presented by earlier inventions involving tubing and electrical wiring combinations. The invention comprises a section of tubing with coupled end connectors and an insert containing at least one electrical wire. The insert has an outside diameter that is approximately equal to the inside diameter of the improved tubing. The insert also has projections at each end such that when two inserts are placed end to end, the projections will mate up. The insert has at least one groove cut into its side and running the length of the insert. The groove is for the placement of a wire for transmission of power to the well bore or for the placement of a wire for transmission of data from the well bore. The groove is installed down the length of the insert. The groove is deep enough so that when a wire is placed inside the groove, the wire does not project beyond the outside diameter of the insert. The insert may contain as many groove and wire combinations as are necessary for the particular application. The wire has an electrical connection at each end of the insert. When the inserts are placed end to end, the insert projections line up the electrical connectors and correct mating of the insert projections will result in correct mating of the electrical connectors.
The inserts, are the same length as the tubing and are installed inside the tubing such that the insert is flush with the first end of the tubing. The inserts are then welded to the tubing or secured to the tubing by some other method. A threaded coupler is then installed on the second end of the tubing to protect the exposed insert and electrical connector. The coupler will also be used to secure the improved tubing together.
Individual pieces of improved tubing are connected together in a three step process. First the coupler is threaded onto the second end of the tubing. Next, the first end of one tubing member is positioned above the second end of another tubing member. Next, the insert projections are properly aligned so that they will mate together. Then, the two pieces of tubing are plugged together so that the electrical connections engage each other. Finally, the coupler is screwed onto the first end of the tubing so that the two pieces of tubing are secured together. The process may be repeated as necessary to create an elongated string of improved tubing.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an illustration of the improved tubing without the insert or the coupler.
FIG. 2 is an illustration of the insert.
FIG. 3 is an illustration of the insert installed in the improved tubing.
FIG. 4A is a cross-sectional illustration of the two wire embodiment of the insert taken along line 4 — 4 in FIG. 2 .
FIG. 4B is a cross-sectional illustration of the three wire embodiment of the insert similar to the two wire embodiment in FIG. 4 A.
FIG. 5 is an exploded illustration of the connection between the first end of the improved drill pipe and the second end of the improved tubing.
FIG. 6 is a cross-section of the two wire embodiment of the insert installed in the improved tubing taken along line 6 — 6 in FIG. 5 .
FIG. 7 is a cross-section of the two wire embodiment of the insert installed in the improved tubing taken along line 7 — 7 in FIG. 5 .
FIG. 8 is an illustration of the positioning and alignments steps for the two wire embodiment of the improved tubing.
FIG. 9A is an illustration of the plugging step for the two wire embodiment of the improved tubing.
FIG. 9B is an illustration of the securing step for the two wire embodiment of the improved tubing.
FIG. 10 is an illustration of the positioning and alignment step for the three wire embodiment of the improved tubing. The dashed line indicates the alignment of the wire connectors in the three wire insert embodiment.
FIG. 11 is a cross-sectional illustration of the three wire embodiment of the insert taken along line 11 — 11 in FIG. 10 .
FIG. 12 is an illustration of the plugging step for the three wire embodiment of the improved tubing.
FIG. 13 is an illustration of the securing step for the three wire embodiment of the improved tubing.
FIG. 14 is a cross-sectional illustration of the three wire embodiment of the insert taken along line 14 — 14 in FIG. 13 .
FIG. 15 is a detail view of the geometry between the insert, the wire, and the improved tubing around the area indicated by circle 15 in FIG. 14 .
FIG. 16 is an illustration of a submerged pump in a production situation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein, the term “improved tubing” means tubing that is adapted to receive a coupler and that has an insert. FIG. 1 is an illustration of improved tubing 100 without insert 200 (see FIG. 2) or coupler 300 (see FIG. 5 ). Improved tubing 100 is comprised, of three sections: first end 120 , midsection 140 , and second end 160 . First end 120 comprises coarse threads 122 , first end weld joint 124 , and wrench grip 126 . Midsection 140 comprises pipe 142 , pipe first end 144 , and pipe second end 146 . Second end 160 comprises fine threads 162 , second end weld joint 164 , and coupler stop flange 166 . First end 120 and second end 160 may be like those found in U.S. Pat. No. 5,950,744 (the '744 patent) entitled “Method and Apparatus for Aligning Pipe and Tubing.” Typically, first end 120 and second end. 160 are manufactured by either casting or forging and pipe 142 is manufactured by some other method (i.e. electric resistance welding or extrusion). The manufacture of improved tubing 100 involves the threading of first end 120 and second end 160 to pipe 142 . While the preferred method of manufacturing first end 120 and second end 160 is threading the two ends of improved tubing 100 , those skilled in the art will be aware of other methods of manufacturing first end 120 and second end 160 . Regardless of the method of manufacture, the inside diameter of first end 120 , midsection 140 , and second end 160 are substantially the same so that when insert 200 engages improved tubing 100 , the outside surface area of insert 200 contacts the inside surface area of improved tubing 100 .
FIG. 2 is an illustration of insert 200 . Insert 200 is comprised of insert first end 220 , insert midsection 240 , and insert second end 260 . Insert first end 220 comprises insert first end projection 222 and insert first end electrical connection 224 . Insert midsection 240 comprises insert body 242 and insert groove 244 . Insert second end 260 comprises insert second end projection 262 and insert second end electrical connection 264 . The depressions in insert second nd 260 in between insert second end projections 262 match up with the insert first end projections 222 . Likewise, the depressions in insert first end 220 in between insert first end projections 222 match up with the insert second end projections 262 . Thus, when two inserts 200 are coaxially aligned with insert first end 220 facing insert second end 260 , insert first end 220 will mate up with insert second end 260 . Insert 200 also contains insert groove 244 which is a groove cut down the long axis of insert 200 . Insert groove 244 is sufficiently large to accommodate at least one wire 246 . Wire 246 is electrically coupled to insert first end electrical connection 224 and insert second end electrical connection 264 and is used as a medium to transfer electricity from the surface to the bottom of the well bore. Insert first end electrical connection 224 and insert first end electrical connection 264 are single plug connectors similar to the K-25 series electrical connectors produced by Kemlon Products and Development Co. of Pearland, Tex. The K-25 series of single plug electrical connections are able to withstand temperatures up to 500° F. and pressures up to 25,000 psi.
FIG. 4A is a cross-section of the two wire embodiment of insert 200 taken along line 4 — 4 in FIG. 2 . Inset 200 may contain only one wire 246 or may contain a plurality of wires 246 . For simplicity of illustration of the invention, FIGS. 1 through 9B (excluding 4 B) depict the invention with only two wires. In alternative embodiments, wire 246 can be a fiber optic in which case the two electrical connections on insert 200 would be optical connections and the fiber optic would be optically coupled to the optical connections. In another alternative embodiment, the invention could employ a mixture of fiber optics and electrical wires. In the preferred embodiment the invention incorporates three wires such that the three wires each carry the appropriate load of a three phase, 440-volt electrical system, as illustrated in FIGS. 4 B and 10 through 15 . However, the number and type of wires is not meant to be a limitation on the invention as those skilled in the art will be aware of how best to configure the invention with fiber optics, electrical wiring, or other connections within insert groove 244 of improved drill pipe 100 .
FIG. 3 is an illustration of improved tubing 100 with insert 200 installed. Insert 200 is sized lengthwise so that when insert 200 is inserted into improved tubing 100 , insert first end projection 222 is flush with first end 120 and insert second end projection 262 is the only portion of insert 200 that is projecting beyond second end 160 . As seen in FIG. 6, insert 200 is circumferentially sized such that the outer diameter of insert 200 is sufficiently equal to the inside diameter of improved tubing 100 . Insert groove 244 is sufficiently deep in insert body 242 so that wire 246 does not extend beyond the outer diameter of insert 200 , yet is not deep enough to affect the structural integrity of insert 200 . Insert 200 is coaxially positioned inside improved tubing 100 and secured in place. In the preferred embodiment, insert 200 is the same material as improved tubing 100 and is secured in place by welding. However, insert 200 can be made of any material suitable for drilling operations including various metal alloys, fiberglass, plastic PVC, polymer, or any other material as determined by those of skill in the art. Likewise, insert 200 can be secured in place by welding, glue, heat shrinking, expanding, set screws, or any other method as determined by those skilled in the art. Heat shrinking is defined as a process in which the outer pipe is heated so that the outer pipe expands, the insert is positioned inside the pipe, and the pipe is allowed to cool so that it contracts and secures the insert in place. Expanding is a process in which a tool (expander), having a slightly larger outside diameter than the inside diameter of the insert, is pulled forcibly through the insert causing the outside surface of the insert to expand and grip the inside of the improved tubing. Set screws is a process in which the improved tubing and insert are tapped and threaded and a screw is inserted through the improved tubing and insert to secure the insert in place relative to the pipe.
FIG. 5 is an exploded illustration of the connection between two separate pieces of improved tubing 100 with insert 200 installed and coupler 300 positioned for installation on first end 120 and drill pipe second end 160 . Coupler 300 is annular in shape and contains coupler fine threads 302 and coupler coarse threads 304 . Coupler fine threads. 302 are configured for screwing engagement with drill pipe fine threads 162 . Coupler coarse threads 304 are configured for screwing engagement with drill pipe coarse threads 122 . The pitch of drill pipe coarse threads 122 and drill pipe fine threads 162 are different pitch so that coupler 300 can only mate up with improved tubing 100 in one orientation. Similarly, when coupler fine threads 302 and coupler coarse threads 304 engage pipe coarse threads 122 and drill pipe fine threads 162 , the coarse threads and the fine threads do not interfere with the threading process of each other. As seen in FIG. 7, coupler stop flange 166 has a larger cross-sectional area than fine threads 162 and acts as a stop for coupler 300 so that coupler 300 does not go past second end 160 . The outside diameter of coupler 300 is sufficiently similar to pipe wrench grip 126 so that when the user is attaching the individual pieces of improved drill pipe 100 together, a pipe wrench will fit onto both pipe wrench grip 126 and coupler 300 without undue adjustment of the pipe wrench. Coarse threads 122 and coupler coarse threads 304 are tapered so that they may be completely engaged with a minimal amount of rotations after first end 120 and second end 160 have been plugged together. Coupler 300 is also sufficiently long so that when coupler 300 is completely screwed onto second end 160 and abuts coupler stop flange 166 , coupler 300 extends past insert second end projection 262 . It is important that coupler 300 extend past insert second end projection 262 because improved tubing 100 will typically be stored, transported, and handled with coupler 300 installed on second end 160 and coupler 300 will protect insert second end 260 and specifically insert second end electrical connection 264 from damage.
FIG. 8 is an illustration of coupler 300 installed on second end 160 just prior to connection of two pieces of improved tubing 100 . FIG. 8 is representative of how improved tubing 100 will be stored, transported, and handled. In FIG. 8, coupler 300 extends past insert second end projection 262 and insert second end electrical connection 264 .
FIGS. 8, 9 A, and 9 B illustrate the process of attaching two sections of improved tubing 100 together. In attaching the two sections of improved tubing 100 together, as far as the scope of this invention is concerned, it does not matter whether the second end 160 of one section of improved tubing 100 is above the first end 120 of the other section of improved tubing 100 or vice-versa. The improved tubing 100 may also be connected in the horizontal. However, the preferred embodiment and industry standard is to place the second end 160 above the first end 120 . The attachment process comprises four steps: positioning, aligning, plugging, and securing. First, in the positioning step the two sections of improved tubing 100 are positioned over one another with a second end 160 of one improved tubing 100 facing the first end 120 of the other improved tubing 100 . As seen in FIG. 8, the aligning step consists of rotating one or both sections of improved tubing 100 such that the insert second end projection 262 in one section of improved tubing 100 will properly mate with the insert first end projection 222 in the other section of improved tubing 100 .
When the two sections of improved tubing 100 are properly aligned, the two sections of improved tubing 100 may be plugged together. FIG. 9A is an illustration of the plugging step in which two sections of improved tubing 100 are plugged together. In the plugging step, the second end 160 of one section of improved tubing 100 is lowered onto the first end 120 of the other section of improved tubing 100 until the two sections of improved tubing 100 contact each other and/or the two inserts 200 fully mate with each other. To properly mate, insert second end projections 262 will fill the depression between insert first end projections 222 and insert first end projections 222 will fill the depression between insert second end projections 262 . When insert first end projection 222 and insert second end projection 262 properly mate, insert first end electrical connection 224 and insert second end electrical connection 264 will electrically couple and provide an electrical connection which will tolerate the harsh environment of the well bore. After the two improved tubing 100 are plugged together, they are secured by screwing coupler 300 onto first end 120 .
FIG. 9B is an illustration of two sections of improved tubing 100 secured together by coupler 300 . Coupler 300 is secured to first end 120 by pipe wrenches (not shown) which grip coupler 300 and pipe wrench grip 126 and torque coupler 300 until coupler 300 is firmly screwed onto drill pipe first end 120 . The two sections of improved tubings 100 may then be used in the production process.
FIGS. 10 through 14 illustrate a three wire embodiment. The manufacture of the three wire improved drill pipe is similar to the manufacture of the two wire improved tubing. Likewise, the assembly of a plurality of three wire improved tubing is similar to the assembly of a plurality of two wire improved tubing. FIG. 10 is an illustration of the alignment step for a three wire embodiment of the insert in which coupler 300 is installed on second end 160 . The dashed line in FIG. 10 indicates the alignment of insert first end electrical connection 224 and insert second end electrical connection 264 . When the two electrical connectors are properly aligned, insert first end projection 222 and insert second end projection 262 are also properly aligned. FIG. 11 is a cross-sectional illustration of the three wire embodiment of insert 200 and improved tubing 100 taken along line 11 — 11 in FIG. 10 . FIG. 12 is an illustration of the plugging step for the three wire embodiment of insert 200 taken along line 11 — 11 in FIG. 10 . FIG. 13 is an illustration of the securing step of two pieces of improved tubing 100 with the three wire embodiment of insert 200 and the coupler disengaged from the first end of the tubing.
FIG. 14 is a cross-section of the three wire embodiment of the insert taken along line 14 — 14 in FIG. 13 . Insert 200 in the three wire embodiment is similar to insert 200 in the two wire embodiment in that the inside diameter of pipe 142 is substantially the same as the outside diameter of inset body 242 . FIG. 15 is a detail view of the geometry between insert 200 , wire 246 , and improved tubing 100 around the area indicated by circle 15 in FIG. 14 . FIG. 15 illustrates the point that insert groove 244 is cut into insert body 242 so that wire 246 does not project above the outer surface of insert body 242 .
FIG. 16 is an illustration of a submerged pump in a production situation. FIG. 16 shows multiple pieces of improved tubing 100 with the inserts installed (not shown). Power comes from an external source 402 and is stepped down in transformer 404 , is routed through vent box 406 , and goes to wellhead 408 . Power is transmitted down tubing pump 412 and or motor 414 . Well bore 418 is typically cased with casing 416 .
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
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The invention comprises a section of improved tubing with coupled end connectors and an insert containing at least one electrical wire. The insert has an outside diameter that is approximately equal to the inside diameter of the improved tubing. The insert also has projections at each end such that when two inserts are placed end to end, the projections will mate up. The insert has at least one groove cut into its side and running the length of the insert. The groove is for the placement of a wire for transmission of power to the well bore or for the placement of a wire for transmission of data from the well bore. When a plurality of the inventions are placed end to end, the insert projections line up the electrical connectors and correct mating of the insert projections will result in correct mating of the electrical connectors.
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[0001] The present patent application is a continuation of application Ser. No. 10/921,363 filed Aug. 19, 2004 and claims priority from a Japanese Patent Applications Nos. 2003-296787 filed on Aug. 20, 2003 and 2004-216537 filed on Jul. 23, 2004, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a liquid seal and a liquid ejection apparatus. More particularly, the present invention relates to a liquid seal which is used for the liquid ejection apparatus and is capable of maintaining quality of the liquid and also relates to a liquid ejection apparatus employing the liquid seal.
[0004] 2. Description of the Related Art
[0005] A liquid ejection apparatus, such as an ink-jet recording apparatus, performs recording on a recording medium, such as a recording paper, by ejecting liquids, such as ink, from a fluid ejection head, such as a recording head. The liquid ejection apparatus includes a liquid accommodating container, such as an ink cartridge, which is detachably mounted with a main body of the liquid ejection apparatus. The liquid accommodating container supplies the liquid therein to a fluid ejection head through a liquid guide member, e.g., a liquid supplying tube as disclosed in Japanese Patent Laid-Open No. 2001-212974.
[0006] If viscosity of the liquid increases due to evaporation of the liquid or if air bubbles is generated in the liquid, performance of the fluid ejection head may deteriorate. In order to prevent a liquid evaporation and the increase of the viscosity, it is necessary to lessen the evaporation through a liquid accommodating chamber, the liquid guide member, and the fluid ejection head. Moreover, in order to prevent generating air bubbles in the liquid, it is necessary to lessen the amount of air being entered into the fluid through the liquid accommodating chamber, the liquid guide member, and the fluid ejection head.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention, there is provided a liquid seal used for a liquid ejection apparatus which performs recording by ejecting a liquid. At least a part of the liquid seal is formed from a layer compound mixture material including a high molecular compound and an inorganic layer compound. The liquid seal seals the liquid. According to the liquid seal, compared with a case if it does not include the inorganic layer compound, the amount of the ink solvent and atmospheric air permeating the liquid seal can be lessened. Therefore, the quality of the liquid is maintainable.
[0008] When the content of the inorganic layer compound in the layer compound mixture material is more than or equal to 1 percent of the weight and less than or equal to 50 percent of the weight, the amount of the ink solvent and atmospheric air permeating the liquid seal can be lessened while the characteristic of the high molecular compound is maintained.
[0009] The liquid seal may be a resin case in which the liquid is accommodated. In this way, the amount of the ink solvent and atmospheric air permeating the liquid accommodating container can be lessened.
[0010] When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; and a liquid ejection unit for ejecting the liquid, the liquid seal may be a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container. In this way, the amount of the ink solvent and atmospheric air permeating the liquid guide member can be lessened.
[0011] When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; a liquid ejection unit for ejecting the liquid; and a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container, the liquid seal may be a container holding member for detachably holding the liquid accommodating container and for connecting the liquid accommodating container to the liquid guide member by connecting the liquid guide member. In this way, the amount of the ink solvent and atmospheric air permeating the container holding member can be lessened.
[0012] When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; a liquid ejection unit for ejecting the liquid; and a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container, and when the liquid ejection unit includes: a head body for ejecting the liquid outside according to a signal input from a body of the liquid ejection apparatus; a base member for holding the head body, where the base member includes a channel unit for guiding the liquid to the head body; and a joint member connecting with each of the liquid guide member and the base member for guiding the liquid supplied from the liquid guide member to the base member, the liquid seal may be the joint member. In this way, the amount of the ink solvent and atmospheric air permeating the joint member can be lessened.
[0013] The liquid seal may include a surface layer which prevents peeling of the inorganic layer compound. Thereby, even if the liquid seal is flexed, the peeling of the inorganic layer compound from the front surface can be prevented. In this case, the surface layer may be unitedly formed by the high molecular compound which does not include the inorganic layer compound. Thereby, the layer including the inorganic layer compound and the surface layer which does not include the inorganic layer compound can be unitedly formed.
[0014] The liquid seal may be formed by extrusion, and the inorganic layer compound may be allotted in the liquid seal along a direction of the extrusion. Thereby, the inorganic layer compound can be densified in a direction perpendicular to the direction of the extrusion, so that the amount of the ink solvent and atmospheric air permeating in the direction perpendicular to the direction of the extrusion can be lessened.
[0015] According to a second aspect of the present invention, there is provided a liquid ejection apparatus which performs recording on a recording medium by ejecting a liquid. The liquid ejection apparatus includes: a liquid accommodating chamber for accommodating the liquid; a liquid ejection unit for ejecting the liquid to the recording medium; a liquid seal for sealing the liquid. The liquid seal is essentially made of layer compound mixture material including a high molecular compound and an inorganic layer compound. According to the second aspect, the same effectiveness as the first aspect can be attained.
[0016] The summary of the invention does not necessarily describe all necessary features of the present invention. The present invention may also be a sub-combination of the features described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of an ink-jet recording apparatus where a cover is removed.
[0018] FIG. 2 is a perspective view of an ink feed system included in the ink-jet recording apparatus.
[0019] FIG. 3 is an exploded perspective view of the ink cartridge.
[0020] FIG. 4 is a sectional view of the ink sealing film.
[0021] FIG. 5 is a top view of the cartridge holder.
[0022] FIG. 6 is a sectional view of the cartridge holder in the A-A cross section of FIG. 5 .
[0023] FIG. 7 is a perspective view of the ink guide member.
[0024] FIG. 8 is a sectional view of the cross direction of the ink guide member.
[0025] FIG. 9 is an exploded perspective view of the recording head unit.
[0026] FIG. 10 is a flowchart illustrating a manufacturing process of the bottom case 410 , etc.
[0027] FIG. 11 is an expanded sectional view in which the cross section of the base is expanded to illustrate the outline of the configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The invention will now be described based on the preferred embodiments, which do not intend to limit the scope of the present invention, but exemplify the invention. All of the features and the combinations thereof described in the embodiment are not necessarily essential to the invention.
[0029] FIG. 1 is a perspective view illustrating an ink-jet recording apparatus 10 using an embodiment of the present invention where a cover is removed, and FIG. 2 is a perspective view of an ink feed system included in the ink-jet recording apparatus 10 . As shown in FIG. 1 and FIG. 2 , the ink-jet recording apparatus 10 includes: a carriage 42 reciprocally moving along with a main scanning direction above a recording medium 11 , such as a recording paper; a recording head unit 300 mounted with the carriage 42 ; a plurality of ink cartridges 400 accommodating a plurality of colors of ink, respectively; a cartridge holder 200 for detachably fixing the plurality of ink cartridges 400 to the body of the ink-jet recording apparatus 10 ; and a rectangular-shaped ink guide member 100 which connects the recording head unit 300 to the cartridge holder 200 . The ink in the ink cartridges 400 is supplied to the recording head unit 300 through the cartridge holder 200 and the ink guide member 100 . The recording head unit 300 reciprocally moves with the carriage 42 along a guide shaft 48 to perform recording by the ink ejection to the recording medium 11 . The cartridge holder 200 is an example of a container holding member.
[0030] At least a part of each of the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 , i.e., the part being in contact with the ink, is essentially made of layer compound mixture material, which is a mixture of high molecular matter and an inorganic layer compound. For this reason, it is hard to transmit atmospheric air through the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 .
[0031] Although the inorganic layer compound is montmorillonite, which is preferably an example of smectite, it may be another smectite, mica, vermiculite, halloysite, or their synthetic analog. Moreover, although the content of the inorganic layer compound in the layer compound mixture material is preferably more than or equal to 1 percent of the weight and less than or equal to 50 percent of the weigh, it is more preferable that it is more than or equal to 5 percent of the weight and less than or equal to 30 percent of the weight. In this case, the layer compound mixture material can maintain the characteristic of the high molecular matter. Moreover, the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 can be formed by ejection molding.
[0032] FIG. 3 is an exploded perspective view of the ink cartridge 400 . The ink cartridge 400 includes a bottom case 410 , a top case 420 , and an ink sealing film 430 . The bottom case 410 includes recess 412 a on a surface joined to the top case 420 , and further includes an ink supply port 414 at a surface for supplying the ink outside. The ink sealing film 430 is welded on the perimeter of the recess 412 a to form an ink accommodating chamber 412 which accommodates the ink in the lower case 410 . The top case 420 is connected to the bottom case 410 to form a resin case of the ink cartridge 400 . The bottom case 410 and the top case 420 are essentially made of the layer compound mixture material. When forming the bottom case 410 and the top case 420 , the layer compound mixture material includes polypropylene as the high molecular matter.
[0033] FIG. 4 is a sectional view of the ink sealing film 430 . The ink sealing film 430 includes a welding film 432 , a mixture film 434 , and a heat-resistant film 436 in this order from a side to be welded to the bottom case 410 . The welding film 432 includes material similar to the bottom case 410 , and welded to the bottom case 410 . When the bottom case 410 includes polypropylene, the welding film 432 is formed with cast polypropylene. The mixture film 434 is essentially made of the layer compound mixture material, and prevents the ink solvent and the atmospheric air permeating the ink sealing film 430 . When forming the mixture film 434 , the layer compound mixture material includes polypropylene as the high molecular matter. The heat-resistant film 436 is essentially made of material of which a softening point higher than the welding film 432 , and when welding the welding film 432 , it maintains shape of the ink sealing film 430 .
[0034] FIG. 5 is a top view of the cartridge holder 200 , and FIG. 6 is a sectional view of the cartridge holder 200 in the A-A cross section of FIG. 5 . As shown in FIG. 6 , the cartridge holder 200 includes a plate-like member 202 and a sealing film 204 welded to a surface of the plate-like member 202 . As shown in FIG. 5 , the plate-like member 202 has a substantially rectangular shape, and includes a plurality of cylindrical cartridge connection units 210 to which the ink supply ports 414 of ink cartridges 400 are connected, a plurality of conveying member communicating pores 220 to which the ink guide member 100 is connected, and a plurality of slot units 230 which connect the plurality of cartridge connection units 210 to the conveying member communicating pores 220 , respectively. The slot units 230 are formed over the surface of the plate-like member 202 , and form the channels for the liquid by sealed by the sealing film 204 . The plate-like member 202 is essentially made of the layer compound mixture material. When forming the plate-like member 202 , the layer compound mixture material includes polypropylene as the high molecular matter. In addition, although the sealing film 204 is formed by inserting the mixture film between the welding film and the heat-resistant film like the ink sealing film 430 shown in FIG. 4 in the present embodiment, the configuration is not limited to it.
[0035] FIG. 7 is a perspective view of the ink guide member 100 . The ink guide member 100 has a rectangular shape, and includes a plurality of cylindrical holder side connection units 102 at one end. The holder side connection units 102 are inserted to the conveying member communicating pores 220 of the cartridge holder 200 . The ink guide member 100 further includes a plurality of cylindrical head side connection units 104 at the other end. The head side connection units 104 are connected to the recording head unit 300 . The holder side connection units 102 and the head side connection units 104 are formed with the base 110 (to be described hereinafter) of the ink guide member 100 shown in FIG. 8 by two colors.
[0036] FIG. 8 is a sectional view of the cross direction of the ink guide member 100 . The ink guide member 100 includes a base 110 and the ink sealing film 120 . The base 110 is essentially made of the layer compound mixture material, and includes a plurality of slot units 112 a , which extend along the longitudinal direction and are spaced apart from each other. The ink sealing film 120 is welded to whole surface of the base 110 , and openings of the plurality of slot units 112 a are sealed to form a plurality of channel units 112 . As shown in FIG. 1 , the ink guide member 100 connects the recording head unit 300 to the cartridge holder 200 . The recording head unit 300 moves with the carriage 42 . For this reason, the ink guide member 100 needs to have flexibility. When forming the base 110 of the ink guide member 100 , the layer compound mixture material includes thermoplastic elastomer, for example, SEPS (polystyrene-polyethylene-polypropylene-polystyrene) polymer as the high molecular matter. In addition, although the ink sealing film 120 is formed by inserting the mixture film between the welding film and the heat-resistant film like the ink sealing film 430 shown in FIG. 3 and FIG. 4 in the present embodiment, the configuration is not limited to it.
[0037] FIG. 11 is an expanded sectional view in which the cross section of the base 110 is expanded to illustrate the outline of its configuration. FIG. 11 illustrates the base 110 being cut in the thickness direction along the longitudinal direction of the base 110 . For purposes of description, scale of the inorganic layer compounds 142 is magnified in the Figure.
[0038] The base 110 shown in FIG. 11 includes an central layer 132 including a inorganic layer compound 142 and a high molecular compound 140 , and the surface layers 130 and 134 arranged on surfaces of the central layer 132 . The central layer 132 and the surface layers 130 and 143 are formed by extruding the layer compound mixture material, which is a mixture of the inorganic layer compound 142 and the high molecular compound 140 , towards a predetermined direction. In FIG. 11 , the direction of the extrusion is right (or left) direction. By the force of the extrusion, the inorganic layer compound 142 is aligned along the direction of the extrusion of the central layer 132 . Thereby, the inorganic layer compound 142 can be densified in a direction perpendicular to the direction of the extrusion. Therefore, in the base 110 , the amount of the ink solvent and atmospheric air passing in the direction perpendicular to the direction of the extrusion (the vertical direction in FIG. 11 ) can be lessened.
[0039] At the time of the extrusion molding, the high molecular compound 140 in the surfaces being in contact with open air is cured faster than a central area. In this case, since the high molecular compound 140 is cured from the front surfaces towards the center pushing the inorganic layer compound 142 to the central area, the surface layers 130 and 134 are essentially made of the high molecular compound 140 which do not include the inorganic layer compound 142 . Therefore, the surface layers 130 and 134 which do not include the inorganic layer compound 142 and the central layer 132 which includes the inorganic layer compound 142 can be formed unitedly and easily. Moreover, since the central layer 132 and the surface layers 130 and 134 are unitedly formed including the same high molecular compound 140 , peeling between these layers can be prevented.
[0040] The above-mentioned surface layers 130 and 134 prevent peeling of the inorganic layer compounds 142 provided in the central layer 132 . Thereby, even if the base 110 is flexed, the peeling of the inorganic layer compound 142 on its front surfaces can be prevented. Moreover, since the inorganic layer compound 142 does not appear on the front surfaces of the base 110 , the inorganic layer compound 142 can be prevented from hooking other components on the front surfaces of the base 110 .
[0041] FIG. 9 is an exploded perspective view of the recording head unit 300 . The recording head unit 300 includes a joint member 302 , a base member 304 , and a head body 306 . The head body 306 ejects the ink onto the recording medium 11 shown in FIG. 2 according to the signal input from the body of the ink-jet recording apparatus 10 . The base member 304 holds the head body 306 , and supplies ink to the head body 306 .
[0042] The joint member 302 includes a sealing film 320 , which is welded to the whole surface of the connection base 310 , and the connection base 310 . The connection base 310 has a plurality of conveying member connection unit 312 , head side connection units 314 , and a plurality of channel grooves 316 . The conveying member connection unit 312 is exposed from film ports 322 formed in the sealing film 320 , and receives a plurality of kinds of ink respectively by inserting the head side connection units 104 of the ink guide member 100 . Sealing of the head side connection units 314 is accomplished by the sealing film 320 , and it is connected to the base member 304 and supplies the plurality of kinds of ink to the base member 304 , respectively. The channel grooves 316 guides the plurality of kinds of ink received by the conveying member connection units 312 to the head side connection units 314 , respectively. The connection base 310 is essentially formed of the layer compound mixture material. When forming the connection base 310 , the layer compound mixture material includes the polyphenylene ether resin as the high molecular matter. The composition of the sealing film 320 is similar to the ink sealing film 430 shown in FIGS. 3 and 4 except for the composition of the welding film 432 . In the sealing film 320 , a layer corresponding to the welding film 432 is essentially made of the material similar to polyphenylene ether resin. However, it should be noted that the sealing films 320 is not limited to it.
[0043] FIG. 10 is a flowchart illustrating a manufacturing process of the bottom case 410 and the top case 420 of the ink cartridge 400 , the plate-like member 202 of the cartridge holder 200 , and the base 110 of the ink guide member 100 . First, the pellet of the layer compound mixture material, which is the mixture of the inorganic layer compound and the high molecular matter, is prepared (S 10 ). Then, the pellet is melted (S 20 ), and placed into a die. Then, the bottom case 410 , the top case 420 , the plate-like member 202 , and the base 110 are ejection molded (S 30 ). In this way, the bottom case 410 , the top case 420 , the plate-like member 202 , the base 110 , and the connection base 310 can be formed by ejection molding.
[0044] As mentioned above, as for the ink-jet recording apparatus 10 , since the bottom case 410 and the top case 420 of the ink cartridge 400 , the plate-like member 202 of the cartridge holder 200 , and the base 110 of the ink guide member 100 are essentially made of the layer compound mixture material, which is the mixture of the inorganic layer compound (e.g., montmorillonite) and the high molecular matter, it is hard for the atmospheric air to dissolve into the ink. For this reason, gas ejection from the recording head unit 300 instead of the ink, or so called “dot defect”, is reduced, and even if it performs continuation recording, recording quality does not deteriorate so easily. Moreover, frequency of ink ejection for the restoration from the dot defect, i.e., frequency of cleaning, is reduced. Therefore, the quantity of the ink that is used for the recording purpose can be increased. Moreover, since the ink solvent cannot evaporate easily until the ink reaches the recording head unit 300 , the viscosity of the ink does not increase so easily.
[0045] Moreover, as for the member conventionally formed by the ejection molding, it can be manufactured by the same process as the former method except that the process of making the layer compound mixture material is added. Therefore, the increase in manufacturing cost is avoidable.
[0046] In addition, the ink-jet recording apparatus 10 is an example of a liquid ejection apparatus. Moreover, the ink cartridge 400 is an example of an ink accommodating container, and the recording head unit 300 is an example of a liquid ejection unit. However, the liquid ejection apparatus is not limited to it. Other examples of a liquid ejection apparatus are a color filter manufacturing apparatus for manufacturing a color filter of a liquid crystal display. In this case, the cartridge accommodating coloring material is an example of a liquid accommodating container. Yet another example of the liquid ejection apparatus is an electrode forming apparatus for forming electrodes of an organic EL display, an FED (field luminescence display), and the like. In this case, a cartridge accommodating electrode material (conduction paste) of the electrode forming apparatus is an example of the liquid accommodating container. Yet another example of the liquid ejection apparatus is a biochip manufacturing apparatus for manufacturing a biochip. In this case, the cartridge of the biochip manufacturing apparatus accommodating organic substance and a sample is an example of the liquid accommodating container. The liquid ejection apparatus of the present invention further includes another liquid ejection apparatus having an industrial application. The recording medium is an object onto which the recording is performed by ejecting the liquid, and includes a circuit board on which circuit patterns such as display electrodes are formed, a CD-ROM on which a label is printed, and a prepared slide on which a DNA circuit is recorded, as well as the recording paper.
[0047] Although the present invention has been described by way of exemplary embodiments, it should be understood that those skilled in the art might make many changes and substitutions without departing from the spirit and the scope of the present invention which is defined only by the appended claims.
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The liquid ejection apparatus is capable of reducing the increase of the viscosity of a liquid due to evaporation of the liquid and also for reducing the quantity of the atmospheric air dissolving into the ink. A liquid seal used for a liquid ejection apparatus which performs recording by ejecting a liquid, at least a part of the liquid seal is formed from a layer compound mixture material including a high molecular compound and an inorganic layer compound. The liquid seal seals the liquid. For example, the liquid seal is an ink cartridge accommodating the liquid therein, or an ink guide member for supplying the ink in the ink cartridge to a recording head unit.
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[0001] This is a divisional of application Ser. No. 10/228,965 filed Aug. 28, 2002. The entire disclosure of the prior application, application Ser. No. 10/228,965 is considered part of the disclosure of the accompanying divisional application and is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to a fluxgate sensor, and more particularly, to a fluxgate sensor integrated in a printed circuit board and a manufacturing method thereof. The present application is based on Korean Patent Application No. 2002-13524, filed Mar. 13, 2002, which is incorporated herein by reference.
[0004] 2. Description of the Prior Art
[0005] Existence of magnetic energy has been proven through various physical phenomena, and a fluxgate sensor enables a human to indirectly perceive the magnetic energy, as it is unperceivable to human sense organs such as eyes and ears. As for the fluxgate sensor, a magnetic sensor employing a soft magnetic coil has been used for a long time. The magnetic sensor is made by winding a coil around a relatively large bar-shaped core or an annular core formed of a soft magnetic ribbon. Also, an electronic circuit is employed to obtain a magnetic field in proportion to the measured magnetic field.
[0006] The conventional fluxgate sensor, however, has the following problems. That is, due to the structure of the conventional fluxgate sensor in which the coil is wound around the large bar-shaped core or the annular core made of the soft magnetic ribbon, production costs are high, and the volume of the overall system is large. Also, flux leakage is inevitable in the flux change due to the excitation coil and the detected magnetic field. Accordingly, high sensitivity cannot be guaranteed.
SUMMARY OF THE INVENTION
[0007] The present invention has been made to overcome the above-mentioned problems of the prior art. Accordingly, it is an object of the present invention to provide a high sensitivity fluxgate sensor integrated in a printed circuit board which is capable of not only reducing overall volume of a system, but also detecting a magnetic field with more accuracy, and a manufacturing method for manufacturing such a high sensitive fluxgate sensor.
[0008] Another object of the present invention is to prevent an induction wave in a flux change detecting coil when the external magnetic field is measured as zero (0).
[0009] The above objects are accomplished by a fluxgate sensor according to the present invention, comprising: a soft magnetic core formed on a printed circuit board to form a closed-magnetic path; an excitation coil formed as a metal film wound around the soft magnetic core; and a pick-up coil formed as a metal film formed on the excitation coil, winding the soft magnetic core.
[0010] The soft magnetic core is formed as two bars that are placed on the same plane in parallel relation. The bars are positioned such that the length of the bars lies in the direction of magnetic field detection. Alternatively, the soft magnetic core can also be formed as a rectangular-ring. Like the bar-type soft magnetic core, the rectangular-ring type core is also positioned such that its length lies in the direction of magnetic field detection.
[0011] The excitation coil can have a structure of alternately winding the two bar-type soft magnetic cores substantially in a number ‘8’ pattern.
[0012] Alternatively, the excitation coil can also have a structure of winding the two bar-type soft magnetic cores, respectively, and substantially in a solenoid pattern.
[0013] When the soft magnetic core is formed as the rectangular-ring, the excitation coil can alternately wind two longer sides of the rectangular-ring type soft magnetic core in the direction of magnetic field detection either altogether or respectively, and substantially in a number ‘8’ pattern.
[0014] The excitation coil can wind the two bar-type soft magnetic cores or the two longer sides of the rectangular-ring type soft magnetic core in the direction of magnetic field detection altogether and substantially in a number ‘8’ pattern, or wind the two bar-type soft magnetic cores or the two longer sides of the rectangular-ring type soft magnetic core, respectively, and in the solenoid pattern, and the pick-up coil is mounted on such excitation coil, having a structure of winding the two bar-type soft magnetic cores or the two longer sides of the rectangular-ring type soft magnetic core altogether and substantially in a solenoid pattern. Alternatively, the excitation coil can wind the two bar-type soft magnetic cores or the two longer sides of the rectangular-ring type soft magnetic core in the direction of magnetic field detection altogether and substantially in a number ‘8’ pattern, or wind the two bar-type soft magnetic cores of the two longer sides of the rectangular-ring type soft magnetic core, respectively, in a solenoid pattern, while the pick-up coil has a structure mounted on such excitation coil, having a structure of winding the two bar-type soft magnetic cores or the two longer sides of the rectangular-ring type soft magnetic core, respectively, and substantially in a solenoid pattern.
[0015] The above objects are also accomplished by a manufacturing method of a fluxgate sensor according to the present invention, including the steps of: bonding a prepreg and a soft magnetic film on a first metal plate; forming a soft magnetic core by etching the soft magnetic film; forming a first substrate by bonding a prepreg and a second metal plates on an upper portion of the soft magnetic core; forming first via holes in the first substrate, at locations distanced from one and the other sides of the soft magnetic core; metal-plating the first via hole; forming an excitation coil on both surfaces of the substrate by etching; forming a second substrate by bonding a prepreg and third metal plates on an both portions of the excitation coil; forming second via holes in the second substrate, corresponding to the first via holes; metal-plating the second via holes; forming a pick-up coil by etching both surfaces of the second substrate; forming a third substrate by bonding a prepreg and fourth metal plates on both portions of the pick-up coil; and forming a pad for an electrical conductivity, by etching both surfaces of the third substrate.
[0016] Preferably, further provided is the step of forming a pattern for the respective components of the fluxgate sensor prior to forming the components, with a photosensitive paint and an exposure. Also provided is the step of metal-plating the pad with gold.
[0017] According to the present invention, by forming a soft magnetic core along a direction of detection, counter-magnetic properties can be reduced, while there is no induction wave in a flux change detecting coil due to the structure in which a pick-up coil is mounted on an excitation coil that is wound around the soft magnetic core.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above-mentioned objects and the feature of the present invention will be more apparent by describing the preferred embodiments of the present invention by referring to the appended drawings, in which:
[0019] FIG. 1 is a conceptual diagram showing a conventional fluxgate sensor;
[0020] FIGS. 2A through 2F are waveforms for illustrating the operation of the fluxgate sensor of FIG. 1 ;
[0021] FIGS. 3A through 3M are sectional views taken along line I-I of FIG. 1 , showing a manufacturing process of the fluxgate sensor;
[0022] FIG. 4A is a plan view showing two bar-type soft magnetic cores arranged on a same plane in parallel relation, and an excitation coil of the united structure winding the two bar-type soft magnetic cores altogether substantially in a number ‘8’ pattern;
[0023] FIG. 4B is a plan view showing a pick-up coil being formed on the two bar-type soft magnetic cores of FIG. 4A substantially in a solenoid pattern;
[0024] FIG. 4C is a plan view showing a soft magnetic core of a rectangular-ring shape arranged on a same plane, and an excitation coil of the united structure winding the rectangular-ring type soft magnetic coil;
[0025] FIG. 4D is a plan view showing a pick-up coil being arranged on the soft magnetic core of FIG. 4C substantially in a solenoid pattern;
[0026] FIG. 5 is a typical diagram showing a fluxgate sensor integrated in a printed circuit board according to a second preferred embodiment of the present invention;
[0027] FIG. 6A is a plan view showing two bar-type soft magnetic cores placed on a same plane in parallel relation, and an excitation coil of the separated structure winding the two bar-type soft magnetic cores, respectively;
[0028] FIG. 6B is a plan view showing a pick-up coil winding the two bar-type soft magnetic cores of FIG. 6A substantially in a solenoid pattern;
[0029] FIG. 6C is a plan view showing a rectangular-ring type soft magnetic core placed on a same plane, and an excitation coil of the separated structure winding the two longer sides of the rectangular-ring type soft magnetic core, respectively; and
[0030] FIG. 6D is a plan view showing a pick-up coil winding the two longer sides of the rectangular-ring type soft magnetic core of FIG. 6C substantially in a solenoid pattern.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] From now on, the present invention will be described in greater detail by referring to the appended drawings.
[0032] FIG. 1 is a conceptual view showing a conventional fluxgate sensor integrated into a printed circuit board. Although preferred embodiments of the present invention may have the same conceptual structure of the conventional fluxgate sensor shown in FIG. 1 , the method of manufacture and physical structure of the fluxgate sensor according to the preferred embodiments of the present invention differ from that of the conventional fluxgate sensor. The fluxgate sensor has a first and a second bar-type soft magnetic cores 1 and 2 with an excitation coil 3 being wound around the first and second bar-type soft magnetic cores 1 and 2 substantially in the pattern of number ‘8’, and a pick-up coil 4 wound around the excitation coil 3 , the first and second bar-type soft magnetic cores 1 and 2 .
[0033] Hereinafter, the winding structure, in which a coil is wound around the two bar-type soft magnetic cores altogether in the number ‘8’ pattern, will be called a ‘united structure’. And the same winding structure on the rectangular-ring type soft magnetic core according to the second preferred embodiment will also be called a ‘united structure’. Meanwhile, the winding structure having a coil that winds the two bar-type soft magnetic cores, respectively, or that winds the two longer sides of a rectangular-ring type soft magnetic core, respectively, will be called a ‘separated structure’.
[0034] FIGS. 2A through 2F are timing views for explaining the operation of the fluxgate sensor of FIG. 1 . FIG. 2A is a waveform of a magnetic field generated from a first soft magnetic core 1 , FIG. 2B is a waveform of a magnetic field generated from a second soft magnetic core 2 , FIG. 2C is a waveform of a flux density generated from the first soft magnetic core 1 , FIG. 2D is a waveform of a flux density generated from the second soft magnetic core 2 , and FIGS. 2E and 2F are waveforms for respectively showing first and second induction voltages Vind 1 and Vind 2 induced at the pick-up coil, and a sum of adding the first and second induction voltages Vind 1 +Vind 2 .
[0035] With the excitation coil 3 winding the first and second bar-type soft magnetic cores 1 and 2 altogether in the pattern of number ‘8’ ( FIG. 1 ), and with the supply of AC excitation current, the internal magnetic field (Hext+Hexc) and the flux density (Bext+Bexc) at the first bar-type soft magnetic core 1 and the internal magnetic field (Hext−Hexc) and the flux density (Bext−Bexc) at the second bar-type soft magnetic core 2 act in opposite directions (See FIGS. 2A, 2B , 2 C, 2 D). Here, Hext is the external magnetic field, Hexc is the magnetic field by excitation coil, Bext is the flux density by external magnetic field and Bexc is the flux density by the excitation coil. The pick-up coil 4 is wound to gain the sum of the flux generated from each of the first and second bar-type soft magnetic cores 1 and 2 , and detects the changes in the flux by the electronic induction by the AC excitation current. Since the internal magnetic fields of the first and second bar-type soft magnetic cores 1 and 2 are in opposite directions, the induction voltage detected at the pick-up coil 4 is the result of offsetting the two symmetrically generated induction voltages Vind 1 and Vind 2 ( FIG. 2F ). More specifically, since the external magnetic field Hext is applied to the first and second bar-type soft magnetic cores 1 and 2 in the same direction, the internal magnetic fields of the first and second cores 1 and 2 are Hext+Hexc and Hext−Hexc. At this time, as shown in FIG. 2E , voltages Vind 1 and Vind 2 are induced at the pick-up coil 4 , and the magnitude of the external magnetic field Hext is obtained by detecting the sum of such induction voltages Vind 1 and Vind 2 .
[0036] As it could be noted from the above, regarding the construction of the fluxgate sensor integrated into the printed circuit board, it is most important to have the appropriate bonding structure of the excitation coil 3 having the united structure in a number ‘8’ pattern, and the pick-up coil 4 winding the first and second bar-type soft magnetic cores 1 and 2 in a solenoid pattern, to have the sum of the flux changes in the first and second bar-type soft magnetic cores 1 and 2 . Here, the pick-up coil 4 can also be formed on the excitation coil 3 , separately winding the first and second bar-type soft magnetic cores 1 and 2 . This is because the structure of the fluxgate sensor described above offsets the induction waves of the magnetic field generated from the first and second bar-type soft magnetic cores 1 and 2 in the absence of the external magnetic field Hext, with the flux generated by the excitation coil forming a closed-magnetic path at the first and second bar-type soft magnetic cores 1 and 2 .
[0037] Meanwhile, the soft magnetic cores of FIG. 1 can take the form of a rectangular-ring. And this can also provide the same benefit as the bar-type soft magnetic cores, with the structure of the excitation coil winding the two longer sides of the rectangular-ring type soft magnetic core in the number ‘8’ pattern, and the pick-up coil winding the two longer sides in a solenoid pattern. Alternatively, the pick-up coil can be wound around the two longer sides of the rectangular-ring, separately.
[0038] The detection of magnetic field is also possible by the structure of a single bar-type soft magnetic core being arranged with the excitation coil and the pick-up coil. This case, however, requires more complicated signal processing of the output from the detecting coil like amplification and filtering, because there are induction voltage waves generated at the detection coil by the larger excitation coil even in the absence of the external magnetic field. Accordingly, using the two bar-type soft magnetic cores, or a single rectangular-ring type core will provide more advantages especially in terms of signal processing requirements.
[0039] FIGS. 3A through 3M are views taken on line I-I of FIG. 1 , showing the processes of mounting the fluxgate sensor in the printed circuit board.
[0040] First, a prepreg 22 and a soft magnetic film 24 are bonded on a first copper foil 21 ( FIG. 3A ). Then, by using a photosensitive paint 28 and an exposure, a pattern for the soft magnetic cores 1 and 2 is formed ( FIG. 3B ). Then, by subjecting the soft magnetic film 24 to an etching process using the photosensitive paint 28 , the soft magnetic cores 1 and 2 are shaped ( FIG. 3C ). The soft magnetic cores 1 and 2 are formed such that the length thereof is in the direction of the magnetic field detection. Next, a prepreg 25 and a copper foil 26 are bonded on the upper portion of the first and second soft magnetic cores 1 and 2 ( FIG. 3D ). Then, by drilling, first via holes 27 are formed through a first substrate consisting of the first and the second soft magnetic cores 1 and 2 , with the first soft magnetic core 1 and the second soft magnetic core 2 positioned therebetween, respectively ( FIG. 3E ), and then the walls of the first via holes 27 are metal-plated ( FIG. 3F ). After that, by using a photosensitive paint 28 and exposure on both sides of the external copper foil, an excitation coil pattern is formed ( FIG. 3G ). Then the excitation coil wiring is formed by subjecting the copper foil 26 to an etching process using the photosensitive paint ( 3 H). The excitation coil is formed to have the united structure, winding the first and second soft magnetic cores 1 and 2 altogether substantially in a number ‘8’ pattern. Then a prepreg 29 and a copper foil 30 are attached to both sides of the excitation coil ( FIG. 3I ). Next, second via holes 31 are formed in correspondence to the first via holes 27 , and the walls of the second via holes 31 are metal-plated. Then a pick-up coil wiring is formed using the photosensitive paint and an exposure ( FIG. 3J ). The pick-up coil 4 has a structure formed on the excitation coil, winding the first and second bar-type soft magnetic cores 1 and 2 altogether and substantially in the solenoid pattern. Then, a prepreg 32 and a copper plate 33 are attached ( FIG. 3K ), and a pad 34 is formed through the exposure and etching for conductivity with the outside ( FIG. 3L ). The copper pad 34 is metal-plated with gold 35 ( FIG. 3M ).
[0041] FIGS. 4A and 4B are plan views of the fluxgate sensor on the printed circuit board according to the first preferred embodiment of the present invention. FIG. 4A is a plan view showing the two bar-type soft magnetic cores placed on the same plane in parallel relation, with the excitation coil of the united structure winding the two bar-type soft magnetic cores altogether, and FIG. 4B is a plan view showing the pick-up coil being wound around the soft magnetic cores substantially in the solenoid pattern. FIG. 4C is a plan view showing a rectangular-ring type soft magnetic core placed on the same plane, with the excitation coil of the united structure winding the rectangular-type soft magnetic core, and FIG. 4D is a plan view showing the pick-up coil formed on the rectangular-ring type soft magnetic core of FIG. 4C substantially in a solenoid pattern.
[0042] FIG. 5 is a view showing the fluxgate sensor integrated in the printed circuit board according to the second preferred embodiment of the present invention. In the fluxgate sensor, there are first and second bar-type soft magnetic cores 1 and 2 placed in parallel with each other, and an excitation coil 3 is separately wound around each of the first and second soft magnetic cores 1 and 2 . In other words, the excitation coil 3 has the separated structure. A pick-up coil 4 is wound on the excitation coil 3 , around the first and second bar-type soft magnetic cores 1 and 2 altogether. Alternatively, the pick-up coil 4 can be wound on the excitation coil 3 , winding the first and second bar-type soft magnetic cores 1 and 2 , respectively.
[0043] Meanwhile, the soft magnetic cores can take the form of a rectangular-ring, and in this case, the excitation coil 3 can separately wind the two longer sides of the rectangular-ring type soft magnetic core in the direction of magnetic field detection, and the pick-up coil 4 is wound around the two longer sides of the rectangular-ring type soft magnetic core altogether and substantially in the solenoid pattern, to achieve the same benefit of induction voltage offset. Alternatively, the pick-up coil 4 can be separately wound around the two longer sides of the rectangular-ring type soft magnetic core in the solenoid pattern.
[0044] Here, the induction voltage detected at the pick-up coil 4 according to the second embodiment is similar to the induction voltage detected at the excitation coil of the united structure according to the first embodiment, i.e., the same benefit of offsetting of induction voltage when the external magnetic field is zero (0) is expected in both of the first and second embodiments.
[0045] FIGS. 6A and 6B are plan views showing the fluxgate sensor in the printed circuit board according to the second preferred embodiment of the present invention. FIG. 6A is a plan view showing two bar-type soft magnetic cores placed on a same plane in parallel relation, and an excitation coil of the separated structure formed on the two soft magnetic cores, and FIG. 6B is a plan view showing a pick-up coil formed on the soft magnetic cores substantially in the solenoid pattern. FIG. 6C is a plan view showing a rectangular-ring type soft magnetic core, with an excitation coil of the separated structure being formed on the rectangular-ring type soft magnetic core, and FIG. 6D is a plan view showing a pick-up coil being formed on the rectangular-ring type soft magnetic core substantially in the solenoid pattern.
[0046] The fluxgate sensor described above can be used in various applications, like navigation system by terrestrial magnetism detection, earth magnetism change monitor (earthquake prediction), biological electric measurement, and defect detection in metals. As for the indirect applications, the fluxgate sensor can also be used in a magnetic encoder, contactless potentiometer, electric current sensor, torque sensor, and displacement sensor.
[0047] With the fluxgate sensor, which can be integrated in the printed circuit board together with other sensors and circuits, the overall size of a system is reduced greatly. Also, as the voltages induced from the respective cores of sides are driven variably, sensitivity is kept high to detect even a weak external magnetic field.
[0048] Also, as the fluxgate sensor according to the present invention can be produced at a cheaper price than the bar-type soft magnetic cores or annular cores, mass-production is enabled.
[0049] Although the preferred embodiments of the present invention have been described, it will be understood by those skilled in the art that the present invention should not be limited to the described preferred embodiments, but various changes and modifications can be made within the spirit and scope of the present invention as defined by the appended claims.
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A fluxgate sensor is integrated in a printed circuit board. The fluxgate sensor has two bar-type (or rectangular-ring shaped) soft magnetic cores to form a closed magnetic path on a printed circuit board and an excitation coil in the form of a metal film is wound around the two bar-type soft magnetic cores either in a united structure that winds the two bar-type soft magnetic cores altogether, or in a separated structure that winds the two bar-type soft magnetic cores respectively, both in a pattern of number ‘8’. A pick-up coil is mounted on the excitation coil, either winding the two bars altogether, or respectively, in a solenoid pattern. The fluxgate sensor integrated in the printed circuit board can be mass-produced at a cheap manufacturing cost. The fluxgate sensor also can be made compact-sized, and at the same time, is capable of forming a closed-magnetic path. As a result, flux leakage is minimized, and the fluxgate sensor has a high sensitivity as it detects the magnetic field through a variable driving.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a microminiature electron source having a vacuum chamber for emitting electrons, the vacuum chamber being disposed at the distal end of a flexible coaxial cable. The microminiature electron source in accordance with the present invention is capable of instantly supplying high peak pulsed power to generate electrons. Because of this feature, the microminiature electron source finds extensive use in the field of medical diagnoses and treatment, including treatment of coronary restenosis, intravascular radiotherapy and cancer therapy, the industrial field, including nondestructive inspection and electron beam irradiation, the field of researches, and the field of microwave electron tubes.
2. Description of the Related Art
Currently, it is said that there are more than 500,000 patients requiring radiotherapy and radiation treatment in the world a year. As a radiation source having a diameter of 2 mm or less, a gamma ray source of cesium or iridium, or a needle or a rod filled with a liquid containing radioactive substance is nowadays being used for medical treatment. The conventional radiotherapy places heavy burdens on both patients and the persons involved in medical treatment. The radiation source employing the radioactive substance constantly emits radioactive rays. Hence, during a preparatory step implemented to locate an affected area of a patient body to be irradiated, a non-affected area will be inevitably irradiated before the patient is subjected to actual medical treatment. This means that extremely complicated handling and high risk have been always involved in the medical treatment, thus further burdening doctors. Accordingly, there have been demands for the development of a small electron medical treatment system that provides high medical treatment effect, causes less burdens on patients, and requires lower total cost.
There has been proposed a pulse X-ray generator using a coaxial line, an electrode, and a target for emitting electrons, although it is not intended for medical treatment (Japanese Examined Patent Application Publication No. 60-20865). The X-ray generator having the coaxial cable uses an inert gas, such as helium, charged in the space between a cold cathode and the target that emits X rays. However, a very small quantity of oxygen gas ions or the like, which are impurities, contained in the inert gas severely collide against the cold cathode, adversely affecting the durability of the cold cathode. Furthermore, since it is not designed for medical treatment, it is bulky as a whole, making it impossible to use it as a radiation source for medical treatment by inserting it into blood vessels, lumens of a body, or tubes.
The inventor has proposed a microminiature X-ray generator (Japanese Patent No. 3090910), which has been achieved by further reducing the size of the foregoing pulse X-ray generator and which generates X rays under the application of high-voltage pulses. The microminiature X-ray generator is considerably advantageous in that no high voltage is applied to generate X rays until an X-ray generating unit is set and ready, thus making it possible to avoid unwanted irradiation to non-affected tissues of a patient body or medical personals involve the treatment.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to improve an electron source used with the foregoing microminiature X-ray generator so as to provide a microminiature microwave electron source that features greater ease of operation and finds further expanded application fields.
In order to achieve the above objections, a microminiature microwave electron source excited by a pulsed microwave power through a coaxial cable to emit electrons according to the present invention includes an electrically conductive cylindrical chamber that is connected to an external conductor of the coaxial cable, and has an opening anode in a bottom portion thereof; a central conductor that has one end thereof connected to a central conductor of the coaxial cable, a cathode formed on the other end thereof being supported by the chamber such that the cathode opposes the anode; and connecting means for electrically and mechanically connecting a chamber assembly comprising a resonator constituted by the chamber and the central conductor with the coaxial cable.
In the microminiature microwave electron source according to the present invention, the cathode is an electric field radiating cold cathode.
In the microminiature microwave electron source according to the present invention, the cold cathode is formed using a carbon nanotube.
In the microminiature microwave electron source according to the present invention, the carbon nanotube is disposed at the center of a distal end of the central conductor, and surrounded by a Welnelt electrode.
In the microminiature microwave electron source according to the present invention, the chamber operates as a resonator of (4/λ) (2n+1) with respect to a microwave.
In the microminiature microwave electron source according to the present invention, the connecting means removably connects the coaxial cable and the chamber by a screw or sliding sleeve fit.
In the microminiature microwave electron source according to the present invention, a flange is provided at a proximal portion of the central conductor in the chamber, and the flange is secured to the chamber through the intermediary of a coupling iris and constitutes an impedance converter for matching a line impedance of the coaxial cable and an impedance of the resonator of the chamber.
In the microminiature microwave electron source according to the present invention, the opening anode of the chamber assembly has a hermetic window that allows an electron beam to pass therethrough so as to directly irradiate a target by the electrons that have passed through the hermetic window.
In the microminiature microwave electron source according to the present invention, the opening anode of the chamber assembly is connected to another vessel having vacuum space.
In the microminiature microwave electron source according to the present invention, the vacuum space of another vessel is connected to the opening anode of the chamber assembly through the intermediary of a beam collimator.
In the microminiature microwave electron source according to the present invention, another vessel having the vacuum space is an electrode vessel of an RF gun, a linear accelerator, a TWT or a klystron.
In the microminiature microwave electron source according to the present invention, the vacuum space of another vessel is an X-ray generating chamber, comprising an X-ray target, which opposes the anode opening, and an X-ray radiation window, thus making the microminiature microwave electron source applicable for radiating X rays.
In the microminiature microwave electron source according to the present invention, the microminiature microwave electron source is a microminiature X-ray source intermittently driven by microwave bursts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view illustrating a chamber and a coaxial cable of a microminiature electron source in accordance with an embodiment of the present invention.
FIG. 2 is a schematic construction diagram showing the microminiature electron source.
FIG. 3 is a schematic diagram illustrating the distribution of an electromagnetic field in the chamber of the microminiature electron source.
FIG. 4 is a graph showing the distribution of the intensity of the electromagnetic field in a cavity of the microminiature electron source.
FIG. 5 is a diagram showing an equivalent circuit of the chamber of a transmission line of the microminiature electron source.
FIG. 6 is a circuit diagram showing a driving circuit of a microminiature electron source in accordance with the present invention.
FIG. 7 is an enlarged sectional view showing a chamber of a microminiature electron source equipped with a collimator in accordance with an embodiment of the present invention.
FIG. 8 is an enlarged sectional view showing a microminiature electron source in accordance with an embodiment of the present invention that is coupled to another vacuum specimen chamber.
FIG. 9 is an enlarged sectional view showing a microminiature electron source in accordance with an embodiment of the present invention that is coupled to a microwave cavity of an RE gun.
FIG. 10 is an enlarged sectional view showing a microminiature electron source for generating X rays in accordance with an embodiment of the present invention that is coupled to an X-ray generating dome.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a microminiature microwave electron source in accordance with the present invention will be described primarily with reference to the accompanying drawings.
FIG. 1 is an enlarged sectional view illustrating a microminiature electron source in accordance with an embodiment of the present invention. A chamber assembly Ch is in connection with a coaxial assembly Co. The microminiature electron source emits electrons excited by microwaves supplied from a driving circuit through a coaxial cable. A chamber 2 has substantially the same diameter as that of an external conductor 14 of the coaxial cable. The chamber assembly Ch is detachably connected to the distal end of the coaxial cable through the intermediary of a connecting device.
The chamber 2 is electrically conductive and cylindrically shaped, having an opening at the center of its bottom (distal end). The neighborhood area of the opening projects into the cylindrical cavity to form an anode 6 . A window 7 formed of titanium or silicone is provided on the outer side of the opening. The window 7 maintains the vacuum inside the chamber and transmits electrons. A carbon nanotube 4 constituting a cold cathode is provided at the distal end of a central conductor 1 disposed at the center of the chamber 2 . The periphery of the carbon nanotube 4 is provided with a Welnelt electrode 5 . A technology available for growing a carbon nanotube on a metal is used to grow the carbon nanotube at the distal end portion of the central conductor 1 in this embodiment.
In the embodiment, the Welnelt electrode 5 is secured to the central conductor 1 and maintained at the same potential as that of the cold cathode 4 . The proximal end of the central conductor 1 is provided with a flange 1 b and a connecting pin 1 a that is split at the distal end thereof. The central conductor 1 is supported at the center of the chamber 2 by a coupling iris 8 through the intermediary of the flange 1 b . A getter 9 forming a part of a coaxial resonator is disposed in the space in the chamber to maintain a vacuum.
The chamber 2 has a coupling screw 2 a at the opening end. The coupling end of the coaxial cable is provided with a connecting ring 16 , and a coupling female screw 16 a is disposed at the distal end of the connecting ring 16 , an external conductor 14 being coupled to the connecting ring 16 . Furthermore, a coupling hole is formed at the distal end of a central conductor 12 of the coaxial cable. An internal insulator 13 of the cable uses a foamy Teflon (PTFE) insulating material to maintain high performance against large power and high frequencies.
The coupling pin 1 a of the central conductor 1 of the chamber assembly Ch is aligned to the connecting hole at the distal end of the central conductor 12 of the coaxial assembly Co. At the opening end of the chamber assembly Ch, the coupling screw 2 a is attached to the coupling female screw 16 a of the connecting ring 16 of the coaxial assembly Co so as to join the chamber assembly Ch and the coaxial assembly Co into one piece. The external surfaces of the chamber 2 and the coaxial assembly Co are covered with films 3 and 15 , respectively, formed of an electrical insulant.
Referring now to FIG. 2 through FIG. 5, the electrical operation of the microminiature X-ray source will be described.
The microminiature transmission line constructed of the coaxial assembly Co used in the present invention is electrically coupled to the chamber 2 and the central conductor 1 of the chamber assembly Ch through the intermediary of a coupling iris 8 formed of a glass or ceramic constituent. FIG. 3 is a schematic diagram illustrating the electromagnetic field in the chamber assembly in accordance with the present invention. FIG. 4 is a graph showing the distribution of a cavity electromagnetic field in the chamber assembly. The circuit of the chamber 2 constitutes a resonance circuit for microwaves. If the wavelength of a microwaves is denoted as λ, then the length of the chamber will be substantially L=λ/4. As shown in FIG. 3, the distribution of the electromagnetic field of microwaves in the chamber is such that an electric field (E) 25 is generated from the central conductor 1 of the chamber 2 toward the surface of the external conductor 14 , and a magnetic field (H) 26 is generated around the axis of the central conductor 1 in the chamber at the chamber end of the glass or ceramic wall. Referring to FIG. 4, the intensity distribution of the electric field (E) 25 is such that the intensity grows higher toward the right of the chamber as observed facing the drawing, while the intensity distribution of the magnetic field (H) 26 grows higher toward the left. To produce electrons by the cold cathode, microwave power is used to produce a high voltage of about 50 kV to about 100 kV between a cold cathode 4 and the anode 6 .
FIG. 5 is an equivalent circuit for the transmission line or the coaxial cable and the chamber of the microminiature electron source in accordance with the present invention. The equivalent circuit is a distributed constant circuit wherein an impedance Z of the coaxial cable of the coaxial cable assembly Co is given by (L/C) 1/2 . In this embodiment, the impedance Z is set to 50Ω. The inner diameter portion of the coupling iris 8 formed of the glass or ceramic wall and the stepped portion of the flange 1 b provided on the central conductor 1 in the chamber (see FIG. 1) make up a microwave impedance transformer. The equivalent circuit is represented by a boosting transformer of 1:N. The equivalent circuit in the chamber will be a resonance circuit composed of Lc and Cc, and the equivalent shunt impedance of the circuit is denoted by Rsh. The equivalent shunt impedance Rsh is related to a loss of the resonance circuit. It is necessary to set the impedance Rsh output from a power amplifying circuit so that it coincides with the impedance Z=(L/C) 1/2 of a transmission circuit so as to efficiently transmit the power-amplified output power of a microwave oscillator to the transmission circuit.
The size of an iris is adjusted by the coupling iris 8 so as to adjust a value of the external Q of the coaxial assembly Qco=ωU/Pco, where Pco denotes the loss of a driver including the coaxial assembly, and U denotes stored energy in the chamber. Thus, all energy from the coaxial assembly can be supplied to the chamber or the resonator without reflection. In other words, the iris functions to adjust a mutual inductance M of coupling (see FIG. 5) so as to make the impedance of a power supply coincide with the impedance of a load.
FIG. 6 is a circuit diagram of a driving circuit of a microminiature electron source in accordance with the present invention.
The oscillating frequencies of a microwave oscillator 30 range from 3 to several tens of GHz. Preferably, higher frequencies are selected to make the apparatus smaller and also to increase the resistance to electric power. Use of microwaves provides an advantage in that high-voltage, high electric power can be transmitted by a smaller system without causing voltage breakdown of a dielectric of a transmission cable. Microwaves are modulated by a PIN diode modulator 31 using a pulse signal 36 for a modulator of 100 nsec to 1 μsec. In this way, successive microwave signals are converted into microwave signals that have been subjected to pulse modulation by the pulse signals. The pulse modulation permits accurate control of an average output of electron beams. The number of repetitions of the modulation pulse signals 36 is set to several hundreds of pulses per second. The modulated microwave signals are connected to branching filters 35 0 to 35 6 in three stages through the intermediary of a variable attenuator 32 , an amplifier 33 , and a circulator 34 0 . The outputs of branching filters 35 3 through 35 6 in the last stage are connected to chamber assemblies Ch 1 through Ch 8 through the intermediary of circulators 34 1 through 34 8 and coaxial cables Co 1 through Co 8 , and emitted in the form of electron beams. Electric power is connected to microminiature microwave electron sources through the intermediary of the circulators 34 1 through 34 8 , thus allowing the microminiature microwave electron sources to stably operate without being affected by other output load conditions.
In the present invention, the chamber 2 constitutes a hollow resonator. The shunt impedance of the hollow resonator is approximately 0.2 MΩ at an exciting frequency of 3 GHz. Therefore, an electron beam of about 100 kV power can be generated for a 50 kW input peak power.
The shunt impedance Rsh can be given by:
Rsh =(60π/δλ)[4 l 2 (ln( r 2 /r 1 )) 2 ]/[2ln( r 2 /r 1 )+1(1 /r 1 +1 /r 2 )]
where δ: Skin effect thickness
λ: Wavelength of microwave
l: Length of chamber
r 1 : Inner radius of central conductor
r 2 : Inner diameter of chamber
g: Length of gap (Distance from the distal end of the central conductor to the anode)
If gap length g is sufficiently smaller than chamber length l, then g may be ignored, as shown in the above expression.
If the voltage of a microwave signal applied between the anode 6 and the cold cathode 4 is set to several hundreds of kilovolts, then the instantaneous power (peak power), which is represented by P=V 2 /Rsh, will be approximately 50 kW. If the width of a modulation pulse is set to 1 μsec and a pulse repetition cycle is set to 100 pulses per second, then the workload (W*SEC) will be approximately 5W*SEC. Thus, the instantaneous power makes it possible to generate an extremely powerful electron beam. A temperature rise in the chamber, however, is minimized because the workload per second is relatively small due to the intermittent operation of an electron gun by microwave bursts.
FIG. 7 is an enlarged sectional view illustrating a chamber of a microminiature electron source equipped with a collimator according to an embodiment of the present invention. This embodiment does not have the window 7 for electron beams of the embodiment shown in FIG. 1, while it has a collimator 20 whose one end is connected to the anode 6 . Like reference numerals will be assigned to like components as those of the embodiment set forth above, and the descriptions thereof will be omitted. The other end of the collimator 20 is connected to a vacuum vessel, such as a microwave electron tube. The chamber is used as the electron source of such an electron tube to supply collimated electron streams.
FIG. 8 is an enlarged sectional view showing a microminiature electron source according to an embodiment of the present invention that is coupled to another vacuum chamber 21 . As in the case of the embodiment shown in FIG. 7, this embodiment does not have the window for emitting electron beams. In the vacuum chamber 21 , a specimen 22 is disposed. Electron beams are applied to the specimen 22 mainly to study the material, the physical properties, and the chemical properties of the specimen.
FIG. 9 is an enlarged sectional view showing a microminiature electron source according to an embodiment of the present invention that is coupled to a microwave cavity of an RF gun. A chamber 2 of the microminiature microwave electron source in accordance with the present invention is hermetically fixed at an electron receiving opening of the RF gun. Microwave energy is supplied to the chamber 2 through a coaxial cable Co. The electrons emitted from a cathode at the distal end of a central conductor 1 turn into a further accelerated bunch beam 24 . The chamber 2 functions as a cavity of λ/4 with respect to microwaves. With this arrangement, the cathode in the chamber is effectively protected against back bombardments by adjusting the distance of chamber 2 and RF gun cavity 23 . The microminiature microwave electron source in accordance with the present invention can be used as the electron source for other microwave electron tubes, such as a klystron, an accelerator, and a TWT, in addition to the RF gun mentioned above. In these microwave electron tubes also, the cathode will be protected from back bombardments while providing bunched electron beams to microwave electron tubes.
FIG. 10 is an enlarged sectional view showing a microminiature electron source for generating X rays according to an embodiment of the present invention. The microminiature electron source is coupled to an X-ray generating dome. An accelerated electron beam that has passed through an anode 6 hits an X-ray target 41 supported by an X-ray generating dome 40 serves for cooling target 41 , so as to produce X rays, and the produced X rays are released to the outside through an X-ray window 42 . The microminiature electron source is connected to the X-ray generating dome 40 by attaching a screw 2 a provided on the outer periphery of the distal end of a chamber 2 to a coupling screw 40 a . The microminiature X-ray source thus assembled is used as an X-ray source for intravascular radiotherapy or as a small radiation source for cancer therapy. The microminiature X-ray generating source and a cable can be detachably connected by a screw or the like, as shown in FIG. 1 .
As explained in detail above, the microminiature electron source in accordance with the present invention has the outside diameter of its cylindrical chamber at the distal end thereof substantially set to be the same as that of the external conductor of the coaxial cable. With this arrangement, it is possible to form the microminiature electron source to be extremely thin (e.g., about 2 mm), allowing it suitably used for irradiating electrons or generating X rays in the field of medical treatment. The microminiature X-ray generating source is used as an X-ray source for intravascular radiotherapy or as a small radiation source for cancer therapy.
Furthermore, the microminiature electron source can be coupled to another vacuum vessel to be used as a linear electron source for industrial or analytical applications. The microminiature electron source can be also used as an electron source for a microwave electronic tube, such as a klystron, a linear accelerator, or TWT.
In addition, the electron source in accordance with the present invention can be used as an electron source for an accelerator for research applications. Especially when the electron source is used with an RF gun, the chances of the back bombardment of electronic beams against a cathode can be minimized. The microminiature electron source or a microminiature X-ray source can be removably connected to a cable by using a screw or the like, permitting easy maintenance or the like of consumable microminiature X-ray generating sources.
A variety of modifications of the embodiments explained in detail above are possible within the scope of the present invention. As a preferred embodiment of a cathode, the cold cathode electric field radiating carbon nanotube has been described; however, another cathode conventionally used may be applied. The example has been shown wherein the X-ray dome is detachably connected to the chamber assembly of the microminiature microwave electron source in accordance with the present invention; alternatively however, the space containing an X-ray target may be combined with the chamber assembly into one piece.
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A microminiature microwave electron source excited by a pulsed microwave power through a coaxial to emit electrons includes an electrically conductive chamber that is connected to an external conductor of the coaxial cable at an openings end thereof and has an opening anode in a bottom portion thereof, a central conductor adjacent to the electron source, the central conductor having one end thereof connected to a central conductor of the coaxial cable, a carbon nanotube cold cathode formed on the other end thereof being supported by the chamber such that the cold cathode opposes the anode, a coupling iris that airtightly and fixedly supports the central conductor at an opening end of the chamber, and a connecting device for electrically and mechanically connecting the opening end of the chamber to the central conductor of the coaxial cable so as to connect the central of the electron source to the central conductor of the coaxial cable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to equine saddle pads, and more particularly to saddle pads having superior moisture-wicking capacity. The moisture-wicking capacity removes perspiration from the saddle area and enhances localized cooling of the horse.
2. Description of the Prior Art
A saddle pad is placed between the horse and the saddle and is traditionally structured from felt, cotton, wool, and sheepskin. More recently cushioning materials such as artificial sheepskin, polyurethane foams and other plastic foams of both open- and closed-cell configurations have been used.
Typically, in constructing saddle pads, extra care is taken to protect the withers and back of the horse from irritation from the weight and movement of the saddle and rider. The saddle pad also needs to enhance the stability of the saddle mounting so that slippage from the proper location on the horse's back is avoided.
In the disclosure which follows, significant attention is paid to the materials of construction and the teachings of prior art fibers have been considered. From 1970 to date E.I. du Pont de Nemours and Company, Wilmington, Del. through the DuPont Dacron Research Laboratory in North Carolina and the Central Research and Development in Delaware developed a family of passive performance fibers utilizing microfiber filaments. These materials are described briefly in the article entitled Viewpoint: 21 st Century Fibers, International Fiber Journal (August, 1999-Vol. 14, Issue 4). The DuPont development of sculpted fibers variously described as oblong, four-channel and scalloped-oval, longitudinally grooved fibers are the subject, among others, of U.S. Pat. No. 3,914,488 to Gorrafa and U.S. Pat. Nos. 5,591,523, 5,626,961, 5,736,243 and, 6,013,368 to Aneja. The sculpted fibers (not round) led to the introduction of the COOLMAX® product group of fibers. Further background of this art is provided in U.S. Pat. No. 5,626,961, which background is incorporated herein by reference.
In the past, several saddle pad patents and published patent applications have come to the attention of the inventor hereof. These are:
Published Patent Applications
Appl. No.
Inventor
U.S. Cl.
Pub. Date
2003/0177742
Brownlie
54/66
Sep. 25, 2003
2002/0162307
Arnold
54/66
Nov. 7, 2002
2002/0104295
Rauch
54/66
Aug. 8, 2002
U.S. Patents
Patent No.
Inventor
U.S. Cl.
Issue Date
6,459,015
Lyon
604/368
Oct. 1, 2002
6,421,989
Leson
54/66
Jul. 23, 2002
5,575,139
Green
54/66
Nov. 19, 1996
5,353,577
Thurston
54/66
Oct. 11, 1994
Brownlie, U.S. patent application 2003/0177742, teaches a two-chambered inflatable interface pad with each chamber having a foam core within a valved, thin-skinned envelope.
Arnold, U.S. patent application No. 2002/0162307, teaches a numnah having a foam polymer base layer and a planar polymer foam scrim layer attached thereto. The foam polymer layer in the first embodiment is of closed-cell, cross-linked polyolefin foam; and in the other embodiment, of open-cell PVC foam.
Rauch, U.S. patent application No. 2002/0104295, teaches a multi-layer saddle pad of non-woven polypropylene foam. The layers are maintained free of any permanent attachments along the periphery.
Lyon, U.S. Pat. No. 6,459,015, teaches a disposable saddle blanket of non-woven polypropylene for absorbing and dispersing therewithin the perspiration from the horse or pony.
Leson, U.S. Pat. No. 6,421,989, teaches a two-panel saddle pad constructed of a thermoformed polymeric material with longitudinal channels in the panels and a connector strip therebetween.
Green, U.S. Pat. No. 5,575,139, teaches a non-slip saddle pad that, when in use, has an innermost layer of open-celled plastic foam (with the cellular structure exposed) in direct contact with the horse. The open cells act like suction cups to reduce slippage of the saddle.
Thurston, U.S. Pat. No. 5,353,577, teaches a reversible saddle pad in which billet keepers can, upon reversing the pad, be moved through an aperture to the opposite side of the saddle pad and avoid the billet keepers irritating the horse. Both sides of the pad have a fleece-like covering.
While the above patented saddle pads use synthetic materials, there still remains a wicking-absorption-evaporation problem which remains unresolved by the combinations shown.
The patents referred to herein are representative of the present state-of-the-art, but do no singly or in combination exhibit the characteristics of the moisture-wicking saddle pad presented, infra. The citing of the patents is not intended as an admission that any such patent constitutes prior art against the claims of the present application. Applicant does not waive any right to take any action that would be appropriate to antidate or otherwise remove any listed document as a competent reference against the claims of this application.
Other technical problems are overcome or resolved by the invention disclosed herein. The innovative approach in the design and construction of the saddle pad hereof is contained in the description which follows.
SUMMARY
The disclosed invention provides a saddle pad, shown in two embodiments, each having a lower covering layer of a comfort fabric formed from a passive performance fiber. In use this layer lies against the back and sides of a horse and acts to wick perspiration from the horse. The perspiration is then absorbed by the cushioning layer which consists of a polymeric foam backing. The foam backing is, in turn, covered by another hydrophilic layer, which in one embodiment is synthetic sheepskin and in the other is a cloth cover. Details of construction are included below as is a description of a withers relief gusset.
OBJECTS AND FEATURES OF THE INVENTION
It is an object of the present invention to provide a saddle pad utilizing a microfiber filamentous fabric with a high rate of moisture wicking;
It is another object of the present invention to provide a layered saddle pad construction that enhances and optimizes wicking and absorption of perspiration;
It is a yet further object to provide a layered saddle pad construction that is light weight and combines comfort fabric with a foam backing layer for cushioning;
It is a feature of the present invention to use a comfort fabric made from passive performance fibers, such as a COOLMAX® fabric.
Other objects and features of the present invention become apparent by the review of drawings and specification which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings similar parts in the various views are provided with the same reference designators.
FIG. 1 is a perspective view of the first embodiment of the moisture-wicking saddle pad of the present invention;
FIG. 2 is a top plan view of FIG. 1 ;
FIG. 3 is a bottom plan view of FIG. 1 ;
FIG. 4 is a cross-sectional view of FIG. 4 taken along line 4 — 4 ;
FIG. 5 is a perspective view of the second embodiment of the moisture-wicking saddle pad of the present invention, similar to FIG. 1 , but being styled differently and having a different upper shell structure;
FIG. 6 is a top plan view of FIG. 5 ;
FIG. 7 is a bottom plan view of FIG. 5 ; and
FIG. 8 is a cross-sectional view of FIG. 6 taken along line 8 — 8 .
DESCRIPTION OF PREFERRED EMBODIMENTS
For the purposes of this Description, the definitions of “passive performance fibers” and “comfort fabrics” are derived from the article in the International Fiber Journal and the DuPont patents cited hereinabove. A passive performance fiber is defined as a sculpted fiber, generally scalloped oval in cross section and having longitudinal grooves in the surface thereof which grooves create a mechanism for wicking away or transporting water from a body. A “comfort fabric” is defined as one utilizing a passive performance fiber and employed in an article that wicks perspiration away from a body.
In the first embodiment a moisture-wicking saddle pad is constructed entirely from synthetic materials. The structure is layered and provides optimal comfort for the horse by having a unique arrangement using recently developed comfort materials. In this embodiment, the pad is constructed with an upper shell which is peripherally attached to the lower shell assemblage and thus may be considered to be a self-binding pad.
Referring now to FIGS. 1 through 4 the saddle pad of the first embodiment is shown and is referred to generally by the reference designator 10 . The upper shell 12 is a synthetic fleece body 14 mounted on a substrate or an open-weave backing material 16 . Unlike natural fleece and, because there are no natural oils to wash off, synthetic fleece 14 retains its compressibility and memory after numerous washings. As noted in Leson, U.S. Pat. No. 6,421,989, supra, saddle pads constructed from natural materials such as raw wool, upon use, lose the natural oils during cleaning and have substantial changes in physical properties.
As best seen in the cross-sectional view FIG. 4 , the perimeter or outer edge 18 is rolled to form a binding portion 20 that surrounds a lower shell 22 . The lower shell 22 is an assemblage of a foam pad 24 and an outer cloth cover 26 fashioned from a fabric constructed of a microfiber filament—a passive performance fiber—described in greater detail hereinbelow. The foam pad 24 , which acts to cushion the impact forces experienced during a ride, is a polymeric cushion foam. The cushion foam is either an open- or a closed-cell plastic foam selected from a cross-linked, low-density polyethylene; ethylene vinyl acetate (EVA); or, polyurethane. It is noted that such foams are most often admixtures of open and closed cells with the “open” and “closed” designation following the predominant cell structure.
In this embodiment, the foam pad 24 is attached to cover 26 by an hour glass quilting stitch 28 which is both decorative and functional. The all-over stitching 28 precludes the shifting or bunching up of the pad 24 relative to the cover 26 . As mentioned previously the cover 26 is manufactured from a passive performance fiber under license from DuPont and is known as COOLMAX® fabric, a comfort fabric. The fiber is a sculpted fiber that when extruded is scalloped-oval in cross-section and has a plurality—four or more—of longitudinal channels. Products utilizing fabrics of these fibers are known for moisture-wicking superiority and special applications of the material continue to be found. Because the wicking characteristic is a function of the channeling of the fiber, the wicking does not change with fabric maintenance.
A nylon webbing or strap 30 is attached to the topside of saddle pad 10 and, when the pad is placed on the horse, the webbing follows the spine of the horse and bridges the two symmetrical sides of the saddle pad 10 . Upon installation the forward portion of the strap 30 is constructed to be pulled upwards so that the area surrounding the withers of the horse is relieved.
Other nylon webbing or straps are mounted on the upper shell 12 to aid in the installation of the saddle pad 10 and saddle (not shown). These include girth straps 32 and 34 and billet straps 36 and 38 .
In use, the saddle pad 10 of the embodiment just described wicks the perspiration of the horse along the fiber channels of the COOLMAX® comfort fabric 26 and transports the perspiration through the foam pad 24 to the area of most highly hydrophilic material, namely, the synthetic fleece 14 of upper shell 12 . Thus, after a ride when the saddle pad is demounted from the horse, the inner surface is dry and the outer surface is wet. Additionally, because synthetic materials are used, washing or hosing down the pads will not change the physical properties thereof.
Turning now to the second embodiment, another moisture-wicking saddle pad is shown which follows the same principles of construction as the above. In the drawing for this embodiment parts similar to those in the first embodiment are afforded reference designators “100” units higher. Thus, girth strap 132 is analogous to girth strap 32 of the first embodiment.
Referring now to FIGS. 5 through 8 , the second embodiment is shown and is referred to generally by the reference designator 110 . The upper shell or cover 112 is a plain fabric such as cotton or nylon and, as a portion of the pad extends, when installed, beyond the saddle, the color of the cover can be selected to match the silks of the owners. Further, in the embodiment as the upper shell 112 is a cloth cover, the binding is external double-roped binding 115 .
As best seen in the cross-sectional view FIG. 8 the perimeter or outer edge 118 is attached by the double-roped binding 115 to a lower shell 122 . Like the prior embodiment the lower shell 122 is an assemblage of a foam pad 124 and an outer cloth cover 126 of COOLMAX® fabric. Here, the COOLMAX® fabric is 65% polyester and 35% COOLMAX® pique. As this embodiment lacks the extremely hydrophilic fleece cover, the foam for cushioning, while selected from the same materials, is optimally more sponge-like and holds more of the perspiration wicked away by the COOLMAX® fabric.
The foam pad 124 is sandwiched between upper shell 112 and lower shell 122 by the hour-glass quilting stitch 128 which, in this embodiment, penetrates all three layers. The stitching performs the same function as described above.
In the second embodiment, the central bridge 130 terminates at the forward end 131 thereof in a withers relief gusset or insert 133 . This structure relieves stress on the withers of the horse. Because of the use of a cloth cover 112 , the withers relief means 133 is more prominent in this embodiment. The nylon webbing for girth straps 132 and 134 and for billet, straps 136 and 138 are analogous to those of the first embodiment.
In use, the saddle pad 110 of the second embodiment wicks the perspiration of the horse along the channeled, sculpted fibers to the sponge—like foam mass therebehind. The superior wicking of the lower shell 122 results, after use, in the surface thereof being dry. This has been found to minimize irritation from saddles and saddle pads.
It is understood that variations and modifications of the present invention may be made without departing from the spirit thereof. Further, the present invention is not limited by the embodiments disclosed, but only by the appended claims when read together with the foregoing specification.
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The saddle pads have a lower covering layer of a comfort fabric formed from a passive performance fiber. In use this layer lies against the back and sides of a horse and acts to wick perspiration from the horse. The perspiration is then absorbed by the cushioning layer which consists of a polymeric foam backing. The foam backing is, in turn, covered by another hydrophilic layer, which in one embodiment is synthetic sheepskin and in the other is a cloth cover. The saddle pads are constructed with a withers relief gusset.
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[0001] This non-provisional patent application claims priority to U.S. Provisional Patent Application 60/632,251 filed on Dec. 1, 2004.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a height adjuster for a safety belt system.
[0003] Typically, a safety belt for a vehicle has a lap belt and a shoulder belt. The safety belt is anchored to a vehicle at three different locations around a passenger. Two anchors secure the lap belt while a third anchor, a loop, web guide or D-ring, provides a sliding support for the shoulder belt and is secured to the B-pillar of the vehicle. The web guide or D-ring (or loop) is preferably located just above the shoulder height of the passenger. Due to varying sizes of passengers, manufacturers use a device known as an adjustable turning loop assembly, or height adjuster, to adjust the height of the web guide up or down to permit for the accommodation of these differing sizes.
[0004] The adjustable turning web guide assembly is mounted to a B-pillar of the vehicle. When the assembly is unlocked, say at the touch of a button, the web guide is movable vertically to its desired position. Most of this assembly is covered by a trim panel. The button that unlocks the assembly may be part of the trim panel. Pressing this button to an actuated position such as downward or inward, unlocks a locking mechanism of the height adjuster and permits movement of the web guide from one vertical position to another.
[0005] Due to its location, the height adjuster supports the weight of the shoulder belt. In addition to this load, many safety belt systems have a seat belt retractor that tensions the safety belt to take up slack. Consequently, a passenger wishing to move the position of the web guide upward must overcome the downward force of the seat belt retractor and the weight of the seat belt. It would be desirable to facilitate the lifting of the height adjuster.
[0006] In addition, the button controlling unlocking of the lock mechanism has a spring to bias the button to a rest position, for example, a force (spring) in an upward direction, so that the button returns to its rest position following actuation. The spring is a separate component. It would be desirable to combine this button spring with other components of the height adjuster assembly.
[0007] A need therefore exists for a device that both assists a passenger in the lifting of the height adjuster assembly and returns the button of the assembly to its original position without increasing the number of components.
SUMMARY OF THE INVENTION
[0008] A height adjuster for a vehicle restraint has a web guide for receiving a seat belt. The web guide is vertically moveable along a track. A lock prevents vertical movement of the web guide along the track when in a locked condition and allows vertical movement of the web guide along the track when in an unlocked condition. A release mechanism is connected to the lock. The release mechanism has a release position for placing the lock in an unlocked condition and an unreleased position for maintaining the lock in a lock condition. Furthermore, a lift mechanism at least partially assists vertical movement of the web guide along the track and biases the release mechanism toward the unreleased position. In this way, a single lift mechanism, such as a spring, acts to both assist the passenger in raising the web guide and biasing the button that releases the web guide in an unreleased position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0010] FIG. 1 illustrates a safety restraint system incorporating the inventive height adjuster.
[0011] FIG. 2 illustrates a view of the height adjuster of FIG. 1 , including web guide.
[0012] FIG. 3 illustrates the height adjuster of FIG. 2 after adjustment of the location of the web guide.
[0013] FIG. 4 illustrates the height adjuster of FIG. 2 from a side exposed view.
[0014] FIG. 5 illustrates a behind view of the height adjuster of FIG. 2 .
[0015] FIG. 6 illustrates the height adjuster of FIG. 3 after adjustment of the location of the web guide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 1 illustrates a safety restraint system 8 for a vehicle. As shown, seat belt 14 is disposed over seat 10 . Seat belt 14 comprises shoulder belt portion 26 , lap belt portion 30 and seat belt buckle 12 and a tongue 12 a insertable into a locking engagement with the buckle 12 . Seat belt retractor 22 is also provided to take up any slack of shoulder belt portion 26 over a passenger. As shown, shoulder belt portion 26 passes from seat belt retractor 22 through a loop 38 , here a D-ring which is also referred to in the art as a web guide.
[0017] Web guide, (formed as a loop) 38 is a part of a height adjuster assembly 18 , which allows web guide 38 to be moved downward in the direction of arrow A or upward in the direction of arrow B. In this way, web guide 38 may be adjusted in height to accommodate differently sized vehicle occupants. Height adjuster assembly 18 , along with web guide 38 , are mounted to B-pillar 34 of the vehicle (see FIG. 4 for example). B-pillar trim panel 42 is provided over height adjuster assembly 18 to hide most of its working components. These features of the invention are well known.
[0018] FIG. 2 shows a view of B-pillar trim panel 42 of FIG. 1 . B-pillar trim panel 42 comprises fixed base 48 , sliding cover 46 , and release actuator cover 50 . Fixed base 48 has trim panel mounting tabs 108 that interlock B-pillar trim panel 42 to other trim panels, which are fixed to B-pillar 34 . Alternatively, the B-pillar trim can be secured directly to the B-pillar. However, sliding cover 46 and release actuator cover 50 , here a button, are free to move relative to fixed base 48 with movement of web guide 38 in the direction of arrow A or arrow B. Furthermore, sliding cover 46 is provided with cover opening 54 through which passes seat belt 14 to web guide 38 .
[0019] FIG. 5 illustrates a back view of B-pillar trim panel 42 . As shown, B-pillar trim panel 42 has sliding cover retaining tabs 116 , which hold sliding cover 46 to fixed base 48 while permitting sliding movement of sliding cover 46 in the direction of arrow A or in the direction of arrow B. In addition, sliding cover stop 92 is provided to prevent further upward travel of sliding cover 46 in the direction of arrow B. Sliding cover 46 in the position shown, however, is free to move in the direction of arrow A, downward, to sliding cover stop 94 . Thus, sliding cover 46 may slide freely between sliding cover stop 92 and sliding cover stop 94 .
[0020] Sliding cover 46 also slideably receives release actuator cover 50 , a button. Here, release actuator cover 50 is retained by release actuator cover retaining tabs 120 that hold release actuator cover 50 to sliding cover 42 while still permitting movement of release actuator cover 50 in the direction of arrow A or in the direction of arrow B. In its highest position, release actuator cover 50 abuts ledge 132 (see FIG. 4 ) of sliding cover 46 . Release actuator cover stop 104 is provided to prevent release actuator cover 50 from traveling further in the direction of arrow A. Accordingly, release actuator cover 50 may slide freely between release actuator cover stop 104 and ledge 132 of sliding cover 46 .
[0021] The operation of height adjuster assembly 18 will now be explained. Referring to FIG. 4 , web guide 38 is mounted to bolt 68 . Head 69 of bolt 68 is received within bolt recess 96 , (see also FIG. 5 ) which is part of sliding cover 46 . Bolt 68 is also mounted to carrier 72 of height adjuster assembly 18 . Further, height adjuster assembly 18 has track 84 , here a rail, which is mounted to B-pillar 34 by mounting bolts 88 . Carrier 72 is slidably received on track 84 so that carrier 72 may move along with web guide 38 and sliding cover 46 in the direction of either arrow A or arrow B.
[0022] Holding carrier 72 in place is locking mechanism 76 , here shown schematically, which locks carrier 72 to track 84 as known. One such carrier, rail and lock mechanism is shown in U.S. Pat. No. 6,733,041 B2 to Arnold, et al., which is incorporated herein by reference. Actuator 80 is linked by actuator link 112 to locking mechanism 76 and unlocks locking mechanism 72 to permit movement of carrier 72 . Additionally, actuator 80 is in contact with release actuator cover 50 at button ledge 134 (see also FIG. 5 ). Thus, movement of release actuator cover 50 in the direction of arrow A causes movement of actuator 80 in the same direction to unlock locking mechanism 76 and to permit carrier 72 to move up or down. Locking mechanism 76 may have a spring (not shown, however, see the above patent) that biases actuator 80 in the direction of arrow B to return to its locked condition so that release of release actuator cover 50 will lock carrier 72 in place.
[0023] Because of a downward tensioning force from seat belt retractor 22 and from the weight of the shoulder belt portion 26 , web guide 38 is subject to a downward force in the direction of arrow A. Accordingly, an individual wishing to move loop 38 upwardly in the direction of arrow B must overcome the combined load of the weight of shoulder belt portion 26 and the downward force from seat belt retractor 22 . This load may make adjustment of height adjuster assembly 18 inconvenient. The prior art shows the use of assist springs acting directly upon the carrier of a height adjuster.
[0024] To facilitate the lifting of sliding cover 46 and web guide 38 , a lift assist spring 66 is provided as shown in FIG. 4 . Lift assist spring 66 is attached at one end portion 67 to fixed base 48 . Another end portion 71 of lift assist spring 66 is attached to release actuator cover 50 , which abuts ledge 132 of sliding cover 46 .
[0025] Hence, as shown in FIG. 6 , following actuation of actuator 80 , carrier 72 along with web guide 38 and sliding cover 46 , may be dropped downward in the direction of arrow A to position 62 shown in FIG. 6 . In this position, lift assist spring 66 is extended creating additional lifting force on release actuator cover 50 , which is linked to sliding cover 46 and web guide 38 by ledge 132 . Thus, when release actuator cover 50 is pressed in the direction of arrow A to release locking mechanism 76 , lift assist spring 66 causes an upward force in the direction of arrow B on release actuator cover 50 .
[0026] To couple this upward force to sliding cover 46 and web guide 38 , one need only place a digit, such as a thumb, at thumb spot 128 while holding release actuator cover 50 down. Typically, when a passenger adjusts height adjuster assembly 18 , he or she will place a digit, such as a finger, at finger spot 124 and a digit, such as a thumb, at thumb spot 128 . The finger presses downward in the direction of arrow A to unlock locking mechanism 76 while the thumb at thumb spot 128 permits the lifting of sliding cover 46 . The link between finger and thumb allows the upward force on the release actuator cover 50 to be transferred to the thumb and thus the sliding cover 50 . In this way, a finger at finger spot 124 squeezes in the direction of arrow A to release locking mechanism 72 while a thumb at thumb spot 128 receives lift in the direction of arrow B from lift assist spring 66 to assist in the lifting of loop 38 .
[0027] As further shown in FIG. 4 , lift assist spring 66 also biases release actuator cover 50 in the direction of arrow B so that when release actuator cover 50 is pressed in the direction of arrow A, lift assist spring 66 will return release actuator cover 50 upwardly in the direction of arrow B. Thus, lift assist spring 66 works to return release actuator cover 50 to its unactuated position. In this way, a single spring performs both the function of assisting in the lifting of loop 38 and in the returning of release actuator cover 50 to its original position.
[0028] The aforementioned description is exemplary rather that limiting. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed. However, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. Hence, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For this reason the following claims should be studied to determine the true scope and content of this invention.
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A height adjuster for a vehicle safety restraint has a web guide ( 38 ) and a track ( 84 ) for the web guide. The web guide ( 38 ) is vertically moveable along the track ( 84 ). A lock ( 76 ) has a lock condition for preventing vertical movement of the web guide ( 38 ) along the track ( 84 ) and an unlocked condition for allowing vertical movement of the web guide ( 38 ) along the track ( 84 ). A release mechanism ( 50, 80 ) is operatively connectable to said lock ( 76 ). The release mechanism ( 50, 80 ) has a release position for placing the lock ( 76 ) in the unlocked condition and an unreleased position from maintaining the lock ( 76 ) in the lock condition. A lift mechanism ( 66 ) at least partially assists vertical movement of the web guide ( 38 ) along the track ( 84 ) and biases the release mechanism ( 50, 80 ) toward the unreleased position.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a 35 U.S.C. “371 national phase conversion of PCT/JP 2005/018771, filed 12 Oct. 2005, which claims priority of Japanese Patent Application No. 2004-299233, filed 13 Oct. 2004, Japanese Patent Application No. 2004-299234, filed 13 Oct. 2004 and Japanese Patent Application No. 2004-299244, filed 13 Oct. 2004. The PCT International Application was published in the Japanese language.
TECHNICAL FIELD
The present invention relates to a chair and the structure for stretching a mesh over the backrest, a seat, a headrest etc. of the chair.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 6,386,634B1 discloses the backrest structure of a chair and the stretching structure of a mesh in the backrest in which edge material is mounted by molding around the mesh to which tension is already applied, the edge material engaging in grooves in a front surface of a back frame to apply mesh over the front surface of the back frame.
JP2004-49685A discloses that an engagement piece mounted to the periphery of a mesh engages on a peripheral groove on the rear surface of a back frame, said engagement piece being pressed into the groove by the binding frame mounted to the rear surface of the back frame to apply tension to the mesh over the upper surface of the back frame.
A hanger for having clothes of a sitting person is mounted to the backrest of a chair in JP6-45553U, JP2004-159745A, JP9-10189U, JP11-155690A and JP5-7179U.
PROBLEMS TO BE SOLVED BY THE INVENTION
However, U.S. Pat. No. 6,386,634B1 discloses that it is necessary to take the width of the back frame to prevent flexure of the back frame by force applied to the mesh when the user sits down, a groove which engages with the edge material around the mesh being formed on the front surface of the back frame so that the periphery of the back frame is exposed from the mesh. The back frame greatly occupying the appearance of the chair causes bad appearance in design.
In JP2004-49685A, when a user sits down on the chair, flexing of the back frame against the force applied to the mesh is prevented by both the back frame and binding frame. Thus, the back frame covered with the mesh and binding frame not covered with the mesh are overlapped and exposed to the outside, which does not produce good appearance in design as well as heavy weight, a lot of the parts, a lot of time for assembling and high cost.
In JP6-45553U and JP2004-159745A, the support rod for supporting the hanger body is directly mounted in the middle of the rear surface of the backrest. It cannot be applied to a chair in which mesh is applied to the back frame. And a special device is required so that the mounting parts do not project from the front surface of the backrest when the support rod is directly attached to the middle of the rear surface of the backrest.
In JP9-10189U, JP11-155690A and JP5-7179U, the support rod is mounted to the transverse rod at the lower part of the rear of the backrest or support post standing from the lower part thereby increasing the length of the support rod. When the chair is pulled with the hunger body, the hanger is likely to be broken.
SUMMARY OF THE INVENTION
In view of the above disadvantages in the prior art, it is objects of the present invention to solve the problems below:
(A) To provide a chair with the backrest structure in which the ratio of the back frame is small with respect to the appearance of the chair, having good design, light weight, reduction in the number of parts and improvement in assembling.
(B) To provide a chair with a hanger in which the hanger is easily mounted to the backrest to allow parts for mounting the hanger not to project from the front surface of the backrest, preventing the hanger from being damaged and providing good appearance.
(C) To provide the structure for a mesh over the backrest of a chair in which the ratio of a frame to appearance of the chair is small to provide good appearance, light weight, reduction in the number of parts and improvement in assembling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the first embodiment of a chair according to the present invention;
FIG. 2 is a side elevational view thereof;
FIG. 3 is a rear perspective view thereof;
FIG. 4 is a front perspective view of the backrest;
FIG. 5 is a sectional view taken along the line V-V in FIG. 4 ;
FIG. 6 is a sectional view taken along the line VI-VI in FIG. 4 ;
FIG. 7 is an enlarged perspective view of the part VII in FIG. 4 ;
FIG. 8 is a side view of the second embodiment of a chair with a hanger according to the present invention;
FIG. 9 is an enlarged rear perspective view of main part of the chair in FIG. 8 ;
FIG. 10 is a rear enlarged exploded perspective view of the chair in FIG. 8 ;
FIG. 11 is a front enlarged exploded perspective view thereof;
FIG. 12 is an enlarged sectional view taken along the line XII-XII in FIG. 9 ; and
FIG. 13 is an enlarged sectional view taken along the line XIII-XIII in FIG. 9 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-7 show the first embodiment of the present invention.
The present application is applied to the structure of the backrest of the chair and the structure of mesh in the backrest.
As shown in FIGS. 1 and 2 , a reclining chair 1 comprises a leg 4 comprising five leg rods 3 each of which has a caster 2 at the end. At the center of the leg 4 , a telescopic leg post 6 which comprises a gas spring 5 stands. At the upper end of the leg post 6 , a rear part of a support base 7 is fixed.
The support base 7 comprises a hollow rhombus-like box which opens at an upper front part, and arms 8 , 8 are integrally formed from each side of the front part of the support base 7 .
A hexagonal pivot 9 passes through the support base 7 in the middle. At each end of the pivot 9 extending from the support base 7 , a tubular portion 11 a fits. The tubular portions 11 a are provided at the lower front ends of a pair of backrest support rods 11 , 11 that support a backrest 10 . The backrest 10 , the backrest support rods 11 , 11 and the backrest 10 are rotated around the pivot 9 with respect to the support base 7 .
Inside the support base 7 , there are provided a rubber torsion unit for promoting the pivot 8 in an anticlockwise direction and a promoting-force adjusting device (not shown). In the middle of the front lower surface of the support base 7 , there is a gas spring unit 13 for assisting promoting force of the rubber torsion unit in connection with the rubber torsion unit to form a force-promoting unit to stand the backrest 10 .
Short arms 12 , 12 project from the backrest support rods 11 , 11 at the back of the pivot 9 . At the upper ends of the arms 12 , 12 , a pair of seat-supporting frames 15 , 15 which support each side of a seat 14 are connected at the rear ends with a shaft 16 .
The backrest 10 will be described with respect to FIGS. 3-7 .
In FIG. 3 , a back frame 17 of the backrest 10 comprises a rectangular synthetic-resin front face frame 18 . The front face frame 18 comprises an upper frame rod 18 a , a lower frame rod 18 b , a left-side frame rod 18 c and a right-side frame rod 18 d . The rods 18 b , 18 d are wider than the rods 18 a , 18 b . A mesh is held on the rods 18 a , 18 b , 18 c , 18 d.
In FIGS. 4 and 5 , a pair of grooves 19 , 20 is formed longitudinally on the outer side surfaces of the right and left side frame rods 18 c , 18 d.
In FIG. 6 , a groove 21 is horizontally formed along the lower edge of the front surface of the upper frame rod 18 a , and a groove 22 is horizontally formed along the upper edge of the front surface of the lower frame rod 18 b.
A surface 21 a between the lower edge of the front surface of the upper frame rod 18 a and the groove 21 and a surface 22 a between the upper edge of the front surface of the lower frame rod 18 b and the groove 22 are grooved by thickness of an outward portion 25 b of an edge piece 25 . When the edge piece 25 engages with a corner between the lower surface and the front surface of the upper frame rod 18 a and the front surface and with a corner between the upper surface and the front surface of the lower frame rod 18 b , the end face of each of the edge piece 25 is coplanar with the front surfaces of the upper frame rod 18 a and the lower frame rod 18 b.
A mesh 23 may be preferably net-like or mesh-like material knitted or woven from high-tension plastic or other elastic fibers, or may be woven fabric, synthetic resin sheet or porous sheet. Synthetic resin edge pieces 24 , 24 which engage in a pair of grooves 19 , 20 are fixed in the left and right side edges of the mesh 23 by molding. The synthetic-resin edge pieces 25 , 25 which has a hook-like portions 25 d , 25 d and engage in the grooves 21 , 22 are fixed in the upper and lower edges by molding.
The edge piece 25 comprises a base 25 a , the outward portion 25 b , and a turning portion 25 c which turns in parallel with the base 25 a from the end of the outward portion 25 b . The base 25 a and the outward portion 25 b constitute the hook-like portion 25 d.
The size of the mesh 23 mounted to the edge pieces 24 , 24 , 25 , 25 is formerly determined to apply a suitable tension to the mesh 23 when the edge pieces 24 , 24 , 25 , 25 engage in the grooves 19 , 20 or the grooves 21 , 22 .
In FIGS. 4-7 , the right and left edge pieces 24 , 24 of the mesh 23 engage in the grooves 19 , 20 of the right and left side frame rods 18 c , 18 d . The upper and lower ends of the mesh 23 are wound from the front surface to the rear surface around the upper and lower surfaces of the upper and lower frame rods 18 a , 18 b . The hook-like portions 25 d , 25 d of the upper and lower edge pieces 25 , 25 engage on the corner between the lower surface and the front surface, and the corner between the upper surface and the front surface. The turning portions 25 c , 25 c of the upper and lower edge pieces 25 , 25 engage in the upper and lower grooves 21 , 22 , so that the mesh 23 is stretched over the entire front surface of the front face frame 18 tensionally.
Thus, the front surface of the front face frame 18 or the front surface of the back frame 17 is entirely covered with the mesh 23 . So the back frame 17 is not so occupied in the appearance of the chair, so that good impression is given in design.
In FIGS. 3 and 6 , to each side end of the upper frame rod 18 a of the front face frame 18 , an arcuate upper reinforcement rod 26 is joined so that the middle of the rod 26 is spaced apart from the upper frame rod 18 a . The upper reinforcement rod 26 and the upper frame rod 18 a is like crescent.
The upper reinforcement rod 26 keeps strength of the upper part of the back frame 17 together with the back frame 17 . When a user is reclined on the backrest 10 , it is allowed for the upper frame rod 18 a to be slightly flexed elastically.
The upper reinforcement rod 26 is spaced apart from the upper frame rod 18 a . Thus, without hindering attachment of the mesh 23 , a headrest 27 as shown by dotted lines in FIG. 4 and an optional member such as a hanger for clothes in FIG. 8 and so on are detachably mounted.
The upper reinforcement rod 26 is also used with a hand when the chair is moved.
In FIGS. 3 , 6 and 7 , to the lower ends of the right and left side frame rods 18 c , 18 d of the front face frame 18 , both ends of the lower reinforcement rod 28 are coupled. The middle of the lower frame rod 18 b is spaced forward of the lower reinforcement rod 28 , but each end thereof is fastened to each end of the lower reinforcement rod 28 with a screw 29 .
The lower end of the mesh 23 is wound around the lower frame rod 18 b after the lower frame rod 18 b is fastened to the front surface of the lower reinforcement rod 28 . A folding portion 25 c of the lower edge piece 25 is engaged in the groove 22 of the lower frame rod 18 b , so that the mesh 23 is mounted to the lower frame rod 18 b.
When the chair is scrapped, a tool such as a screwdriver (not shown) is stuck through the mesh 23 and engaged with a head of the screw 29 which is loosened, so that the lower frame rod 18 b is removed from the lower reinforcement rod 28 . Thereafter, the upper edge of the mesh 23 and the right and left side edges are removed from the upper frame rod 18 a and the right and left side frame rods 18 c , 18 d with the edge members 25 , 24 , 24 . The mesh 23 is separately removed from the back frame 17 and replaced with a new one.
When the chair is moved and hit with another chair, the lower frame rod 18 b is protected by the lower reinforcement rod 28 , so that the lower ends of the lower frame rod 18 b and the mesh 23 are prevented from being damaged.
FIGS. 8-13 show the second embodiment in which a hanger is mounted to the chair in the first embodiment of the present invention. The basic structure of the chair is similar to the first embodiment, and the same numerals are allotted to the same members. Description thereof is omitted.
A chair 30 with a hanger in the second embodiment of the invention comprises a hanger 31 that moves up and down behind the backrest 10 .
The hanger 31 comprises a hanger body 32 on which a suit can be hung; and a pair of support rods 33 , 34 which support the body 32 . The support rods 33 , 34 are mounted on the backrest 10 with a mounting member 35 and a screw seat piece 36 by a screws 37 .
The backrest 10 comprises the back frame 17 in which the mesh 23 in FIGS. 1-7 is stretched over the front face frame 18 . The middle of the hanger 31 is spaced apart from the upper frame rod 18 a of the front face frame 18 , and each end of the hanger 31 is mounted to the middle of the upper reinforcement rod 26 connected to the upper frame rod 18 a.
A pair of support rods 33 , 34 comprises parallel vertical rod portions 33 a , 34 a ; extending rod portions 33 b , 34 b inclined upward of the vertical rod portions 33 a , 34 a ; and connecting portions 33 c , 34 c curved downward of the vertical rod portions 33 a , 34 a . The support rods 33 , 34 are connected at inner ends of the connecting portions 33 c , 34 c.
The upper ends of the extending rod portions 33 b , 34 b are plain. The extending rod portions 33 b , 34 b are mounted to the right and left ends of the hanger body 32 with screws (not shown), so that the support rods 33 , 34 are fixed to the hanger body 32 .
The extending rod portions 33 b , 34 b of the support rods 33 , 34 are curved forward. So the hanger body 32 is positioned in front of the rear end of the upper reinforcement rod 26 .
FIGS. 12 and 13 are enlarged sectional views taken along the line XII-XII and XIII-XIII in FIG. 9 .
In FIGS. 9-12 , plain portions 40 , 41 are formed on opposite surfaces 38 , 39 of the vertical rod portions 33 a , 34 a of the right and left support rods 33 , 34 .
A mounting member 35 comprises a thick rectangular plate. The right and left ends 42 , 42 are formed in size such that the mounting member 35 can engage in the plain portions 40 , 41 of the vertical rod portions 33 a , 34 a of the right and left support rods 33 , 34 .
On the inner side edges of the plain portions 40 , 41 , vertical projections 43 , 44 are provided in parallel with each other.
The projections 43 , 44 engage in engagement grooves 45 , 45 on the front surface of the mounting member 35 so that the support rods 33 , 34 slidably move with respect to the mounting member 35 .
In FIGS. 11 and 12 , vertical forward projections 46 , 46 are provided on the front surface of the vertical rod portions 33 a , 34 a of the right and left support rods 33 , 34 . On the rear surface of the upper reinforcement rod 26 of the backrest 10 , vertical engagement grooves 47 , 47 are provided to engage with the forward projections 46 , 46 .
Through holes 48 , 48 are formed in the mounting member 35 , and through holes 49 , 49 are formed in the upper reinforcement rod 26 . Blind bores 50 , 50 are formed in the rear surface of a screw seat piece 36 at a position corresponding to the through holes 48 , 48 .
The hanger 31 will be mounted to the upper reinforcement rod 26 below.
The right and left support rods 33 , 34 having the hanger body 32 at the upper end contacts the upper reinforcement rod 26 to allow the forward projections 46 , 46 of the vertical rods 33 a , 34 a of the support rods 33 , 34 to engage in the engagement grooves 47 , 47 on the rear surface of the screw seat piece 26 , thereby positioning the support rods 33 , 34 .
Then, the right and left ends of the mounting member 35 engage in the plain portions 40 , 41 of the vertical rod portions 33 a , 34 a of the right and left support rods 33 , 34 . In the engagement grooves 45 , 45 on the front surface of the mounting member 35 , the projections 43 , 44 of the plain portions 40 , 41 of the vertical rod portions 33 a , 34 a engage, and the mounting member 35 is positioned between the right and left vertical rod portions 33 a and 34 a.
Then, the screw seat piece 36 contacts the front surface of the upper reinforcement rod 26 . While the support rods 33 , 34 are put between the upper reinforcement rod 26 and the mounting member 35 , the upper reinforcement rod 26 is held between the mounting member 35 and the screw seat piece 36 . The screws 37 , 37 pass into the blind bores 50 of the screw seat piece 36 through the through holes 48 , 49 , so that the hanger 31 is mounted to move up and down with suitable resistance behind the backrest.
An engagement bore 52 for mounting a cover member 51 is formed in the middle of the mounting member 35 . An inward projection 53 is provided on a rear edge of the engagement bore 52 . The cover member 51 comprises a thin elongate plate and has in the middle an engagement claw 54 which is engagable with the inward projection 53 of the engagement bore 52 .
On the rear surface of the mounting member 35 , there is formed a recess 55 which engages with the cover member 51 . The engagement claw 54 of the cover member 51 is put in the engagement bore 52 of the mounting member 35 to allow the claw 54 to engage on the inward projection 53 . The entire cover member 51 engages in the recess 55 , so that the cover member 51 is mounted to the mounting member 35 .
The cover member 51 is also used as nameplate.
The hanger 31 is slidable up and down. When a suit is hung at an upper limit where the hanger slides, the hanger 31 moves down owing to the weight of the suit and the lower end of the suit contacts a floor, so that the suit is likely to become dirty.
For prevention, in FIGS. 10 and 12 , a plurality of small rearward projections 56 a , 56 b are provided on the vertical rod portions 33 a , 34 a . and an engagement groove 57 which is elastically engagable with the small projections 56 a , 56 b are provided in FIGS. 11 and 12 . Thus, at a plurality of vertical positions where the small projections 56 a , 56 b elastically engage in the engagement groove 57 , the hanger can be held against a certain load.
By tightening the screw 37 , the support rods 33 , 34 may be held between the upper reinforcement rod 26 and the mounting member 35 . To change a height of the hanger 31 , the screw 37 is loosened to allow the support rods 33 , 34 to move up and down. Thereafter, the screw 37 is tightened again to allow the hanger 31 to be held at a desired height.
Various modifications of the present invention may be possible without departing from the scope of claims.
For example, in the foregoing embodiment, the upper reinforcement rod 26 and the lower reinforcement rod 28 are mounted on the rear surface of the upper and lower frame rods 18 a , 18 b . But the upper reinforcement rod 26 or the lower reinforcement rod 28 may be omitted.
In the foregoing embodiments, the present invention is applied to the stretching structure of the mesh 23 of the backrest 10 of the chair, but may be applied to a seat of a chair or a headrest.
The edge member 25 is made like a letter L and may engage to a corner between the lower surface and front surface of the upper frame rod 18 a or lower frame rod 18 b.
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An upholstered structure including an upholstery material for a chair or a backrest of a chair is proposed, which may achieve: reduced proportion of the appearance of the rear frame of the backrest over the appearance of the whole chair; more sophisticated design; reduced weight; reduced number of parts; and improved assemble-ability. In the chair having the backrest upholstered with the upholstery material over the front surface of the rear frame, the rear frame comprises a front frame to which the peripheral edge part of the upholstery material is fixed and an upper reinforcement frame rod. The laterally facing upper reinforcement frame rod is connected at its both ends to both ends of the laterally facing upper frame rod at the top of the front frame with the center part of the upper reinforcement frame rod separated backward from the upper frame rod.
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RELATED APPLICATIONS
[0001] This application claims priority from Mexican application Serial No. MX/a/2009/013992 filed Dec. 17, 2009, which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention falls under the washer category, in particular that of top loading washers and even more specifically; it applies to washers which has a metal cabinet, from which four fastened suspension rods hang each having a lower extremity comprised of a shock absorber; these are inserted into an equal number of disposable ears in the tub intended specifically for this purpose which in turn support the tub and additionally act as a good suspension system for the vibrations which are generated during the washing, rinsing and centrifuge motions. The tub holds in its interior a perforated basket, which itself contains an agitator in concentric form: the shaft of said agitator is mechanically connected to an electric motor which is suspended in the lower portion of the tub.
BACKGROUND
[0003] The tub not only holds the weight of the water and the articles to be washed, but also supports the static and dynamic charges which are generated with the washing or centrifuge motions, some of which can be large enough to deform the shape of the tub, knowing that these are generally manufactured by thermoplastic injections, the most popular being polypropylene. So, for example, when the basket is turning at a high speed in order to achieve centrifuge it is very common that the weight of articles to be washed in the basket cause an imbalance of the system, which cause the basket to not only have a rotational movement but also a translational one within the tub, even causing possible scraping against the tub's internal wall, not a desired effect of the design. If this occurs in addition to the deformation caused in the tub's mouth, the gap between the basket and the tub is greatly reduced.
[0004] This is why it is necessary to design a tub for a top loading washer which is highly rigid, not discounting the difficulty of manufacture, using thermoplastics like polyethylene or polypropylene, which help absorb, distribute and transmit the different forces and efforts created by the varying washing and centrifuge cycles.
[0005] Various efforts in this area have taken place with said objectives in mind, such as Paul Gregory Hall's AU2006235808 patent application which deals with a bombing system which is fastened to the lower portion of the tub; FIG. 2 shows a cross section of the lower portion of the tub where the reinforcements of the inferior external part of the tub can be seen, where a pancake type motor is grasped emphasizing the bomb's assembly, the part of particular interest in this tub being the use of lobes in the tub's superior part which are aligned with the reinforcement of the support ears.
[0006] Jonathan David Hartwood's et al EP 1 783 264 A2 published patent application which presumably shows in FIG. 2 , the same tub as Hall's, where there appear a pair of lobes aligned with the ear reinforcements, wherein said lobes were presumably designed to create more space for the basket inside the tub, given their number, as it only is comprised of two lobes which do not significantly increase the area's rigidity in the tub's mouth, allowing a larger space to the basket as well as to the tub's cover which can house a grid, window or passage in the precise additional area created by the lobes intended to transport chemicals deeper into the tub to be mixed with greater ease.
[0007] Even so, though the tubs shown in both documents at a simple glance appear to have strong reinforcements at the ears making them better able to hold heavy loads, no concern seems to be given to avoiding the deformation neither to the tub's mouth nor to the tub's cylindrical wall with an end result of attaining a more rigid tub which supports, absorbs, cushions and transmits the forces generated inside the basket while washing or centrifuge motions take place.
[0008] Given the above discussion, the need to develop a tub with higher rigidity yet using the traditional manufacturing materials, thereby reducing cost becomes apparent. The tub also allows for larger baskets to be held due to lesser deformities and thus transmits more efficiently the efforts to the suspension rods with shock absorbers, and also avoids the scraping between the tub and the basket during centrifuge, where larger baskets allow for larger washing loads as well as water and detergent (mixes water with chemicals or additives), allowing for larger washing loads in an equal volume sized cabinet, this being the purpose of this invention.
BRIEF DESCRIPTION OF THE INVENTION
[0009] Derived from the experience of designing and manufacturing washers it is noted that the tub, far from being solely an object which contains water and detergent, has structural functions as well. It supports the basket's assembly which is aligned with the tub in its symmetrical axis, as well as to the transmission or reduction box which can be fitted to the agitator; it also supports the electric motor, hoses, overflow ducts etc. This entire group afore mentioned plus the suspension rods are known as the sub-washer. The tub itself hangs from four suspension rods whose lower area has a shock absorber mechanism, whereas the higher section of said suspension rods are attached to the upper corners of the cabinet which statically and kinematically support the sub-washer. The lower area of the suspension rods are fastened to the tub by means of ears lodged in the shock absorbers, this system allows the tub at least three degrees of freedom, because if it were a rigid assembly, the washer would tend to “walk” or jump, not being capable of softening the vibrations emerging from its own operation, such as those being created from the agitation of the wash load itself or the centrifuge stages.
[0010] This is why the tub is comprised of a robust system of reinforced ears with veins which run along its length as well as the tub's circumference.
[0011] Another characteristic of the tub discussed in the present invention, are reinforcements running like a belt on the external periphery of the tub's cylindrical wall, which discourage possible deformations to said tub, and knowing that water's own weight exerts a force on said wall, coupled with certain washing conditions which require hot water for proper stain removal or to activate chemicals or detergents mixed in the wash, said temperatures can reach near 60° C., which can cause a considerable re-softening in the equatorial area of the tub's cylindrical wall inflating it to a balloon shape, not a desirable deformation because when this happens, the tub's mouth itself tends to deform inwardly reducing the gap or area between the basket and the tub, which in turn creates friction due to scraping between these two parts during the agitation and specially centrifuge motions which leads to wear out and possible permanent damage as a hole can be formed on the cylindrical wall where the repeated and prolonged scraping take place.
[0012] Another characteristic to be outlined, are the higher petal lobes located in the tub's mouth which allow the tub's mouth higher rigidity avoiding deformities to the tub's mouth caused by the basket's rotations, widening the gap between the tub and the basket precisely in the area where the basket's nodding occurs considerably avoiding the friction due to scraping between the tub and the basket. To help avoid deformities to the tub's circular wall between the lobes and over the reinforcement belt, reinforcements are placed in arc form. These reinforcements allow for the distribution of forces created by the dynamic and hydrostatic charges allowing for a better transmission of these to the shock absorbers of the suspension rods.
[0013] Yet another aspect of the present invention is found in the tub's bottom crafted as a truncated cone which allows drainage and guides the washing mixture unto the lower area, followed by an inclined plane which then guides the washing mixture towards a trough, where the valves or the pumps are fed.
[0014] On the opposite side of the tub's bottom, that is, the deep exterior, a reinforcement of a series of ribs is found which allow for extraordinary rigidity using minimum material. In this way, the elements herein described coupled with others to be detailed later, constitute the present invention creating a robust top loading washing machine with exceptional structural rigidity which allows for withstanding of high temperatures of washing mixtures without causing major deformities, high work effort, a reduced gap between the tub and the basket which allows for significant water conservation while being able to use a smaller volume tub, among other attributes.
BRIEF DESCRIPTION OF DRAWINGS
[0015] These and other characteristics, aspects and advantages of the present invention will be better understood upon reading the following detailed description referencing the accompanying drawings in which:
[0016] FIG. 1 is an isometric cross-section of a sub-washer.
[0017] FIG. 1 a is an isometric representation of the tub with suspension rods, a drainage duct and a spraying hose.
[0018] FIG. 2 is an isometric representation of the tub with suspension rods, an overflow duct, a spraying hose and an exploded drainage system.
[0019] FIG. 3 is an upper view of the tub.
[0020] FIG. 4 is a lateral cross view of the tub.
[0021] FIG. 5 is an inferior isometric view of the tub.
[0022] FIG. 6 is a detailed view of the lower part of the tub, specifically that of the ear.
[0023] FIG. 7 is a lateral view of the tub.
[0024] FIG. 8 is a detailed cross section of the tub's ear.
[0025] FIG. 9 is an upper isometric view of the tub.
[0026] FIG. 10 is a detailed cross-section of the overflow drain.
[0027] FIG. 11 is a detailed view of the assembly of the drainage duct unto the overflow drain.
[0028] FIG. 12 is a detailed isometric view of the tub's mouth.
DETAILED DESCRIPTION
[0029] The washing machine being described in the present invention, illustrated in FIG. 1 , is a top loading machine or vertical axis, and possesses a cabinet from which four suspension rods 12 are attached, said suspension rods 12 support the tub's weight 11 with the additional accessories to said cabinet, said suspension rods in addition of supporting static charges, mitigate the dynamic charge through shock absorbers present in its lower part, which help dissipate the vibrations caused by the washing motions.
[0030] Thus the tub 11 is hung from the suspension rods 12 by means of ears 35 placed in the lower portion of said tub 11 . The remaining peripheral equipment is mounted on said tub 11 , such as the motor 21 , in a preferred embodiment, a planetary gear for reduction 24 , which, in an alternative embodiment of the present invention, can be omitted thereby adjusting the pulley relationship 22 ; in this form, the pulley 22 with the largest diameter will be adjusted over the internal shaft 25 which will receive energy proceeding from the electric motor 21 thanks to the arrangement of pulleys 22 and band. In a preferred embodiment the shaft 25 on its upper part shall be coupled to a planetary gear for reduction 24 with the purpose of reducing angular speed, thereby accomplishing greater torque the exiting shaft from the planetary gear for reduction which reintegrates into one shaft 25 , on whose upper part the agitator is placed 13 . In an alternative embodiment the internal shaft 25 has a pulley with the largest diameter coupled to its lower part 22 and on its upper part is coupled to the agitator 13 . The interior of the hollow shaft 26 houses the internal shaft 25 . Said hollow shaft 26 is mechanically coupled to a clutch 28 , which can make both shafts 25 , 26 rotate together or independently, and also said hollow shaft 26 is mechanically coupled to the basket's center called the “hub” 32 , so that when shafts 25 , 26 are clutched and rotating together, the hollow shaft 26 shall transmit energy to the basket 10 so that it turns along with the agitator 13 .
[0031] The basket 10 is crowned with a balance hoop 27 which counteracts the unbalancing caused by the shifting of the wash load inside the basket 10 . In a preferred embodiment, the tub 11 on its upper part is joined to a covered tub which houses a grill 19 and a spray deflector 18 . The cabinet itself is covered with the main cover 30 which covers the washer's upper part 20 , said main cover 30 serves as a support to the crest (not shown) wherein the electric components such as the controls 40 , the interrupting or relief drivers, the pressure switch 41 etc are housed as well as the washer's cover or lid 29 through which the items to be washed shall be loaded.
[0032] As can be seen in FIGS. 3 , 4 the tub's bottom 11 which is crafted in its center by a truncated cone 49 which allows the liquid or washing mixture to slide to a lower area aided by the force of gravity, this lower zone is formed by a ring with a β pendant whose lowest point coincides with the entrance to the trough 46 , wherein the liquid or washing mixture is collected to be extracted by a bomb 15 whether it be for drainage or whether the liquid or washing mixture be transported to the spraying system. FIG. 5 shows the tub's lower side 11 and it is here that the series of reinforced ribs which have been implemented can be seen. It should be highlighted that a series of diametrical ribs 53 have been traced in cross shape. That is to say, they emerge from the sides of the ears 35 , as can be seen in FIG. 6 , and cross diametrically at the opposite ear 35 , discontinuing the ribs as they pass through the center, the remaining being the radial ribs 52 . In a preferred embodiment to the present invention, another set of diametric ribs 53 emanate from the tub's center 11 towards the periphery of the tub's bottom 42 , said diametric ribs 53 are preferably traced precisely in the middle of the diametric ribs which go from ear 35 to ear 35 . This intricate rib arrangement gives the bottom of the tub 42 greater rigidity with a minimum amount of material used. Using this intricate rib arrangement ensures the placement of sufficient material in the precise area where the forces require strength.
[0033] The ears 35 can be seen in FIGS. 1 a , 5 , 6 , 7 , 8 . It should be noted that said ears 35 are formed by a pair of petals 54 which wrap the shock absorbers from the suspension rod 12 as can be seen in FIG. 1 a . Said petals have the end result of distributing the final dynamic forces, that is, the forces which are generated when the washer is in a wash, centrifuge or rinse mode. In this way, said dynamic forces are not transmitted in their full capacity to the suspension rods' 12 shock absorbers, but rather, are diluted into the tub's body 11 .
[0034] That is, the suspension rod's 12 shock absorber makes contact on a horizontal plane which protrudes from the ear 35 . The lower side of said plane has a spherical surface which has an opening which can be coupled in a swivel form to the upper side of the suspension rod's shock absorber 12 . Said aperture allows the suspension rod access through said horizontal plane of the ear 35 allowing it enough space to allow for angular movement on the vertical axis, this being one degree of freedom: a second and third degree of freedom are obtained on the horizontal axis, allowing the tub 11 a limited translational movement.
[0035] In this way, this system ensures restricted amplitude of movement with 3 degrees of freedom, not allowing movement in the 3 remaining degrees of freedom. However, if the horizontal plane protruding from the ear 35 could be formed as a cantilevered beam (see FIG. 8 ) this would create a strong lever arm on the tub's 11 cylindrical wall 34 and create large forces on the tub's bottom 42 . In a best case scenario, this can cause deformities to said tub's parts 11 , which once said applied forces cease being applied, will return to its original shape. In another case, said deformities can be permanent or cause premature fatigue on said parts of the tub 11 . With the intent of reinforcing said protrusion from the ears 35 on the horizontal plane a pair of petals 54 are added to the ear which help distribute the dynamic forces over a greater area on the tub's 11 cylindrical wall 34 .
[0036] The mentioned petals possess an alternative embodiment from the present invention with reinforcement ribs 36 . The distinct shape of these ears 35 allow a better way to transmit the forces concentrated there unto a larger area of the tub's 11 cylindrical wall 34 and also restrain them to some degree from reaching the deepest part of the tub 42 , lessening the lever's effect on said deepest part 42 . As can be seen from the previous discussion as well as from the figures, this design can transmit to a great degree the forces on the tub 11 and dissipate them unto the tub's body transmitting these forces to a lesser degree on the suspension 12 . The ears' robust design 3 is more difficult to deform, thereby increasing the tub's life, lessening fatigue and additionally increasing the tub's total rigidity 11 .
[0037] Another facet of the present tub's 11 invention, making reference to FIGS. 1 a , 2 , 5 , 7 , 8 is based on the arch shaped reinforcements 39 which can be directed on the external side of the tub's 11 cylindrical wall 34 . Said arch's base is precisely on the side of the ear 35 , which itself serves as reinforcement to the ear 35 . It should also be noted that the lower part of the arch 39 presents a greater radial height, this helps increase moment of inertia in the lower part, which in turn helps the rigidity of the tub's lower part as well as aids in the distributing of forces over a greater area. Thus, when the arch's curvature increases in height over the tub's 11 cylindrical wall 34 , radial height decreases, understanding that the upper portion of the tub 11 does not require high rigidity, therefore being able to economize material with this design, as well as allowing for coherent distribution of dynamic and static forces. The arch as can be discerned, can be formed in different curvatures and configurations, the preferred curvature shall depend on the particular design of each tub, depending on variations of the ear's 35 design, the presence or lack of belts or cylindrical reinforcements 37 , and in case of the actual configuration of these, on the design of the mold itself, are among other factors which can alter the shape or curvature of the arch 39 , which is built with the best possible shape to ensure the best distribution of forces on the tub's 11 cylindrical wall 34 .
[0038] Now turning attention to the belts or cylindrical reinforcements 37 shown in FIGS. 1 a , 2 , 5 , 6 , 7 , 8 it can be seen that said belt or cylindrical reinforcements 37 can be developed preferably in the tub's lower part 11 surrounding the cylindrical wall 34 . The reinforcements 37 are ribs in rectangular or trapezoidal transverse sections, which protrude in radial shape from the cylindrical wall's 34 exterior surface. This allows for a greater moment of inertia giving the mid to lower area of the cylindrical wall 34 excellent rigidity which decreases the deformations caused to this area of the tub 11 and also allows for more efficient distribution of dynamic and static forces to which said tub 11 is subjected to.
[0039] The lobes 38 shown in FIGS. 1 a , 3 , 4 , 5 , 9 , 10 , 11 in addition to giving rigidity to the tub's 11 mouth 47 , confer a greater action radius to the basket 10 , since it is precisely in this area where the gap or space between the tub 11 and the basket 10 is decreased when the basket spins, this is due to the basket's 10 head movement which has its greatest translation movement on the horizontal plane at this point, taking into account that said basket 10 is fastened in its lower or deepest part to the hollow shaft 26 . So that when a considerable shift in the wash load causes imbalance within the basket 10 , the translational movement of the basket's 10 upper part is exacerbated and can indeed scrape the tub's 11 mouth 47 causing the tub 11 harm such as perforations to the cylindrical wall's 34 higher interior surface or in the best of scenarios, loss of energy due to friction caused by the surface contact between the tub 11 and the basket 10 . Thereby the lobes increase the space within which the basket 10 in case of being subjected to translational movement due to its imbalance, avoid to a great degree the scraping problem and as has been mentioned before, increase to a great degree the rigidity of the tub's 11 mouth 47 , which in a common tub 11 or one which does not possess said lobes 38 nor the arch 39 , due to the weight or static and kinematic forces which are transmitted to the tub 11 originating from the basket 10 when it is loaded with articles to be washed submerged in the washing mixture coupled to the lever arms which are generated in supporting the tub 11 to the suspension rods through the ears 35 , cause the tub's 11 mouth to lose its cylindrical shape tending to collapse inwardly or along the tub's 11 own symmetrical axis. In this way, said lobes 38 help avoid the inconveniences mentioned above.
[0040] The tub's 11 mouth 47 has an interesting spout 48 , which has the function of draining the washing mixture or liquid contained in the tub 11 , which for whatever reason is found in excess guaranteeing a maximum level of washing mixture or liquid within the tub 11 . This spout acquires particular relevance since it avoids, should the operator overfill the system with water or in case the pressure switch 41 or the full capacity valve 45 or electronic control 40 malfunction and cause the overfilling of water above the tub's 11 maximum water capacity and the washer 20 can then carry out the washing and rinsing functions. Said liquid or washing mixture excess has to be drained because otherwise the liquid or washing mixture can overflow from the tub 11 over its upper part with the liquid or washing mixture sliding in fountain form over the exterior surface of the tub's 11 cylindrical wall 34 , possibly causing the pumps or motors among other electrical devices to become wet when the overflow of liquid or washing mixture moistens the floor where the washer 20 is placed causing this flow of events to create a dangerous situation, which in a worst possible outcome, could lead to the operator's electrocution since the liquid or washing mixture previously mentioned, has a high water content and water is an electric conductor. In order to avoid such a dangerous situation, the spout 48 , has been designed as shown in FIGS. 1 a , 10 , 11 , as coupled via a ring, clasp or another securing mechanism to a sleeve 55 , which itself is a tube preferably made from a polyethylene extruded with low density, similar to a plastic bag with no bottom. Said sleeve 55 transports the excess liquid or washing mixture to the washer's 20 lower part.
[0041] Having fully described the present invention, it is found to attain a high degree of inventive activity, its industrial application undeniable, warning at the same time that a technician with knowledge in the area can discern alternative modalities which shall be included within the reach and spirit of the following claims.
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In a household washer which contains a tub with a cylindrical wall suspended by means of suspension rods, the tub also is comprised of ears with petals by which the tub is held in one extreme by suspension rods, at least one cylindrical reinforcement which surrounds the cylindrical wall, at least one pair of lobes in a substantially upper area of the tub, and additionally preferably one spout for over-flow in a substantially upper area of the tub.
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BACKGROUND OF THE INVENTION
The present invention relates to an improved process for the preparation of fibers of syndiotactic vinylaromatic polymers. More particularly, the present invention relates to such a process wherein the resulting fibers possess improved physical properties, particularly increased modulus, tenacity and/or maximum strain properties.
In U.S. Pat. No. 5,006,296 a process for preparing fibers of syndiotactic polystyrene (SPS) or a mixture of SPS and isotactic polystyrene was disclosed. At col. 4, lines 18-52, fibers having drawdown ratios (measured as a ratio of fiber cross-sectional area before and after drawing) from 10:1 to 100:1 were disclosed. The fibers were further disclosed as being desirably redrawn. In the redrawing step, the fiber was elongated at a ratio between 1.5:1 and 10:1. The teachings of U.S. Pat. No. 5,006,296 is hereby incorporated by reference.
Fibers prepared by the above technique possess desirable physical properties, however in many respects they lack optimum physical properties, especially tensile modulus, tenacity and/or maximum strain properties. Accordingly it would be desirable if there were provided an improved fiber spinning process for preparing fibers of syndiotactic vinylaromatic polymers having improved physical properties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 show the physical properties of fibers prepared in Example 4.
SUMMARY OF THE INVENTION
According to the present invention there is provided an improved process for the preparation of fibers of syndiotactic vinylaromatic polymers comprising:
A) heating the polymer to a temperature above its crystalline melting point;
B) extruding the molten polymer through a multiplicity of orifices in a spinnerette to form fibers;
C) drawing the fibers at a spin/draw ratio from 120:1 to 5000:1; and
D) cooling the fibers to ambient temperature.
The fibers prepared by the process of this invention exhibit improved modulus, tenacity, percent elongation, and/or maximum strain properties compared to fibers of syndiotactic vinylaromatic polymers prepared according to prior art fiber forming techniques. The resulting fibers are usefully employed in fabrics or cording for filtration, strengthening and reinforcement applications. They are especially useful alone or blended with other fibers in the preparation of nonwoven fabrics by spun bonded, lace bonded, wet laid, dry laid, needle punched or any alternate technique. The fabrics may ultimately be formed into useful articles such as belting or webbing for end uses requiring resistance to high temperatures and/or corrosive environments.
DETAILED DESCRIPTION
The fibers of the present invention are prepared by modification of the technique disclosed in U.S. Pat. No. 5,006,296. In the present process, higher spin/draw ratios are used in the drawing operation than have been previously disclosed in the prior art. Spin/draw ratios are equivalent to draw-down ratios of U.S. Pat. No. 5,006,296, but are more easily measured under continuous fiber spinning conditions. It has been discovered that optimum physical properties are imparted to the resulting fibers if spin/draw ratios between 120:1 and 5000:1, preferably between 130:1 and 1000:1, most preferably between 140:1 and 500:1 are employed in the drawing step during fiber formation. At such spin/draw ratios, it has been discovered that the fiber deforms in a ductile rather than a brittle manner. Among other benefits, this allows the fiber to achieve previously unattainable physical properties during a later, optional, redrawing operation. If the presently discovered spin/draw ratios are not utilized, later redrawing of the fibers does not consistently impart maximum strength properties to the fiber.
The fibers of this invention may be prepared from syndiotactic vinylaromatic homopolymers or copolymers as well as mixtures thereof. Suitable vinyl aromatic polymers include polymers of styrene, vinyltoluene (all isomers and mixtures of isomers, but preferably p-vinyltoluene), t-butylstyrene, chlorostyrene, bromostyrene, 2,5-dimethylstyrene and mixtures thereof. Preferred syndiotactic vinylaromatic polymers are polystyrene, and copolymers of styrene and p-vinyltoluene containing from 2 to 10 weight percent p-vinyltoluene. The latter copolymers have been found to attain maximum physical properties at relatively lower resin processing temperatures. Syndiotactic vinyl aromatic polymers may be prepared by methods well known in the art. Suitable procedures are disclosed in U.S. Pat. Nos. 4,680,353, 5,066,741, 5,206,197 and 5,294,685, the teachings of which are herein incorporated by reference.
As used herein, the term "syndiotactic" refers to polymers having a stereoregular structure of greater than 90 percent syndiotactic, preferably greater than 95 percent syndiotactic, of a racemic triad as determined by 13 C nuclear magnetic resonance spectroscopy. Weight average molecular weight (Mw) of the polymer is preferably from 100,000 to 500,000, more preferably from 125,000 to 400,000.
The fibers of this invention preferably have a tensile modulus (ASTM D-885) of 1,500,000 psi (114 gm/dn) or greater, preferably 3,000,000 psi (228 gm/dn) or greater, a tenacity (ASTM D-885) of 20,000 psi (1.5 gm/dn) or greater, preferably 50,000 psi (3.8 gm/dn) or greater, and a percent elongation at 50 percent of maximum load (taken when the measured load decays to 50 percent of it maximum value) of 50 percent or less, preferably 30 percent or less.
In the process of the invention the neat polymer is preferably heated to the desired extrusion temperature using an extruder and supplied in the molten state to the fiber spinning apparatus (spinnerette). Preferred extrusion temperatures for the polymer are from 250° C. to 350° C., more preferably 255° C. to 300° C. Generally, the syndiotactic copolymers of styrene and p-vinyltoluene are extruded at lower temperatures than syndiotactic polystyrene homopolymer, and are preferably used for this reason. The spinnerette head may be heated in order to maintain a uniform extrusion temperature. The molten polymer is forced through the holes of the spinnerette and desirably is quenched (cooled) in a quench zone so that the extruded fiber may be more readily drawn. Preferred is the use of an air cooled quench zone, however a liquid cooled quench zone may also be suitable for use. Tension is applied to the fibers by means of a set of godets, each comprising one or more reels, which may or may not be heated, engaging the fibers and operating at different speeds to thereby stretch the fiber. The difference in surface velocity in the godets (subsequent godets operating at higher velocities) determines the spin/draw ratio or drawdown of the fibers. That is, a spin/draw ratio of 100:1 indicates the use of a final surface velocity of the godet that is 100 times faster than the extrusion rate of the spinnerette, and consequently a fiber cross-sectional area 100 times smaller than the cross-sectional area of the fiber as extruded. After exiting the godet, the fibers are cooled to ambient temperature (less than 140° C. preferably less than 100° C.) and collected on a take-up reel or other fiber collection device or optionally subjected to redrawing.
The fibers are redrawn in order to impart further strength properties. Redrawing may be performed at temperatures less than 140° C. (cold redrawing) or performed after first reheating the fiber to a temperature from 140° to 250° C. (hot redrawing). Hot redrawing is the preferred redrawing technique. Preferred redrawing ratios are as high as 10:1, preferably from 2.0:1 to 5:1 (meaning a further reduction of cross-sectional area before and after redrawing corresponding to the stated ratio). After redrawing, the fibers are again cooled to ambient temperature and may again be collected on a take-up reel or other fiber collection device.
The skilled artisan will appreciate that the invention disclosed herein may be practiced in the absence of any component which has not been specifically disclosed. The following examples are provided as further illustration thereof and are not to be construed as limiting. Unless stated to the contrary all parts and percentages are expressed on a weight basis.
EXAMPLES
Fiber Spinning and Redrawing
Fibers were extruded using a 0.75 inch (19 mm) single screw extruder equipped with a general purpose screw. The polymer was metered by a gear pump to a 0.03 in (0.8 mm) 24 hole spinnerette employing a face heater. Discharge pressure to the spinnerette was maintained at less than 600 psi (4 MPa). The 24-filament tow was extruded across a 15 inch (38 cm) air cooled quench zone to a godet with 12 inch (30 cm) circumference rolls that were not temperature controlled. The godet had a maximum surface speed of 500 ft/min (2.5 M/sec) and no differential draw was set between the primary and secondary godet rolls. Fiber from the godet was collected on an automatic fiber winding machine. Spin/draw ratios were calculated using the following formula: ##EQU1## where V g is the surface velocity of the godet in cm/sec, Q p is the volume rate of flow to the spinnerette in cm 3 /sec, R is the radius in cm of the holes in the spinnerette, and N is the number of holes in the spinnerette.
The fibers were hot redrawn by passing through a ceramic tube furnace to a take-up roll using a stainless steel pull rod. The feed spool was calibrated to turn at a fixed surface velocity for all experiments. The surface velocity of the take-up reel was electronically controlled to accomplish the required redraw ratios. Redraw ratios were calculated by calculating the ratio of the surface velocity of the take-up reel to the surface velocity of the feed spool.
Physical Property Testing
Fiber physical property measurements were performed using an INSTRON™ model 4201 brand tensile testing frame operating under INSTRON™ Series Nine brand software control. A 200 lb (91 Kg) load cell was used for force measurements. Experiments were run in displacement control at a cross-head speed of 1.0 inches/min (25.4 mm/min). INSTRON™ brand air actuated fiber grips were utilized to secure the samples during testing. All the experiments were conducted at 23° C. and 50 percent relative humidity.
Denier measurements were made on each sample prior to testing. Denier is defined as the weight in grams of 9000M of fiber. The denier measurement used for the present calculations was made by extrapolation using four meters of fiber. The tenacity values reported were calculated by taking the ultimate load (in grams of force) observed during the test divided by the denier of the sample. The reported tensile modulus and percent elongation values were determined at the point where the sample load had decayed, due to individual fiber failure, to 50 percent of the maximum load achieved during testing.
Example 1
A copolymer of 96 weight percent styrene and 4 weight percent p-vinyltoluene (syndiotacticity greater than 98 percent) having a molecular weight (Mw) of 285 kg/mole was spun into fibers at a melt temperature of 335° C. and a spinnerette die temperature of 290° C. with a spin draw ratio of 200. The fibers were collected then subjected to a redraw of 2.4× at 140° C. Physical properties of the redrawn fibers are provided in Table 1.
TABLE 1______________________________________Tensile Modulus Tenacity Elongationpsi (g/DN) psi (g/DN) (%)______________________________________1.6 × 10.sup.6 (122) 2.3 × 10.sup.4 (1.7) 26______________________________________
Example 2
A copolymer of 92 weight percent styrene and 8 weight percent p-vinyltoluene (syndiotacticity greater than 98 percent) having a molecular weight (Mw) of 255 kg/mole was spun into fibers at a melt temperature of 335° C. and a spinnerette die temperature of 285° C. with a spin draw ratio of 200. The fibers were collected then subjected to a redraw of 5× at 140° C. Physical properties of the redrawn fibers are provided in Table 2.
TABLE 2______________________________________Tensile Modulus Tenacity Elongationpsi (g/DN) psi (g/DN) (%)______________________________________1.5 × 10.sup.6 (115) 2.0 × 10.sup.4 (1.5) 30______________________________________
Example 3
A homopolymer of styrene (syndiotacticity greater than 98 percent) having a molecular weight (Mw) of 225 kg/mole was spun into fibers at a melt temperature of 335° C. and a spinnerette die temperature of 290° C. with a spin draw ratio of 200. The fibers were collected then subjected to a redraw of 2.5× at 180° C. Physical properties of the redrawn fibers are provided in Table 3.
TABLE 3______________________________________Tensile Modulus Tenacity Elongationpsi (g/DN) psi (g/DN) (%)______________________________________3.1 × 10.sup.6 (234) 5.4 × 10.sup.4 (4.1) 8______________________________________
Example 4
The polymer used in Example 3 was spun into fibers at an extrusion temperature of 300° C. and at various spin-draw ratios. Tensile properties of the fibers after hot redrawing (2.45×, 140° C.) are shown in FIGS. 1-3. From the figures it may be seen that fiber physical properties, especially tensile modulus, tenacity and elongation, are significantly improved by the use of spin draw ratios greater than 120:1. Specifically, the modulus and tenacity values for such fibers increased dramatically at such spin/draw ratios. Conversely, percent elongation at 50 percent strength retention was reduced, i.e. improved, for such fibers.
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Fibers of syndiotactic vinylaromatic polymers are prepared in an improved process comprising:
A) heating the polymer to a temperature above its crystalline melting point;
B) extruding the molten polymer through a multiplicity of orifices in a spinnerette to form fibers;
C) drawing the fibers at a spin/draw ratio from 120:1 to 5000:1; and
D) cooling the fibers to ambient temperature.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a flashing member for waterproofing corners of recessed windows and other rough openings in buildings such as doorway openings, ductwork passages, and other types of openings that can be found in houses and other building structures.
[0003] 2. Description of the Prior Art
[0004] In building construction, it is important to provide a water-tight seal around any rough openings in exterior walls, including windows and doors. One specific challenge in many buildings is sealing recessed windows. Recessed windows include an outer wall opening that is flush with the exterior of the building, and an inner, recessed framed opening, that lies in a plane behind that of the exterior. Generally, the inner framed opening has a height and width less than that of the outer framed opening. When the window is finally installed, it lies within the inner framed opening.
[0005] The corners of recessed windows are particularly difficult to flash and seal adequately. US Patent Publication Number 2005/0055890A discloses a corner flashing system for sealing the corners of recessed window frames against moisture penetration. The system comprises double-flap members, a half-cube member, and caulking. The double-flap members and the half-cube member are preferably made of asphalt or petroleum based material. U.S. Pat. No. 6,401,402 also discloses a flashing system and method for controlling water and air intrusion around windows such as recessed windows, utilizing flashing material creased and folded to form a corner flashing component. However, both of these flashing systems includes seams and gaps through which water can infiltrate, and both systems rely on piercing fasteners to install the flashing, such as staples, providing further opportunity for water to infiltrate.
[0006] Therefore, there is a need for a corner flashing system that is well adapted to installation in recessed window frames.
SUMMARY OF THE INVENTION
[0007] In one aspect thin invention is directed to a method for flashing recessed corners in a building comprising:
[0008] providing a strip of flashing material comprising an elastic, conformable, flexible water resistant topsheet having an extension of at least about 150% at an applied stress no greater than 10 N/cm, a pressure-sensitive adhesive layer covering one surface of said topsheet having an equivalent extension as the top sheet at an equivalent applied stress; and a release sheet removably attached to said adhesive layer having a cross direction perforation dividing the release sheet into two major portions and a machine direction perforation dividing the release sheet into an edge portion and a bulk portion; removing a triangular portion of said release sheet wherein the triangular portion is in the shape of an isosceles triangle bisected by the cross direction perforation of said release sheet, wherein the triangle has a 90° angle at the intersection of the machine direction perforation and the cross direction perforation and to 45° angles along the edge of said edge portion of said release sheet, thereby exposing a triangular portion of said adhesive layer; folding said flashing material along said cross direction perforation, thereby attaching the exposed adhesive layers on opposite sides of the fold line such that the exposed adhesive layers make continuous contact; folding said flashing material along said cross direction perforation to form a right angle between the top sheet surfaces and folding said flashing material along said machine direction perforation to form a right angle between the top sheet surfaces, thereby forming the corner-shaped flashing member; removing the remaining release sheet from said corner-shaped flashing member to expose the remaining adhesive layer; and
[0000] attaching said exposed remaining adhesive layer to the recessed corner surfaces, thereby affixing the corner-shaped flashing member in an installation position.
[0009] In one aspect, the invention is also directed to a flashing member, comprising a unitary self-adhering sheet conformable to a recessed corner in a building opening, wherein fasteners are not required to hold the member within the recessed corner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective illustration of the corner flashing member of the invention.
[0011] FIG. 2 illustrates the cross section of flashing material for forming the corner flashing member of the invention.
[0012] FIG. 3 is an illustration of the self-adhesive flashing material used to form the corner flashing member of the invention, illustrating the pattern of the release sheet covering the adhesive layer of the flashing material.
[0013] FIG. 4 is a perspective illustration of a recessed window with the corner flashing member of the invention installed.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 illustrates a corner flashing member 10 according to the invention. Flashing material 12 has four faces in three planes, 10 a, 10 a ′ (it is noted that 10 a and 10 a ′ are coplanar), 10 b and 10 c, where the three planes are at right angles to each other in the shape of a recessed corner. The three planes share three common edges 11 a, 11 b and 11 c. The corner flashing member is free of seams or holes through which water could infiltrate behind the flashing. The flashing material is elastic, conformable and flexible such that it can not only fit into the recessed corner of a recessed window, but it may also be extended and wrapped around the exterior wall. The length of the flashing material on either side of the corner is at least about 1 inch, and is typically about 6 inches.
[0015] FIG. 2 illustrates a cross section of the flashing material 12 . Flashing material 12 has a topsheet 14 , a pressure sensitive adhesive layer 16 on one surface of the top sheet and a release sheet 18 removably attached to said adhesive layer. The top sheet 14 is an elastic, conformable and flexible material. Suitable materials for use as the top sheet include elastic polymer films, elastic woven fabrics, elastic nonwovens, elastic knit fabrics, and laminates thereof. The top sheet has an extension of at least 150% when exposed to an applied stress no greater than 10 N/cm. Preferably, for durability the top sheet has tensile strength of greater than 1000 N/m when measured according to ASTM D1682, section 19.
[0016] The adhesive layer 16 is an elastic, conformable and flexible adhesive. Suitable adhesives include materials conventionally used in the waterproofing art, such as rubber-modified asphaltic or butyl adhesive. The adhesive layer extends an equivalent amount as the top sheet when exposed to an equivalent level of stress. The average thickness of the adhesive layer 16 can be 5-100 mils. The minimum thickness of the adhesive layer depends on what is needed to provide good adhesion and, optionally, if desired, nail sealability given the adhesive composition used. For instance, a 10-60 mils thick layer of butyl adhesive has been found to be sufficient.
[0017] The release sheet 18 can be any known material suitable for use as a release liner on rubberized asphalt and butyl adhesive.
[0018] An inventive method for forming the corner flashing member 10 will now be described. A discrete section of an elongated strip of flashing material 12 is provided. FIG. 3 illustrates the pattern of perforations in the release sheet 18 . For each corner flashing member, perforations 18 e extending in the cross direction (XD) divide the release sheet into two roughly equal major portions along the machine direction and perforations 18 f extending in the machine direction (MD) divide the release sheet into two unequal portions along the cross direction, a narrower edge portion 18 a and a wider bulk portion 18 b. A plurality of corner flashing members 10 can be formed from an elongated strip of flashing material 12 . A cut line 18 d represents where a cut is made in the flashing material in order to divide the elongated strip of the flashing material into individual sections of the flashing material, each forming a single corner flashing member.
[0019] A triangular portion 18 c of the release sheet is removed from the flashing material 12 , thereby exposing a triangular portion of the underlying adhesive layer. The triangle is defined by the perforations in the release sheet and the edge of the strip of flashing material. The tip of the triangle is located at the intersection of the machine direction perforation 18 f and the cross direction perforation 18 e, where the triangle has a 90° angle, and the base of the triangle is the edge of the strip where the triangle has two 45° angles. The triangular portion is bisected by the cross direction perforation 18 e. For embodiments in which the triangular portion 18 c of the release sheet is removed at the building site just prior to installation, the triangular portion 18 c of the release sheet can be perforated for removal at the building site; alternatively the triangular portion can be scored and removed using a knife or box cutter.
[0020] The strip of flashing material 12 is folded along the cross direction perforation, thereby attaching the exposed adhesive layers on opposite sides of the fold line such that the exposed adhesive layers make continuous contact. The resulting adhesive-to-adhesive layer effectively becomes one continuous adhesive layer with no space between the original adhesive layers. This provides no seam or hole for water to infiltrate. When the flashing material is folded, the resulting adhesive-to-adhesive layer forms a strong, durable dog-eared seal 20 as shown in FIG. 1 . In both FIGS. 1 and 4 , the corner flashing member 10 is depicted in a right hand corner, however the flashing material can be folded such that the corner flashing member fits into either a right hand corner or a left hand corner.
[0021] It is common in some recessed windows to install a second framing member within the framing member in which the window is installed. In order to accommodate this type of construction, the edge portion of the release sheet of the flashing material is made wider in order to cover the nailing fin of the window. Multiple perforations can be made in the machine direction on the flashing material in anticipation that the corner flashing numbers could be used on multiple types of window construction.
[0022] Once the seal 20 is formed, the flashing material is folded along the cross direction perforation in the direction opposite the direction it was folded to form the seal 20 , to form a right angle between topsheet surfaces. The flashing material is also folded along the machine direction perforation to form a right angle between topsheet surfaces, such that the corner-shaped flashing member 10 is formed.
[0023] The method for forming the flashing member can be carried out at the time of installation starting with a strip of flashing material. Alternatively, the corner members can be preformed and delivered to the building site for subsequent installation. According to one preferred embodiment, a length of flashing material having the above described pattern of perforations in the release sheet is formed and the triangular portions 18 c of the release sheet are removed to expose the underlying butyl adhesive. The length of flashing material is then folded in a “fanfold” manner such that the material is folded in alternating directions at each cross direction perforation, and such that the exposed butyl adhesive is folded on itself to form the seal 20 . The thus folded material can be packaged for delivery to installation sites. At the installation site, the installer can complete the formation of the corner member just prior to installation, by cutting along perforation 18 d to form individual corner flashing members which are folded onto themselves, and subsequently inverting or turning the corner “inside out” to form the shape of a right angle corner for installation.
[0024] In order to install the corner flashing member, the release sheet is removed from the outer surfaces of the flashing member to expose the adhesive layer on the outer surfaces. The exposed adhesive can then be attached directly to the interior surfaces of the recessed window, thereby affixing the flashing member in an installation position, as illustrated in FIG. 4 . In order to ensure that the corner flashing member is affixed securely in the corner of the window, preferably only one piece of the release sheet is removed at a time, so that the corner flashing member can be first affixed to the framing members 22 forming the window opening. Once the flashing member is adhered to the framing members and/or nailing fin of the windows, the remaining pieces of release sheet are removed, so that the corner flashing member can be affixed to recessed sill 24 and window jamb 26 surfaces. As can be seen from FIG. 3 , the flashing material can also be extended and wrapped around the corner of the recessed sill and window jamb surfaces to cover a portion of the exterior wall 28 . Typically, fasteners F such as nails or staples are installed through the flashing material to secure it to the exterior wall. Also typically, the flashing material on the exterior wall extends at least 2 inches from the recessed sill and jamb surfaces of the recessed window opening. As depicted in FIG. 1 , the seal 20 extends outward in a dog-eared manner, but for convenience purposes can be attached to surface 10 a (or 10 a ′) as shown in FIG. 4 .
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The invention pertains to a self-adhesive corner-shaped flashing member for flashing a corner of a recessed window or other opening in a building and a method for making the member. The invention also pertains to a method for flashing recessed corners of recessed windows and the like.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of color characterization of color input devices, and specifically relates to generating a color characterization model for performing transformation from a device-dependent color space to a device-independent color space. The color characterization model is based on measured color data points.
2. Description of the Related Art
Traditional color management systems (CMSs) use color characterizations of color input devices to derive color transformations that transform color coordinates between a device-dependent color space that depends on the device, and a device-independent color space. In particular, color characterization for a color input device such as a camera or scanner can be derived by first capturing a target consisting of predesignated color patches. In a device-dependent color space such as the RGB color space, this results in an RGB bitmap image in which the color of each patch is encoded in an RGB value.
Given a particular target, the color transformation between the device-dependent and device-independent color spaces can be modeled reasonably by polynomials of low degrees. The mathematical method or technique for fitting these polynomials is known as polynomial regression.
A problem arises in the use of polynomial regression based on measured data points. In particular, the use of polynomials tends to overshoot or undershoot beyond the range of the measured data points in a given space. An aspect of this problem is that the device-independent color space typically has constraints associated with it that are imposed by the physical range of the quantities being modeled. In other words, a color in the device-independent color space is typically represented by three coordinates. These three coordinates must satisfy certain constraints and relationships among them to represent a physically possible color. To impose these constraints, domain knowledge rather than the use of purely statistical techniques is required.
If the measured data points from the color input device uniformly fill in the device-dependent color space, the problem of overshooting or undershooting beyond the range of the data points does not arise. However, data points measured from a standard target are rarely distributed uniformly in the device-dependent color space. For instance, measured RGB points typically fill up the inner portions of the RGB cube, or reside in a lower dimensional manifold of the RGB cube. When this happens, the regressed polynomials based on the measured data points are inaccurate in predicting device-independent values beyond the range of the measured data points.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing problems by imposing boundary conditions in the color space of the color device on which polynomial regression is performed. In particular, the invention generates a set of boundary data points that are outside a measurement range of the captured data set, which preferably correspond to axes or corner points of the device-dependent color space of the color input device, and obtains a color characterization based on a best fit to both the actual measurements and the generated data points.
In one aspect, the present invention generates a color characterization model for performing transformation from a device-dependent color space of a color device to a device-independent color space. A first set of color measurement data is accessed corresponding to actual measurements of the color device, wherein the actual measurements define a measurement range in the device-dependent color space, and wherein the measurement data includes data point pairs, each data point pair having corresponding device-dependent values and device-independent values. Next, a second set of data point pairs is generated based on a predesignated set of device-dependent values outside the measurement range, by extrapolating device-independent values from the first set of color measurement data. The color characterization model is then determined based on both the first set of color measurement data and the generated second set of data point pairs.
Preferably, the second set of data point pairs is generated by extrapolating the device-independent values from the first set of color measurement data based on distance and hue angle. Shepard extrapolation may be used. The first set of color measurement data is preferably obtained from a measurement-only color profile corresponding to the color device.
The color characterization model is preferably determined by either multivariate linear regression or nonlinear regression. In addition, the predesignated set of device-independent values preferably corresponds to axes or corner boundaries of the device-dependent color space. The device-dependent color space of the color device is preferably the RGB space. The device-independent color space is preferably any one of the CIELUV space, the CIELAB space or the JAB space. The color characterization model is preferably usable by a color management system.
Because the present invention introduces a set of boundary data points that are outside of the measurement range of the first set of color measurement data, extra penalty is imposed on undesirable polynomials that overshoot or undershoot near device-dependent color space boundaries. In addition, the added data points allow for constraints which are imposed by the physical range of the color space being modeled to be considered.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing the appearance of one embodiment of the invention.
FIG. 2 is a block diagram depicting an example of an internal architecture of the FIG. 1 embodiment.
FIG. 3 is a block diagram depicting a color management module which can carry out a method of generating a color characterization model according to the present invention.
FIG. 4 is a flowchart that illustrates generating a color characterization model for a color input device according to the present invention.
FIG. 5 is a representational diagram depicting the generation of additional data points according to the present invention.
FIG. 6 is a flowchart illustrating the generation of additional data points according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a view showing the exterior appearance of one embodiment of the invention is shown. Specifically, FIG. 1 depicts computing equipment 100 , which includes host processor 103 comprising a personal computer (hereinafter “PC”). Provided with computing equipment 100 are color monitor 101 including display screen 107 for displaying text and images to a user, keyboard 106 for entering text data and user commands into PC 103 , and pointing device 111 . Pointing device 111 preferably comprises a mouse, for pointing, selecting and manipulating objects displayed on display screen 107 .
Computing equipment 100 includes a computer readable memory medium such as floppy disk drive 108 , fixed disk 110 , and/or CD-ROM drive 109 . Such computer readable memory media allow computing equipment 100 to access information such as image data, computer-executable process steps, application programs, and the like, stored on removable and non-removable memory media. In addition, network access 105 allows computing equipment 100 to acquire information, images and application programs from other sources, such as a local area network or the Internet.
Digital scanner 104 and digital camera 102 are both color input devices for which a color characterization model can be generated according to the present invention. Digital color scanner 104 is provided for scanning documents and images and sending the corresponding image data to computing equipment 100 . Digital color camera 102 is provided for sending digital image data to computing equipment 100 . Of course, computing equipment 100 may acquire digital image data from other color input devices, such as a digital video camera.
FIG. 2 is a block diagram illustrating the internal architecture of the FIG. 1 embodiment. As shown in FIG. 2 , PC 103 includes network interface 202 for network access 105 , and a central processing unit (“CPU”) 201 , that interfaces with computer bus 200 . Also interfacing with computer bus 200 are fixed disk 110 , random access memory (“RAM”) 207 for use as main memory, read only memory (“ROM”) 208 , floppy disk interface 209 to allow PC 103 to interface with floppy disk drive 108 , display interface 210 for interfacing with monitor 101 , keyboard interface 203 for interfacing with keyboard 106 , mouse interface 204 for interfacing with pointing device 111 , scanner interface 205 for interfacing with scanner 104 , and camera interface 206 for interfacing with digital camera 102 .
Main memory 207 interfaces with computer bus 200 so as to provide quick RAM storage to CPU 201 during execution of software programs such as the operating system application programs, and device drivers. More specifically, CPU 201 loads computer-executable process steps from fixed disk 110 or other memory media into a region of main memory 207 in order to execute software programs. Data such as color measurement data can be stored in main memory 207 , where the data can be accessed by CPU 201 during execution.
Read only memory 208 stores invariant computer-executable program code, or program or process steps, for basic system functions such as basic input and output (I/O), startup, or reception of keystrokes from keyboard 106 .
As also shown in FIG. 2 , fixed disk 110 stores computer-executable code for application programs 211 such image processing programs like Adobe® Photo shop™.
Fixed disk 110 also stores color management module (CMM) 218 . CMM 218 renders color image data from a device-dependent color space to a device-independent color space, and vice versa. CMM 218 uses measurement data from color measurement profiles to generate the device transforms necessary to transform color image data into the color space of the destination color image data.
Forward model 219 is a data structure by which color behavior of a color device is modeled, and performs the transformation from the device-dependent color space of a color input device to a device-independent color space. Forward model 219 can be embodied into a single device driver such as scanner driver 213 or camera driver 214 . The generation of forward model 219 , being the color characterization model for performing transformation from a device-dependent color space of a color input device to a device-independent color space, is described in more detail below.
It is also possible to implement CMM 218 according to the invention as a dynamic link library (“DLL”), or as a plug-in to other application programs such as image manipulation programs like the Adobe® Photoshop™ image manipulation program, or as part of scanner driver 213 or camera driver 214 .
Fixed disk 110 further stores computer-executable code for monitor driver 212 , scanner driver 213 , camera driver 214 , other device drivers 215 , image files 216 and other files 217 .
FIGS. 1 and 2 illustrate one example of a computing system that executes program code, or program or process steps, configured to generate a color transform using a data structure by which behavior of a color input device is modeled. Other types of computing systems may also be used.
With reference to FIG. 3 , a block diagram depicting CMM 218 , which carries out a method of generating a color characterization model according to the present invention, is shown. CMM 218 contains color input characterization module 301 for characterizing color input device 300 , as well as color output device profile 305 for defining a color characterization for color output device 306 . CMM 218 operates to accept color values in device-dependent coordinates (such as scanner RGB coordinates), apply the color characterization model and output corresponding color values in the device-independent coordinates (such as Luv). CMM 218 also operates to transform the device-independent coordinates into device-dependent coordinates (such as printer CMYK or monitor RGB) based on color output device profile 305 . CMM 218 also operates to perform gamut-mapping between the device-dependent and device-independent color spaces.
Color input characterization module 301 contains process steps for an access data module 302 to access sampled color measurement data of color input device 300 , including data point pairs of measured device-dependent values and their corresponding device-independent values. Color input characterization module 301 also contains process steps for a generate additional points module 303 for generating additional points outside a range defined by the actual measurements of the color input device. In addition, color input characterization module 301 contains process steps for a determine forward model module 304 for determining a color characterization model (forward model 219 ) based on the original color measurement data and the additional generated data points.
Color input characterization module 301 , access data module 302 , generate additional points module 303 , determine forward model module 304 , and color output device profile 305 can all be embedded within CMM 218 , or can be separate application programs accessed by CMM 218 , or can be combined into a single application program accessed by CMM 218 . In addition, image data can be input from color input device 300 to CMM 218 using forward model 219 . In this embodiment, color input device 300 is scanner 104 or digital camera 102 , although a different color input device such as a digital video camera can be used.
Color characterization of color input device 300 generally consists of capturing an image of a target consisting of color patches with known color values in a device-independent color space. Popular choices of such a target include the IT8.7 target and the Color Checker. The result of the capture is an device-dependent bitmap image in which the color of each patch is encoded in a device-dependent value such as RGB. Data point pairs having corresponding RGB values and Luv values make up the color measurement data, and define a measurement range. The measurement range typically does not extend to the boundaries of the RGB color space cube.
These color measurement data are specific to color input device 300 , and the goal of calorimetric characterization is to establish an empirical relationship between RGB values and color values in a device-independent color space such as CIELUV. More specifically, a mathematical transformation is sought from RGB to Luv that models as accurately as possible the behavior of color input device 300 . Such a transformation can be modeled reasonably well by polynomials of low degrees.
In the preferred embodiment, RGB is the device-dependent color space, Luv is the device-independent color space, and a 20-term cubic polynomial is used as the color characterization model for color input device 300 . However, other device-dependent and device-independent color spaces can be used, as well as polynomials with a different number of terms. Given the 20-term cubic polynomial, coefficients λ i , α i , β i are sought such that the following equations satisfy the least squares error condition on the data points.
L
^
(
R
,
G
,
B
)
=
λ
1
+
λ
2
R
+
λ
3
G
+
λ
4
B
+
λ
5
R
2
+
λ
6
RG
+
λ
7
RB
+
λ
8
G
2
+
λ
9
GB
+
λ
10
B
2
+
λ
11
R
3
+
λ
12
R
2
G
+
λ
13
R
2
B
+
λ
14
RG
2
+
λ
15
RGB
+
λ
16
RB
2
+
λ
17
G
3
+
λ
18
G
2
B
+
λ
19
GB
2
+
λ
20
B
3
u
^
(
R
,
G
,
B
)
=
α
1
+
α
2
R
+
α
2
R
+
α
3
G
+
α
4
B
+
α
5
R
2
+
α
6
RG
+
α
7
RB
+
α
8
G
2
+
α
9
GB
+
α
10
B
2
+
α
11
R
3
+
α
12
R
2
G
+
α
13
R
2
B
+
α
14
RG
2
+
α
15
RGB
+
α
16
RB
2
+
α
17
G
3
+
α
18
G
2
B
+
α
19
GB
2
+
α
20
B
3
v
^
(
R
,
G
,
B
)
=
β
1
+
β
2
R
+
β
3
G
+
β
4
B
+
β
5
R
2
+
β
6
RG
+
β
7
RB
+
β
8
G
2
+
β
9
GB
+
β
10
B
2
+
β
11
R
3
+
β
12
R
2
G
+
β
13
R
2
B
+
β
14
RG
2
+
β
15
RGB
+
β
16
RB
2
+
β
17
G
3
+
β
18
G
2
B
+
β
19
GB
2
+
β
20
B
3
These polynomials should minimize the sum of squares of errors:
SSE=Σ ( {circumflex over (L)} ( R i , G i , B i )− L i ) 2 +( û ( R i , G i , B i )− u i ) 2 +( {circumflex over (v)} ( R i , G i , B i )− v i ) 2 ),
where the data point pairs are (R i , G i , B i ) and (L i , u i , v i ). The least squares problem can be stated as solving the following matrix equation, where N is the number of color measurement data points:
( 1 R 1 G 1 B 1 … G 1 B 1 2 B 1 3 1 R 2 G 2 B 2 … G 2 B 2 2 B 2 3 ⋮ ⋮ ⋮ ⋮ … ⋮ ⋮ 1 R N G N B N … G N B N 2 B N 3 ) ( λ 1 λ 1 ⋮ λ 20 ) = ( L 1 L 1 ⋮ L N )
or, more compactly, RΛ=L.
Typically, N is larger than 20, so the above-equation is over-determined, necessitating a least squares solution. A closed form for the solution for Λ can be given by:
Λ=( R T R ) −1 ( R T L )
In practice, the closed form solution is not used. Instead, for a more numerically stable algorithm, the least squares solution is obtained by first decomposing the matrix R into a matrix product (for example, using singular value decomposition), followed by back substitution.
As noted above, the use of polynomials tends to overshoot or undershoot beyond the range of the measured data points in a region beyond the range of the measured data points. An aspect of this problem is that the Luv color space typically has constraints associated with it that are imposed by the physical range of the quantities being modeled. In other words, a color in the device-independent color space is typically represented by three coordinates. These three coordinates must satisfy certain constraints and relationships among them to represent a physically possible color. To impose these constraints, domain knowledge rather than the use of purely statistical techniques is required. The present invention addresses the foregoing by introducing boundary points outside of the measurement range of the color measurement data.
Referring now to FIG. 4 , a flowchart that illustrates generating a color characterization model for a color input device according to the present invention is shown. Following start bubble S 400 , color measurement data is accessed in step S 401 , additional points are generated in step S 402 based on the color measurement data, and forward model 219 is determined using both the color measurement data and the generated data points in step S 404 . The generation of additional points is described in more detail in relation to FIGS. 5 and 6 .
With reference to FIG. 5 , a representational diagram depicting the generation of additional data points according to the present invention is shown. In the preferred embodiment, eight control points are introduced corresponding to the corners of the RGB color space cube. These points are typically outside of the measurement range of the color measurement data. If the values for color input device 300 are normalized to unity, then the RGB values for these control points are:
R=0, G=0, B=0 R=0, G=0, B=1 R=0, G=1, B=0 R=0, G=1, B=1 R=1, G=0, B=0 R=1, G=0, B=1 R=1, G=1, B=0 R=1, G=1, B=1
Luv values corresponding to each of the listed (R, G, B) control points are then determined. In determining the Luv values, the hue of the (R, G, B) color should be considered.
Generally, for a given (R, G, B) from above, a weight is assigned to each of the (R i , G i , B i ) within a neighborhood of (R, G, B) in the sampled data set. Weight is determined based on two criteria. First, the weight is inversely proportional to the distance between (R, G, B) and (R i , G i , B i ). Second, data points having a significantly different hue than the given (R, G, B) point should be discarded, meaning the weight for those data points should be set to 0. To take the hue into account, only points that lie within a cone whose vertex is at (0, 0, 0) are considered, whose axis coincides with the line joining (0, 0, 0) to (R, G, B), and whose semi-vertical angle θ satisfies cos θ=0.9, if such points exist.
With reference to FIG. 6 , a flowchart illustrating the generation of additional data points according to the present invention is shown. Following start bubble S 600 , the Luv value for white R=G=B=1) is assigned L=100 and u=v=0 in step S 601 . Then, in step S 602 , a determination is made as to whether all the Luv values corresponding to the eight corners of the RGB cube have been assigned. If the answer to this inquiry is yes, step S 602 is followed by end bubble S 613 . Otherwise, in step S 603 , an RGB point without a corresponding Luv value is selected. Cos θ is initialized to 0.9 in step S 604 , followed by a decision as to whether cos θ is greater than or equal to 0 in step S 605 . If the answer to this inquiry is no, an error condition occurs in end bubble S 614 . Otherwise, a maximum radius value MAX_R is initialized to a maximum distance (MAXD) divided by 5 if cos θ exceeds 0, or MAX_R is initialized to MAX_D if cos θ equals 0. MAX_D equals 3 in the case of 1-norm. In step S 607 , a radius value R is initialized to 0.1. This is followed by an inquiry in step S 608 as to whether R is less than or equal to MAX_R. If the answer to this inquiry is no, cos θ is decremented by 0.05 and step S 605 is revisited. Otherwise, sample points are collected for a set S in step S 609 . Then, in step S 610 , a determination is made as to whether set S is empty. If set S is not empty, an Luv value is calculated based on set S. The calculation of the Luv value is discussed in more detail below. If set S is empty, R is incremented by 0.1 in step S 611 , and step S 608 is revisited. This repeats until set S is not empty.
After yielding a non-empty set S of points (R i , G i , B i ) and corresponding (L i , u i , v i ), then for each such point, a normalized weight w i is assigned as follows:
h i = ( max ( MAX_D - d i , 0 ) d i ) 2 where d i = R - R i + G - G i + B - B i w i = h i / ∑ j ∈ S h j
where h i is the weight before normalization and satisfies the inverse-distance property, and d i is the distance of (R, G, B) from (R i , G i , B i ).
The extrapolated Luv value for (R, G, B) is then calculated by:
L
=
∑
i
∈
S
w
i
L
i
u
=
∑
i
∈
S
w
i
u
i
v
=
∑
i
∈
S
w
i
v
i
Referring back to FIG. 4 , once the additional data points are generated, multivariate linear regression is performed on the N+8 data points (color measurement data points+generated data points). This results in a color characterization model (forward model 219 ) for input color device 300 .
By introducing boundary data points outside of the measurement range of the original color measurement data, extra penalty is imposed on the polynomials that overshoot or undershoot near polynomial boundaries. In addition, the generated data points allow for constraints which are imposed by the physical range of the color space being modeled to be considered.
The invention has been described above with respect to particular illustrative embodiments. It is understood that the invention is not limited to the above-described embodiments and that various changes and modifications may be made by those skilled in the relevant art without departing from the spirit and scope of the invention.
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The present invention generates a color characterization model for performing transformation from a device-dependent color space of a color device to a device-independent color space. A first set of color measurement data is accessed corresponding to actual measurements of the color device, wherein the actual measurements define a measurement range in the device-dependent color space, and wherein the measurement data includes data point pairs, each data point pair having corresponding device-dependent values and device-independent values. Next, a second set of data point pairs is generated based on a predesignated set of device-dependent values outside the measurement range, by extrapolating device-independent values from the first set of color measurement data. The color characterization model is then determined based on both the first set of color measurement data and the generated second set of data point pairs. Because the color characterization model is determined based on actual measurements and extrapolated values, the color characterization model is well-behaved and does not exhibit significant overshooting or undershooting beyond the measurement range.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/336,266, filed Jun. 14, 1999, now U.S. Pat. No. 6,608,060, which is a continuation of International Application No. PCT/US97/23392, filed Dec. 17, 1997, which is a continuation-in-part of U.S. patent application Ser. No. 08/862,925, filed Jun. 10, 1997, now U.S. Pat. No. 6,147,080, which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned; and a continuation-in-part of U.S. application Ser. No. 08/822,373, filed Mar. 20, 1997, now U.S. Pat. No. 5,945,418, which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned; and which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned.
TECHNICAL FIELD OF INVENTION
The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders.
BACKGROUND OF THE INVENTION
Protein kinases are involved in various cellular responses to extracellular signals. Recently, a family of mitogen-activated protein kinases (MAPK) have been discovered. Members of this family are Ser/Thr kinases that activate their substrates by phosphorylation [B. Stein et al., Ann. Rep. Med. Chem., 31, pp. 289–98 (1996)]. MAPKs are themselves activated by a variety of signals including growth factors, cytokines, UV radiation, and stress-inducing agents.
One particularly interesting MAPK is p38. p38, also known as cytokine suppressive anti-inflammatory drug binding protein (CSBP) and RK, was isolated from murine pre-B cells that were transfected with the lipopolysaccharide (LPS) receptor CD14 and induced with LPS. p38 has since been isolated and sequenced, as has the cDNA encoding it in humans and mouse. Activation of p38 has been observed in cells stimulated by stresses, such as treatment of lipopolysaccharides (LPS), UV, anisomycin, or osmotic shock, and by cytokines, such as IL-1 and TNF.
Inhibition of p38 kinase leads to a blockade on the production of both IL-1 and TNF. IL-1 and TNF stimulate the production of other proinflammatory cytokines such as IL-6 and IL-8 and have been implicated in acute and chronic inflammatory diseases and in post-menopausal osteoporosis [R. B. Kimble et al., Endocrinol., 136, pp. 3054–61 (1995)].
Based upon this finding it is believed that p38, along with other MAPKs, have a role in mediating cellular response to inflammatory stimuli, such as leukocyte accumulation, macrophage/monocyte activation, tissue resorption, fever, acute phase responses and neutrophilia. In addition, MAPKs, such as p38, have been implicated in cancer, thrombin-induced platelet aggregation, immunodeficiency disorders, autoimmune diseases, cell death, allergies, osteoporosis and neurodegenerative disorders. Inhibitors of p38 have also been implicated in the area of pain management through inhibition of prostaglandin endoperoxide synthase-2 induction. Other diseases associated with IL-1, IL-6, IL-8 or TNF overproduction are set forth in WO 96/21654.
Others have already begun trying to develop drugs that specifically inhibit MAPKs. For example, PCT publication WO 95/31451 describes pyrazole compounds that inhibit MAPKs, and in particular p38. However, the efficacy of these inhibitors in vivo is still being investigated.
Accordingly, there is still a great need to develop other potent, p38-specific inhibitors that are useful in treating various conditions associated with p38 activation.
SUMMARY OF THE INVENTION
The present invention solves this problem by providing compounds which demonstrate strong and specific inhibition of p38.
These compounds have the general formula:
wherein each of Q 1 and Q 2 are independently selected from 5–6 membered aromatic carbocyclic or heterocyclic ring systems, or 8–10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 –C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 –C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 –C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 –C 3 )-alkyl; O—(C 1 –C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 –C 3 )-alkyl; (C 2 –C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5–6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 –C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5–6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 )—S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 —.
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4–8 membered carbocyclic or heterocyclic ring;
R 2 is selected from hydrogen, (C 1 –C 3 )-alkyl, or (C 2 –C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 –C 3 )-alkyl, OH, or O—(C 1 –C 3 )-alkyl.
In another embodiment, the invention provides pharmaceutical compositions comprising the p38 inhibitors of this invention. These compositions may be utilized in methods for treating or preventing a variety of disorders, such as cancer, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, viral diseases and neurodegenerative diseases. These compositions are also useful in methods for preventing cell death and hyperplasia and therefore may be used to treat or prevent reperfusion/ischemia in stroke, heart attacks, organ hypoxia. The compositions are also useful in methods for preventing thrombin-induced platelet aggregation. Each of these above-described methods is also part of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides inhibitors of p38 having the general formula:
wherein each of Q 1 and Q 2 are independently selected from 5–6 membered aromatic carbocyclic or heterocyclic ring systems, or 8–10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 –C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 –C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 –C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 –C 3 )-alkyl; O—(C 1 –C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 –C 3 )-alkyl; (C 2 –C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5–6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 –C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5–6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 )—S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 .
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 , —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4–8 membered carbocyclic or heterocyclic ring;
When the two R components form a ring together with the Y components to which they are respectively bound, it will obvious to those skilled in the art that a terminal hydrogen from each unfused R component will be lost. For example, if a ring structure is formed by binding those two R components together, one being —NH—CH 3 and the other being —CH 2 —CH 3 , one terminal hydrogen on each R component (indicated in bold) will be lost. Therefore, the resulting portion of the ring structure will have the formula —NH—CH 2 —CH 2 —CH 2 —.
R 2 is selected from hydrogen, (C 1 –C 3 )-alkyl, or (C 2 –C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 –C 3 )-alkyl, OH, or O—(C 1 –C 3 )-alkyl. It will be apparent to those of skill in the art that if R 1 is OH, the resulting inhibitor may tautomerize resulting in compounds of the formula:
which are also p38 inhibitors of this invention.
According to another preferred embodiment, Q 1 is selected from phenyl or pyridyl containing 1 to 3 substituents, wherein at least one of said substituents is in the ortho position and said substituents are independently selected from chloro, fluoro, bromo, —CH 3 , —OCH 3 , —OH, —CF 3 , —OCF 3 , —O(CH 2 ) 2 CH 3 , NH 2 , 3,4-methylenedioxy, —N(CH 3 ) 2 , —NH—S(O) 2 -phenyl, —NH—C(O)O—CH 2 -4-pyridine, —NH—C(O)CH 2 -morpholine, —NH—C(O)CH 2 —N(CH 3 ) 2 , —NH—C(O)CH 2 -piperazine, —NH—C(O)CH 2 -pyrrolidine, —NH—C(O)C(O)-morpholine, —NH—C(O)C(O)-piperazine, —NH—C(O)C(O)-pyrrolidine, —O—C(O)CH 2 —N(CH 3 ) 2 , or —O—(CH 2 ) 2 —N(CH 3 ) 2 .
Even more preferred are phenyl or pyridyl containing at least 2 of the above-indicated substituents both being in the ortho position.
Some specific examples of preferred Q 1 are:
Most preferably, Q 1 is selected from 2-fluoro-6-trifluoromethylphenyl, 2,6-difluorophenyl, 2,6-dichlorophenyl, 2-chloro-4-hydroxyphenyl, 2-chloro-4-aminophenyl, 2,6-dichloro-4-aminophenyl, 2,6-dichloro-3-aminophenyl, 2,6-dimethyl-4-hydroxyphenyl, 2-methoxy-3,5-dichloro-4-pyridyl, 2-chloro-4,5 methylenedioxy phenyl, or 2-chloro-4-(N-2-morpholino-acetamido)phenyl.
According to a preferred embodiment, Q 2 is phenyl or pyridyl containing 0 to 3 substituents, wherein each substituent is independently selected from chloro, fluoro, bromo, methyl, ethyl, isopropyl, —OCH 3 , —OH, —NH 2 , —CF 3 , —OCF 3 , —SCH 3 , —C(O)OH, —C(O)OCH 3 , —CH 2 NH 2 , —N(CH 3 ) 2 , —CH 2 -pyrrolidine and —CH 2 OH.
Some specific examples of preferred Q 2 are:
unsubstituted 2-pyridyl or unsubstituted phenyl.
Most preferred are compounds wherein Q 2 is selected from phenyl, 2-isopropylphenyl, 3,4-dimethylphenyl, 2-ethylphenyl, 3-fluorophenyl, 2-methylphenyl, 3-chloro-4-fluorophenyl, 3-chlorophenyl, 2-carbomethoxylphenyl, 2-carboxyphenyl, 2-methyl-4-chlorophenyl, 2-bromophenyl, 2-pyridyl, 2-methylenehydroxyphenyl, 4-fluorophenyl, 2-methyl-4-fluorophenyl, 2-chloro-4-fluorphenyl, 2,4-difluorophenyl, 2-hydroxy-4-fluorphenyl or 2-methylenehydroxy-4-fluorophenyl.
According to yet another preferred embodiment, X is —S—, —O—, —S(O 2 )—, —S(O)—, —NR—, —C(R 2 )— or —C(O)—. Most preferably, X is S.
According to another preferred embodiment, n is 1 and A is N.
According to another preferred embodiment, each Y is C.
According an even more preferred embodiment, each Y is C and the R attached to those Y components is selected from hydrogen or methyl.
Some specific inhibitors of this invention are set forth in the table below.
TABLE 1
Formula Ia and Ib Compounds.
cpd #
structure
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ia) depicted above. These methods involve reacting a compound of formula II:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula IIa:
wherein R′ is as defined above, or a leaving group reagent of formula IIb:
wherein each of L 1 , L 2 , and L 3 independently represents a leaving group.
The leaving group reagent used in this reaction is added in excess, either neat or with a co-solvent, such as toluene. The reaction is carried out at a temperature of between 25° C. and 150° C.
Leaving group reagents of formula IIa that are useful in producing the p38 inhibitors of this invention include dimethylformamide dimethylacetal, dimethylacetamide dimethylacetal, trimethyl orthoformate, dimethylformamide diethylacetal and other related reagents. Preferably the leaving group reagent of formula IIa used to produce the inhibitors of this invention is dimethylformamide dimethylacetal.
Leaving group reagents of formula IIb that are useful in producing the p38 inhibitors of this invention include phosgene, carbonyldiimidazole, diethyl carbonate and triphosgene.
More preferred methods of producing the compounds of this invention utilize compounds of formula II wherein each of the variables are defined in terms of the more preferred and most preferred choices as set forth above for the compounds of this invention.
Because the source of R 1 is the leaving group reagent (C—R′ or C═O), its identity is, of course, dependent on the structure of that reagent. Therefore, in compounds where R 1 is OH, the reagent used must be IIb. Similarly, when R 1 is H or (C 1 –C 3 )-alkyl, the reagent used must be IIa. In order to generate inhibitors wherein R 1 is O—(C 1 –C 3 )-alkyl, a compound wherein R 1 is OH is first generated, followed by alkylation of that hydroxy by standard techniques, such as treatment with Na hydride in DMF, methyl iodide and ethyl iodide.
The immediate precursors to the inhibitors of this invention of formula Ia (i.e., compounds of Formula II) may themselves be synthesized by either of the synthesis schemes depicted below:
In Scheme 1, the order of steps 1) and 2) can be reversed. Also, the starting nitrile may be replaced by a corresponding acid or by an ester. Alternatively, other well-known latent carboxyl or carboxamide moieties may be used in place of the nitrile (see scheme 2). Variations such as carboxylic acids, carboxylic esters, oxazolines or oxizolidinones may be incorporated into this scheme by utilizing subsequent deprotection and functionalization methods which are well known in the art
The base used in the first step of Scheme 1 (and in Scheme 2, below) is selected from sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases that will deprotonate the position alpha to the nitrile.
Also, the addition of HX—Q 2 in the single step depicted above may be substituted by two steps—the addition of a protected or unprotected X derivative followed by the addition of a Q 2 derivative in a subsequent step.
In Scheme 2, Z is selected from COOH, COOR′, CON(R′) 2 , oxazoline, oxazolidinone or CN. R′ is as defined above.
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ib) depicted above. These methods involve reacting a compound of formula III:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula:
as described above.
Two full synthesis schemes for the p38 inhibitors of formula (Ib) of this invention are depicted below.
In scheme 3, a Q 1 substituted derivative may be treated with a base such as sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases to deprotonate the position alpha to the Z group, which represents a masked amide moiety. Alternatively, Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone. The anion resulting from deprotonation is then contacted with a nitrogen bearing heterocyclic compound which contains two leaving groups, or latent leaving groups, in the presence of a Palladium catalyst. One example of such compound may be 2,6-dichloropyridine.
In step two, the Q 2 ring moiety is introduced. This may be performed utilizing many reactions well known in the art which result in the production of biaryl compounds. One example may be the reaction of an aryl lithium compound with the pyridine intermediate produced in step 1. Alternatively, an arylmetallic compound such as an aryl stannane or an aryl boronic acid may be reacted with the aryl halide portion of the pyridine intermediate in the presence of a Pd o catalyst.
In step 3 the Z group is deprotected and/or functionalized to form the amide compound. When Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone, variations in deprotection and functionalization methods which are well known in the art are employed to produce the amide. Finally in step 4, the amide compound is cyclized to the final product utilizing reagents such as DMF acetal or similar reagents either neat or in an organic solvent.
Scheme 4 is similar except that the a biaryl intermediate is first generated prior to reaction with the Q1 starting material.
According to another embodiment, the invention provides inhibitors of p38 similar to those of formulae Ia and Ib above, but wherein the C═N in the ring bearing the Q 1 substituent is reduced. These inhibitors have the formula:
wherein A, Q 1 , Q 2 , R, R′, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). R 5 is selected from hydrogen, —CR′ 2 OH, —C(O)R 4 , —C(O)OR 4 , —CR′ 2 OPO 3 H 2 , —PO 3 H 2 , and salts of —PO 3 H 2 .
When R 5 is not hydrogen, the resulting compounds are expected to be prodrug forms which should be cleaved in vivo to produce a compound wherein R 5 is hydrogen.
According to other preferred embodiments, in compounds of formula Ic, A is preferably nitrogen, n is preferably 1, and X is preferably sulfur. In compounds of formula Ic or Id, Q 1 and Q 2 are preferably the same moieties indicated above for those variables in compounds of formulae Ia and Ib.
Compounds of formulae Ic and Id may be prepared directly from compounds of formulae Ia or Ib which contain a hydrogen, C 1 –C 3 alkyl or C 2 –C 3 alkenyl or alkynyl at the R 1 position (e.g., where R 1 ═R′). The synthesis schemes for these compounds is depicted in Schemes 5 and 6, below.
In these schemes, compounds of formula Ia or Ib are reduced by reaction with an excess of diisobutylaluminum hydride, or equivalent reagent to yield the ring reduced compounds of formula Ic or Id, respectively.
The addition of an R 5 component other than hydrogen onto the ring nitrogen is achieved by reacting the formula Ic or Id compounds indicated above with the appropriate reagent(s). Examples of such modifications are provided in the Example section below.
Some specific inhibitors of this invention of formula Ic are set forth in the table below.
TABLE 2
Formula Ic Compounds.
cpd #
structure
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
According to yet another embodiment, the invention provides p38 inhibitors of the formulae:
wherein A, Q 1 , Q 2 , R, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). More preferably, in compounds of formula Ie, Q 2 is unsubstituted phenyl.
Q 3 is a 5–6 membered aromatic carbocyclic or heterocyclic ring system, or an 8–10 membered bicyclic ring system comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring. The rings of Q 3 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 –C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 –C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
According to one preferred embodiment, Q 3 is substituted with 2 to 4 substituents, wherein at least one of said substituents is present in the ortho position relative to the point of attachment of Q 3 to the rest of the inhibitor. When Q 3 is a bicyclic ring, the 2 substituents in the ortho position are present on the ring that is closest (i.e., directly attached) to the rest of the inhibitor molecule. The other two optional substituents may be present on either ring. More preferably, both such ortho positions are occupied by one of said substituents.
According to another preferred embodiment, Q 3 is a monocyclic carbocyclic ring, wherein each ortho substituent is independently selected from halo or methyl. According to another preferred embodiment, Q 3 contains 1 or 2 additional substituents independently selected from NR′ 2 , OR′, CO 2 R′CN, N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
Preferably, Q 3 is selected from any of the Q 3 moieties present in the Ie compounds set forth in Table 3, below, or from any of the Q 3 moieties present in the Ig compounds set forth in Table 4, below.
Those of skill will recognize compounds of formula Ie as being the direct precursors to certain of the formula Ia and formula Ic p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Those of skill will also recognize that compounds of formula Ig are precursors to certain of the formula Ib and Id p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Accordingly, the synthesis of formula Ie inhibitors is depicted above in Schemes 1 and 2, wherein Q 1 is replaced by Q 3 . Similarly, the synthesis of formula Ig inhibitors is depicted above in Schemes 3 and 4, wherein Q 1 is replaced by Q 3 .
The synthesis of formula If and formula Ih inhibitors is depicted below in Schemes 7 and 8.
Scheme 8 depicts the synthesis of compounds of type Ih. For example, treating an initial dibromo derivative, such as 2,6 dibromopyridine, with an amine in the presence of a base such as sodium hydride yields the 2-amino-6-bromo derivative. Treatment of this intermediate with a phenylboronic acid analog (a Q2-boronic acid) such as phenyl boronic acid in the presence of a palladium catalyst gives the disubstituted derivative which can then be acylated to the final product. The order of the first two steps of this synthesis may be reversed.
Without being bound by theory, applicants believe that the diortho substitution in the Q 3 ring of formula Ie and Ig inhibitors and the presence of a nitrogen directly attached to the Q 1 ring in formula If and Ih inhibitors causes a “flattening” of the compound that allows it to effectively inhibit p38.
A preferred formula Ie inhibitor of this invention is one wherein A is carbon, n is 1, X is sulfur, each Y is carbon, each R is hydrogen, Q 3 is 2,6-dichlorophenyl and Q 2 is phenyl, said compound being referred to as compound 201. A preferred formula Ig inhibitor of this invention is one wherein Q 3 is 2,6-dichlorophenyl, Q 2 is phenyl, each Y is carbon and each R is hydrogen. This compound is referred to herein as compound 202. Other preferred formula Ig compounds of this invention are those listed in Table 4, below.
Preferred Ih compounds of this invention are those depicted in Table 5, below. Other preferred Ih compounds are those wherein Q 1 is phenyl independently substituted at the 2 and 6 positions by chloro or fluoro; each Y is carbon; each R is hydrogen; and Q 2 is 2-methylphenyl, 4-fluorophenyl, 2,4-difluorophenyl, 2-methylenehydroxy-4-fluorophenyl, or 2-methyl-4-fluorophenyl.
Some specific inhibitors of formulae Ie, Ig and Ih are depicted in the tables below.
TABLE 3
Formula Ie Inhibitors.
cmpd #
structure
201
203
204
205
206
207
208
209
TABLE 4
Formula Ig Inhibitors.
cpd #
structure
202/301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
1301
TABLE 5
Compound Ih Inhibitors.
cpd #
structure
401
402
403
404
405
406
407
408
409
410
411
412
The activity of the p38 inhibitors of this invention may be assayed by in vitro, in vivo or in a cell line. In vitro assays include assays that determine inhibition of either the kinase activity or ATPase activity of activated p38. Alternate in vitro assays quantitate the ability of the inhibitor to bind to p38 and may be measured either by radiolabelling the inhibitor prior to binding, isolating the inhibitor/p38 complex and determining the amount of radiolabel bound, or by running a competition experiment where new inhibitors are incubated with p38 bound to known radioligands.
Cell culture assays of the inhibitory effect of the compounds of this invention may determine the amounts of TNF, IL-1, IL-6 or IL-8 produced in whole blood or cell fractions thereof in cells treated with inhibitor as compared to cells treated with negative controls. Level of these cytokines may be determined through the use of commercially available ELISAs.
An in vivo assay useful for determining the inhibitory activity of the p38 inhibitors of this invention is the suppression of hind paw edema in rats with Mycobacterium butyricum -induced adjuvant arthritis. This is described in J. C. Boehm et al., J. Med. Chem., 39, pp. 3929–37 (1996), the disclosure of which is herein incorporated by reference. The p38 inhibitors of this invention may also be assayed in animal models of arthritis, bone resorption, endotoxin shock and immune function, as described in A. M. Badger et al., J. Pharmacol. Experimental Therapeutics, 279, pp. 1453–61 (1996), the disclosure of which is herein incorporated by reference.
The p38 inhibitors or pharmaceutical salts thereof may be formulated into pharmaceutical compositions for administration to animals or humans. These pharmaceutical compositions, which comprise and amount of p38 inhibitor effective to treat or prevent a p38-mediated condition and a pharmaceutically acceptable carrier, are another embodiment of the present invention.
The term “p38-mediated condition”, as used herein means any disease or other deleterious condition in which p38 is known to play a role. This includes, conditions which are known to be caused by IL-1, TNF, IL-6 or IL-8 overproduction. Such conditions include, without limitation, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, neurodegenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, thrombin-induced platelet aggregation, and conditions associated with prostaglandin endoperoxide synthase-2.
Inflammatory diseases which may be treated or prevented include, but are not limited to acute pancreatitis, chronic pancreatitis, asthma, allergies, and adult respiratory distress syndrome. Autoimmune diseases which may be treated or prevented include, but are not limited to, glomerulonephritis, rheumatoid arthritis, systemic lupus erythematosus, scleroderma, chronic thyroiditis, Graves' disease, autoimmune gastritis, diabetes, autoimmune hemolytic anemia, autoimmune neutropenia, thrombocytopenia, atopic dermatitis, chronic active hepatitis, myasthenia gravis, multiple sclerosis, inflammatory bowel disease, ulcerative colitis, Crohn's disease, psoriasis, or graft vs. host disease.
Destructive bone disorders which may be treated or prevented include, but are not limited to, osteoporosis, osteoarthritis and multiple myeloma-related bone disorder.
Proliferative diseases which may be treated or prevented include, but are not limited to, acute myelogenous leukemia, chronic myelogenous leukemia, metastatic melanoma, Kaposi's sarcoma, and multiple myeloma.
Angiogenic disorders which may be treated or prevented include solid tumors, ocular neovasculization, infantile haemangiomas.
Infectious diseases which may be treated or prevented include, but are not limited to, sepsis, septic shock, and Shigellosis.
Viral diseases which may be treated or prevented include, but are not limited to, acute hepatitis infection (including hepatitis A, hepatitis B and hepatitis C), HIV infection and CMV retinitis.
Neurodegenerative diseases which may be treated or prevented by the compounds of this invention include, but are not limited to, Alzheimer's disease, Parkinson's disease, cerebral ischemias or neurodegenerative disease caused by traumatic injury.
“p38-mediated conditions” also include ischemia/reperfusion in stroke, heart attacks, myocardial ischemia, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
In addition, p38 inhibitors in this invention are also capable of inhibiting the expression of inducible pro-inflammatory proteins such as prostaglandin endoperoxide synthase-2 (PGHS-2), also referred to as cyclooxygenase-2 (COX-2). Therefore, other “p38-mediated conditions” are edema, analgesia, fever and pain, such as neuromuscular pain, headache, cancer pain, dental pain and arthritis pain.
The diseases that may be treated or prevented by the p38 inhibitors of this invention may also be conveniently grouped by the cytokine (IL-1, TNF, IL-6, IL-8) that is believed to be responsible for the disease.
Thus, an IL-1-mediated disease or condition includes rheumatoid arthritis, osteoarthritis, stroke, endotoxemia and/or toxic shock syndrome, inflammatory reaction induced by endotoxin, inflammatory bowel disease, tuberculosis, atherosclerosis, muscle degeneration, cachexia, psoriatic arthritis, Reiter's syndrome, gout, traumatic arthritis, rubella arthritis, acute synovitis, diabetes, pancreatic β-cell disease and Alzheimer's disease.
TNF-mediated disease or condition includes, rheumatoid arthritis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions, sepsis, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, adult respiratory distress syndrome, cerebral malaria, chronic pulmonary inflammatory disease, silicosis, pulmonary sarcoisosis, bone resorption diseases, reperfusion injury, graft vs. host reaction, allograft rejections, fever and myalgias due to infection, cachexia secondary to infection, AIDS, ARC or malignancy, keloid formation, scar tissue formation, Crohn's disease, ulcerative colitis or pyresis. TNF-mediated diseases also include viral infections, such as HIV, CMV, influenza and herpes; and veterinary viral infections, such as lentivirus infections, including, but not limited to equine infectious anemia virus, caprine arthritis virus, visna virus or maedi virus; or retrovirus infections, including feline immunodeficiency virus, bovine immunodeficiency virus, or canine immunodeficiency virus.
IL-8 mediated disease or condition includes diseases characterized by massive neutrophil infiltration, such as psoriasis, inflammatory bowel disease, asthma, cardiac and renal reperfusion injury, adult respiratory distress syndrome, thrombosis and glomerulonephritis.
In addition, the compounds of this invention may be used topically to treat or prevent conditions caused or exacerbated by IL-1 or TNF. Such conditions include inflamed joints, eczema, psoriasis, inflammatory skin conditions such as sunburn, inflammatory eye conditions such as conjunctivitis, pyresis, pain and other conditions associated with inflammation.
In addition to the compounds of this invention, pharmaceutically acceptable salts of the compounds of this invention may also be employed in compositions to treat or prevent the above-identified disorders.
Pharmaceutically acceptable salts of the compounds of this invention include those derived from pharmaceutically acceptable inorganic and organic acids and bases. Examples of suitable acid salts include acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptanoate, glycerophosphate, glycolate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oxalate, palmoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, salicylate, succinate, sulfate, tartrate, thiocyanate, tosylate and undecanoate. Other acids, such as oxalic, while not in themselves pharmaceutically acceptable, may be employed in the preparation of salts useful as intermediates in obtaining the compounds of the invention and their pharmaceutically acceptable acid addition salts.
Salts derived from appropriate bases include alkali metal (e.g., sodium and potassium), alkaline earth metal (e.g., magnesium), ammonium and N—(C 1-4 alkyl) 4+ salts. This invention also envisions the quaternization of any basic nitrogen-containing groups of the compounds disclosed herein. Water or oil-soluble or dispersible products may be obtained by such quaternization.
Pharmaceutically acceptable carriers that may be used in these pharmaceutical compositions include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
The compositions of the present invention may be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial injection or infusion techniques. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
Sterile injectable forms of the compositions of this invention may be aqueous or oleaginous suspension. These suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or di-glycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant, such as carboxymethyl cellulose or similar dispersing agents which are commonly used in the formulation of pharmaceutically acceptable dosage forms including emulsions and suspensions. Other commonly used surfactants, such as Tweens, Spans and other emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms may also be used for the purposes of formulation.
The pharmaceutical compositions of this invention may be orally administered in any orally acceptable dosage form including, but not limited to, capsules, tablets, aqueous suspensions or solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening, flavoring or coloring agents may also be added.
Alternatively, the pharmaceutical compositions of this invention may be administered in the form of suppositories for rectal administration. These can be prepared by mixing the agent with a suitable non-irritating excipient which is solid at room temperature but liquid at rectal temperature and therefore will melt in the rectum to release the drug. Such materials include cocoa butter, beeswax and polyethylene glycols.
The pharmaceutical compositions of this invention may also be administered topically, especially when the target of treatment includes areas or organs readily accessible by topical application, including diseases of the eye, the skin, or the lower intestinal tract. Suitable topical formulations are readily prepared for each of these areas or organs.
Topical application for the lower intestinal tract can be effected in a rectal suppository formulation (see above) or in a suitable enema formulation. Topically-transdermal patches may also be used.
For topical applications, the pharmaceutical compositions may be formulated in a suitable ointment containing the active component suspended or dissolved in one or more carriers. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound, emulsifying wax and water. Alternatively, the pharmaceutical compositions can be formulated in a suitable lotion or cream containing the active components suspended or dissolved in one or more pharmaceutically acceptable carriers. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water.
For ophthalmic use, the pharmaceutical compositions may be formulated as micronized suspensions in isotonic, pH adjusted sterile saline, or, preferably, as solutions in isotonic, pH adjusted sterile saline, either with or without a preservative such as benzylalkonium chloride. Alternatively, for ophthalmic uses, the pharmaceutical compositions may be formulated in an ointment such as petrolatum.
The pharmaceutical compositions of this invention may also be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other conventional solubilizing or dispersing agents.
The amount of p38 inhibitor that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated, the particular mode of administration. Preferably, the compositions should be formulated so that a dosage of between 0.01–100 mg/kg body weight/day of the inhibitor can be administered to a patient receiving these compositions.
It should also be understood that a specific dosage and treatment regimen for any particular patient will depend upon a variety of factors, including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, rate of excretion, drug combination, and the judgment of the treating physician and the severity of the particular disease being treated. The amount of inhibitor will also depend upon the particular compound in the composition.
According to another embodiment, the invention provides methods for treating or preventing a p38-mediated condition comprising the step of administering to a patient one of the above-described pharmaceutical compositions. The term “patient”, as used herein, means an animal, preferably a human.
Preferably, that method is used to treat or prevent a condition selected from inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, degenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
According to another embodiment, the inhibitors of this invention are used to treat or prevent an IL-1, IL-6, IL-8 or TNF-mediated disease or condition. Such conditions are described above.
Depending upon the particular p38-mediated condition to be treated or prevented, additional drugs, which are normally administered to treat or prevent that condition may be administered together with the inhibitors of this invention. For example, chemotherapeutic agents or other anti-proliferative agents may be combined with the p38 inhibitors of this invention to treat proliferative diseases.
Those additional agents may be administered separately, as part of a multiple dosage regimen, from the p38 inhibitor-containing composition. Alternatively, those agents may be part of a single dosage form, mixed together with the p38 inhibitor in a single composition.
In order that the invention described herein may be more fully understood, the following examples are set forth. It should be understood that these examples are for illustrative purposes only and are not to be construed as limiting this invention in any manner.
EXAMPLE 1
Synthesis of p38 Inhibitor Compound 1
Examples of the synthesis of several compounds of formula Ia are set forth in the following 4 examples.
A.
To a slurry of sodium amide, 90% (1.17 g., 30 mmol) in dry tetrahydrofuran (20 ml) we added a solution of benzyl cyanide (2.92 g., 25.0 mmol) in dry tetrahydrofuran (10 ml) at room temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture we added a solution of 3,6-dichloropyridazine (3.70 g., 25.0 mmol) in dry tetrahydrofuran (10 ml). After stirring for 30 minutes, the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 30% ethyl acetate in n-hexane) to give 3.71 g. (16.20 mmol ˜54%) of product as a white solid.
B.
To a slurry of sodium hydride, 95% (0.14 g., 6.0 mmol) in dry tetrahydrofuran (10 ml) we added thiophenol (0.66 g, 6.0 ml.) at room temperature. The reaction mixture was then stirred for 10 minutes. To the reaction mixture we added a solution of the product from step A., above (1.31 g., 5.72 mmol) in absolute ethanol (20 ml.). The reaction mixture was then brought to reflux and stirred there for one hour. The cool reaction mixture was concentrated in vacuo. The residue was diluted with a 1N sodium hydroxide solution (10 ml), then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 20% ethyl acetate in n-hexane) to give 0.66 g. (2.19 mmol ˜40%) of product as a white solid.
C.
A mixture of the product from step B. (0.17 g., 0.69 mmol) and concentrated sulfuric acid (5 ml) was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and Concentrated in vacuo to give 0.22 g. (0.69 mmol ˜100%) of compound pre-1 as an orange oil. 1 H NMR (500 MHz, CD3OD) d7.7 (d), 7.5 (d), 7.4 (m), 7.3–7.2 (m).
D.
A solution of pre-1 from step C. (0.22 g., 0.69 mmol) and N,N-dimethylformamide dimethylacetal (0.18 g., 1.5 mmol) in toluene (5 ml) was heated at 100° C. for one hour. Upon cooling, the resulting solid was filtered and dissolved in warm ethyl acetate. The product was precipitated with the dropwise addition of diethyl ether. The product was then filtered and washed with diethyl ether to give 0.038 g. of compound 1 as a yellow solid. 1 H NMR (500 MHz, CDCl3) d8.63 (s), 7.63–7.21 (m), 6.44 (d).
EXAMPLE 2
Synthesis of p38 Inhibitor Compound 2
A.
The first intermediate depicted above was prepared in a similar manner as in Example 1A, using 4-fluorophenylacetonitrile, to afford 1.4 g (5.7 mmol, ˜15%) of product.
B.
The above intermediate was prepared in a similar manner as in Example 1B. This afforded 0.49 g (1.5 mmol, 56%) of product.
C.
The above intermediate was prepared in a similar manner as Example 1C. This afforded 0.10 g (0.29 mmol, 45%) of compound pre-2. 1 H NMR (500 MHz, CDCl3) d 7.65–7.48 (m), 7.47–7.30 (m) 7.29–7.11 (m) 7.06–6.91 (m), 5.85 (s, br).
D.
Compound 2 (which is depicted in Table 1) was prepared from pre-2 in a similar manner as in Example 1D. This afforded 0.066 g of product. 1 H NMR (500 MHz, CDCl3) d 8.60 (s), 7.62–7.03 (m), 6.44 (d)).
EXAMPLE 3
Synthesis of p38 Inhibitor Compound 6
A.
The first intermediate in the preparation of compound 6 was prepared in a manner similar to that described in Example 1A, using 2,6-dichlorophenyl-acetonitrile, to afford 2.49 g (8.38, 28%) of product.
B.
The next step in the synthesis of compound 6 was carried out in a similar manner as described in Example 1B. This afforded 2.82 g (7.6 mmol, 91%) of product.
C.
The final intermediate, pre-6, was prepared in a similar manner as described in Example 1C. This afforded 0.89 g (2.3 mmol, 85%) of product. 1 H NMR (500 MHz, CD3OD) d 7.5–7.4 (dd), 7.4 (m), 7.3 (d), 7.2 (m), 7.05 (d).
D.
The final step in the synthesis of compound 6 (which is depicted in Table 1) was carried out as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) d 8.69 (s), 7.65–7.59 (d), 7.58–7.36 (m), 7.32–7.22 (m), 6.79 (d), 6.53 (d).
EXAMPLE 4
Preparation of p38 Inhibitor Compound 5
A.
The first intermediate in the synthesis of compound 5 was prepared in a similar manner as described in Example 1A, using 2,4-dichlorophenylacetonitrile, to afford 3.67 g (12.36 mmol, 49%) of product.
B.
The second intermediate was prepared in a similar manner as described in Example 1B. This afforded 3.82 g (9.92 mmol, 92%) of product.
C.
The final intermediate, pre-5, was prepared in a similar manner as described in Example 1C. This afforded 0.10 g (0.24 mmol, 92%) of product. 1 H NMR (500 MHz, CD3OD) d 7.9 (d) 7.7 (d), 7.6–7.5 (dd), 7.4–7.3 (m), 2.4 (s).
D.
The final step in the preparation of compound 5 (which is depicted in Table 1) was carried out in a similar manner as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) d 8.64 (s), 7.51–7.42 (m), 7.32–7.21 (m), 6.85 (d), 6.51 (d), 2.42 (s).
Other compounds of formula Ia of this invention may be synthesized in a similar manner using the appropriate starting materials.
EXAMPLE 5
Preparation of A p38 Inhibitor Compound of Formula Ib
An example of the synthesis of a p38 inhibitor of this invention of the formula Ib is presented below.
A.
To a slurry of sodium amide, 90% (1.1 eq) in dry tetrahydrofuran was added a solution of 2,6-dichlorobenzyl cyanide (1.0 eq) in dry tetrahydrofuran at room-temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture was added a solution of 2,6-dichloropyridine (1 eq) in dry tetrahydrofuran. The reaction was monitored by TLC and, when completed the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic layer was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield pure product.
B.
To a solution of 4-fluoro-bromobenzene (1 eq) in dry tetrahydrofuran at −78° C. was added t-butyllithium (2 eq, solution in hexanes). The reaction mixture was then stirred for 30 minutes. To the reaction mixture was added a solution of the product from Step A (1 eq) in dry THF. The reaction mixture was then monitored and slowly brought to room temperature. The reaction mixture was quenched with water then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield the product.
C.
A mixture of the product step B and concentrated sulfuric acid was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo to give product. The final product was purified by silica gel flash chromatography
D.
A solution of the product Step C (1 eq) and N,N-Dimethylformamide dimethylacetal (2 eq) in toluene is heated at 100° C. for one hour. Upon cooling, the resulting mixture is filtered and dissolved in warm ethyl acetate. The product is precipitated with the dropwise addition of diethyl ether. The product is then filtered and washed with diethyl ether to give a p38 inhibitor of formula Ib. The final product is further purified by silica gel chromatography.
Other compounds of formula Ib of this invention may be synthesized in a similar manner using the appropriate starting materials.
EXAMPLE 6
Synthesis of p38 Inhibitor Compound 103
This example sets forth a typical synthesis of a compound of formula Ic.
A.
The p38 inhibitor compound 12 is prepared essentially as set forth for in Example 4, except that 4-fluorothiophenyl is utilized in step B.
B.
Compound 12 was dissolved in dry THF (5 ml) at room temperature. To this solution we added diisobutylaluminum hydride (1M solution in toluene, 5 ml, 5 mmol) and the reaction was stirred at room temperature for 1 hour. The reaction mix was then diluted with ethyl acetate and quenched by the addition of Rochelle salt. The layers were separated and the organic layer was isolated, washed with water, washed with brine, dried over magnesium sulfate and filtered to yield crude compound 103. The crude product was chromatographed on silica gel eluting with 2% methanol in methylene chloride. Pure compound 103 was thus obtained (210 mg, 50% yield): 1 H NMR (500 Mhz, CDCl3) 7.51 (m, 1H), 7.38 (d, 2H), 7.20 (t, 2H), 7.08 (t, 2H), 6.70 (broad s, 1H), 6.30 (dd, 2H), 5.20 (s, 2H).
EXAMPLE 7
Synthesis of p38 Inhibitor Compound 201
A.
The starting nitrile shown above (5.9 g, 31.8 mmol) was dissolved in DMF (20 ml) at room temperature. Sodium hydride (763 mg, 31.8 mmol) was then added, resulting in a bright yellow-colored solution. After 15 minutes a solution of 2,5 dibromopyridine (5.0 gr., 21.1 mmol) in DMF (10 ml) was added followed by Palladium tetrakis (triphenylphosphine) (3 mmol). The solution was then refluxed for 3 hrs. The reaction was cooled to room temperature and diluted with ethyl acetate. The organic layer was then isolated, washed with water and then with brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (5.8 g, 84%) as an off white solid.
B.
The bromide produced in step A (194.8 mg, 0.57 mmol) was dissolved in xylene (15 ml). To this solution we added thiophenylstannane (200 μl, 587 mmol) and palladium tetrakis (triphenylphosphine) (25 mg). The solution was refluxed overnight, cooled, filtered and evaporated in vacuo. The crude product was chromatographed on silica gel, eluting with methylene chloride, to yield pure product (152 mg, 72%) as a yellow oil.
C.
The nitrile produced in step B (1.2 g, 3.37 mmol) was dissolved in glacial acetic acid (30 ml). To this solution we added water (120 μl, 6.67 mmol) followed by titanium tetrachloride (760 μl, 6.91 mmol), which resulted in an exotherm. The solution was then refluxed for two hours, cooled and poured into 1N HCl. The aqueous layer was extracted with methylene chloride. The organic layer was backwashed with 1N NaOH, dried over magnesium sulfate and filtered over a plug of silica gel. The plug was first eluted with methylene chloride to remove unreacted starting materials, and then with ethyl acetate to yield compound 201. The ethyl acetate was evaporated to yield pure compound 201 (1.0 g, 77%).
EXAMPLE 8
Synthesis of p38 Inhibitor Compound 110
A.
The starting nitrile (3.76 g, 11.1 mmol) was first dissolved in glacial acetic acid (20 ml). To this solution we added titanium tetrachloride (22.2 mmol) and water (22.2 mmol) and heated the solution to reflux for 1 hour. The reaction mixture was then cooled and diluted in water/ethyl acetate. The organic layer was then isolated, washed with brine and dried over magnesium sulfate. The organic layer was then filtered and evaporated in vacuo. The resulting crude product was chromatographed on silica gel eluting with 5% methanol in methylene chloride to afford pure product as a yellow foam (2.77 g, 70%)
B.
The amide produced in step A (1.54 g, 4.3 mmol) was dissolved in toluene (20 ml). We then added N,N-dimethylformamide dimethylacetal (1.53 g, 12.9 mmol), heated the resulting solution for 10 minutes then allowed it to cool to room temperature. The reaction was then evaporated in vacuo and the residue was chromatographed on silica gel eluting with 2–5% methanol in methylene chloride. The recovered material was then dissolved in hot ethyl acetate. The solution was allowed to cool resulting in the crystallization of pure product as a yellow solid (600 mg, 40%). Additional material (˜800 mg) was available from the mother liquor.
C.
The bromide from step B (369 mg, 1 mmol) was dissolved in THF (10 ml). We then added Diisobutylaluminum hydride (1.0M solution, 4 mmol), stirred the reaction at room temperature for 10 minutes, and then quenched the reaction with methanol (1 ml). A saturated solution of Rochelle salts was then added and the mixture was extracted with ethyl acetate. The organic layer was isolated, dried over magnesium sulfate, evaporated and the residue was chromatographed on silica gel eluting, with 1–3% methanol in methylene chloride to afford a bright orange solid (85 mg, 23% yield).
D.
The bromide produced in step C (35.2 mg, 0.1 mmol) was dissolved in xylene (12 ml). To this solution we added thiophenol (0.19 mmol) followed by tributyltin methoxide (0.19 mmol). The resulting solution was heated to reflux for 10 minutes, followed by the addition of palladium tetrakis(triphenylphosphine) (0.020 mmol). The reaction was heated and monitored for the disappearance of the bromide starting material. The reaction was then cooled to room temperature and passed through a plug of silica gel. The plug was eluted initially with methylene chloride to remove excess tin reagent and then with 5% methanol in ethyl acetate to elute the p38 inhibitor. The filtrate was concentrated and then re-chromatographed on silica gel using 5% methanol in ethyl acetate as eluant affording pure compound 110 (20 mg, 52%).
EXAMPLE 9
Synthesis of p38 Inhibitor Compound 202
A.
The starting nitrile (2.32 g, 12 mmol) was dissolved in DMF (10 ml) at room temperature. Sodium hydride (12 mmol) was then added resulting in a bright yellow colored solution. After 15 minutes, a solution of 2,6 dibromopyridine (2.36 gr., 10 mmol) in DMF (5 ml) was added, followed by Palladium tetrakis (triphenylphosphine) (1.0 mmol). The solution was then refluxed for 3 hours. The reaction was next cooled to room temperature and diluted with ethyl acetate. The organic layer was isolated, washed with water and brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (1.45 g, 42%) as a white solid.
B.
The bromo compound produced in step A (1.77 g, 5.2 mmol) was dissolved in toluene (20 ml) and the resulting solution was degassed. Under a nitrogen atmosphere, a solution of phenylboronic acid (950 mg, 7.8 mmol) in ethanol (4 ml) and a solution of sodium carbonate (1.73 g, 14 mmol) in water (4 ml) were added. The reaction mixture was heated to reflux for one hour and then was cooled to room temperature. The reaction was diluted with ethyl acetate and washed with water and brine. The organic layer was then dried with magnesium sulfate, filtered and concentrated in vacuo. The residue was purified on silica gel eluting with 30% ethyl acetate in hexane to afford product as a white solid (1.56 g, 88%).
C.
The nitrile from step B (700 mg, 2.07 mmol) was dissolved in concentrated sulfuric acid (10 ml) and heated to 80° C. for 1 hour. The reaction was then cooled to room temperature and the pH was adjusted to 8 using 6N sodium hydroxide. The mixture was next extracted with ethyl acetate. The organic layer was isolated, dried with magnesium sulfate and evaporated in vacuo to yield compound 202 as a yellow foam (618 mg, 84%).
EXAMPLE 10
Synthesis of Compound 410
A.
In a flame-dried 100 ml round-bottomed flask, 2.28 g (93.8 mmol) of magnesium chips were added to 50 ml of anhydrous tetrahydrofuran. One crystal of iodine was added forming a light brown color. To the solution was added 1.5 ml of a 10.0 ml (79.1 mmol) sample of 2-bromo-5-fluorotoluene. The solution was heated to reflux. The brown color faded and reflux was maintained when the external heat source was removed indicating Grignard formation. As the reflux subsided, another 1.0–1.5 ml portion of the bromide was added resulting in a vigorous reflux. The process was repeated until all of the bromide had been added. The olive-green solution was externally heated to reflux for one hour to ensure complete reaction. The solution was cooled in an ice-bath and added via syringe to a solution of 9.3 ml (81.9 mmol) of trimethyl borate in 100 ml of tetrahydrofuran at −78° C. After the Grignard reagent had been added, the flask was removed from the cooling bath and the solution was stirred at room temperature overnight. The grayish-white slurry was poured into 300 ml of H 2 O and the volatiles were evaporated in vacuo. HCl (400 ml of 2N solution) was added and the milky-white mixture was stirred for one hour at room temperature. A white solid precipitated. The mixture was extracted with diethyl ether and the organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford 11.44 g (94%) of the boronic acid as a white solid.
B.
In a 100 ml round-bottomed flask, 7.92 g (33.4 mmol) of 2,6-dibromopyridine was dissolved in 50 ml of anhydrous toluene forming a clear, colorless solution. 4-fluoro-2-methylbenzene boronic acid (5.09 g, 33.1 mmol) produced in step A was added forming a white suspension. Thallium carbonate (17.45 g, 37.2 mmol) was added followed by a catalytic amount (150 mg) of Pd(PPh 3 ) 4 . The mixture was heated to reflux overnight, cooled, and filtered over a pad of silica gel. The silica was washed with CH 2 Cl 2 and the filtrate was evaporated to afford a white solid. The solid was dissolved in a minimal amount of 50% CH 2 Cl 2 /hexane and chromatographed on a short column of silica gel using 30% CH 2 Cl 2 /hexane to afford 6.55 g (74%) of the 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine as a white solid.
C.
In a 50 ml round-bottomed flask, 550 mg (2.07 mmol) of 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine produced in step B was dissolved in 30 ml of anhydrous tetrahydrofuran forming a clear, colorless solution. 2,6-difluoroaniline (2.14 ml, 2.14 mmol) was added followed by 112 mg (2.79 mmol) of a 60% NaH suspension in mineral oil. Gas evolution was observed along with a mild exotherm. The solution was heated to reflux overnight and then cooled. The reaction mixture was poured in 10% NH 4 Cl and extracted with CH 2 Cl 2 . The organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 50% CH 2 Cl 2 /hexane to afford 262 mg (40%) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine as a colorless oil.
D.
In a 100 ml round-bottomed flask, 262 mg (834 mmol) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine produced in step C was dissolved in 30 ml of anhydrous CHCl 3 forming a clear, colorless solution. Chlorosulfonyl isocyanate (1.0 ml, 11.5 mmol) was added and the light yellow solution was stirred at room temperature overnight. Water (˜30 ml) was added causing a mild exotherm and vigorous gas evolution. After stirring overnight, the organic layer was separated, dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 10% EtOAc/CH 2 Cl 2 . The recovered starting material was re-subjected to the reaction conditions and purified in the same manner to afford a total of 205 mg (69%) of the urea as a white solid.
EXAMPLE 11
Synthesis of Compound 138
Compound 103 (106 mg, 0.25 mmol) was dissolved in THF (0.5 ml) and to this solution was added triethylamine (35 μl, 0.25 mmol) followed by and excess of formaldehyde (37% aqueous solution, 45 mg). The reaction was allowed to stir at room temperature overnight. The reaction mixture was then rotovapped under reduced pressure and the residue was dissolved in methylene chloride and applied to a flash silica gel column. The column was eluted with 2% methanol in methylene chloride to yield pure product (78 mg, 70% yield).
EXAMPLE 12
Synthesis of Prodrugs of Compound 103
A.
Compound 138 (1 equivalent) is dissolved in methylene chloride and to this solution is added triethylamine (1 equivalent) followed by dibenzylphosphonyl chloride (1 equivalent). The solution is stirred at room temperature and monitored by TLC for consumption of starting material. The methylene chloride layer is then diluted with ethyl acetate and washed with 1N HCl, saturated sodium bicarbonate and saturated NaCl. The organic layer is then dried, rotovapped and the crude product is purified on silica gel. The pure product is then dissolved in methanol and the dibenzyl esters are deprotected with 10% palladium on charcoal under a hydrogen atmosphere. When the reaction is monitored as complete, the catalyst is filtered over celite and the filtrate is rotovapped to yield the phosphate product.
B.
Compound 103 (210 mg, 1.05 mmol) was dissolved in THF (2 ml) and cooled to −50° C. under a nitrogen atmosphere. To this solution was added lithium hexamethyldisilazane (1.1 mmol) followed by chloroacetyl chloride (1.13 mmol). The reaction was removed from the cooling bath and allowed to warm to room temperature, after which time the reaction was diluted with ethyl acetate and quenched with water. The organic layer was washed with brine, dried and rotovapped to dryness. The crude product was flash chromatographed on silica gel using 25% ethyl acetate in hexane as eluant to yield 172 mg (70%) of pure desired product, which was used as is in the next reactions.
C.
The chloroacetyl compound is dissolved in methylene chloride and treated with an excess of dimethyl amine. The reaction is monitored by TLC and when complete all volatiles are removed to yield desired product.
EXAMPLE 13
Synthesis of Compounds 34 and 117
A.
The nitrile from Example 5, step A (300 mg, 1.0 mmol) was dissolved in ethanol (10 ml) and to this solution was added thiourea (80.3 mg, 1.05 mmol). The reaction was brought to reflux for 4 hours at which point TLC indicated that all starting material was consumed. The reaction was cooled and all volatiles were removed under reduced pressure, and the residue was dissolved in acetone (10 ml).
To this solution was then added 2,5-difluoronitrobenzene (110 μl, 1.01 mmol) followed by potassium carbonate (200 mg, 1.45 mmol) and water (400 μl). The reaction was allowed to stir at room temperature overnight. The reaction was then diluted with methylene chloride (25 ml) and filtered through a cotton plug. All volatiles were removed under reduced pressure and the residue was flashed chromatographed on silica gel eluting with a gradient from 10%–25% ethyl acetate in hexane to yield the desired product (142 mg, 33%)
B.
The nitrile product from Step A (142 mg, 0.33 mmol) was mixed with concentrated sulfuric acid (2 ml), heated to reflux for 1 hour and then allowed to cool to room temperature. The mixture was then diluted with ethyl acetate and carefully neutralized with saturated potassium carbonate solution (aqueous). The layers were separated and the organic layer was washed with water, brine and dried over magnesium sulfate. The mixture was filtered and evaporated to dryness. The residue was used in the next step without further purification (127 mg, 85% yield).
C.
The amide from the step B (127 mg, 0.28 mmol) was dissolved in THF (3 ml) and to this solution was added dimethylformamide dimethylacetal (110 μl, 0.83 mmol). The reaction was heated to reflux for 5 minutes then cooled to room temperature. All volatiles were removed in vacuo and the residue was flash chromatographed on silica gel eluting with 2.5% methanol in methylene chloride to yield pure desired compound 34 (118 mg, 92%).
D.
A solution of nickel dichloride hexahydrate (103 mg, 0.44 mol) in a mixture of benzene/methanol (0.84 mL/0.84 ml) was added to a solution of compound 34 (100.8 mg, 0.22 mmol) in benzene (3.4 ml) and this solution was cooled to 0° C. To this solution was then added sodium borohydride (49 mg, 1.3 mmol). The reaction was stirred while allowing to warm to room temperature. The reaction was evaporated in vacuo and the residue was flash chromatographed eluting with 2% methanol in methylene chloride to yield pure desired product, compound 117 (21 mg, 25% yield).
EXAMPLE 14
Synthesis of Compounds 53 and 142
A.
The product indicated in the above reaction was synthesized using the procedure in example 1 step B using chloropyridazine (359 mg, 1.21 mmol) and 2,4 difluorothiophenol (176 mg, 1.21 mmol). The product was obtained after flash silica gel chromatography (451 mg, 92%).
B.
The above reaction was carried out as described in Example 1, step C, using 451 mg of starting material and 5 ml of concentrated sulfuric acid to yield the indicated product (425 mg, 90%).
C.
The reaction above was carried out as described in Example 1, step D, using starting amide (410 mg, 0.96 mmol) and dimethylformamide dimethylacetal (3 mmol). The reaction was heated at 50° C. for 30 minutes and worked up as described previously. Compound 53 was obtained (313 mg, 75%).
D.
Compound 34 (213, 0.49 mmol) was dissolved in THF (10 ml), cooled to 0° C. and to this solution was added Borane in THF (1M, 0.6 mmol). The reaction was stirred for 30 minutes quenched with water and diluted with ethyl acetate. The organic layer was washed with water and brine, dried and rotovapped. The residue was purified on silica gel eluting with a gradient of 1% to 5% methanol in methylene chloride to afford compound 142 (125 mg, 57%).
EXAMPLE 15
Cloning of p38 Kinase in Insect Cells
Two splice variants of human p38 kinase, CSBP1 and CSBP2, have been identified. Specific oligonucleotide primers were used to amplify the coding region of CSBP2 cDNA using a HeLa cell library (Stratagene) as a template. The polymerase chain reaction product was cloned into the pET-15b vector (Novagen). The baculovirus transfer vector, pVL-(His)6-p38 was constructed by subcloning a XbaI-BamHI fragment of pET15b-(His)6-p38 into the complementary sites in plasmid pVL1392 (Pharmingen).
The plasmid pVL-(His)6-p38 directed the synthesis of a recombinant protein consisting of a 23-residue peptide (MGSS HHHHHH SSG LVPRGS HMLE, where LVPRGS represents a thrombin cleavage site) fused in frame to the N-terminus of p38, as confirmed by DNA sequencing and by N-terminal sequencing of the expressed protein. Monolayer culture of Spodoptera frugiperda (Sf9) insect cells (ATCC) was maintained in TNM-FH medium (Gibco BRL) supplemented with 10% fetal bovine serum in a T-flask at 27° C. Sf9 cells in log phase were co-transfected with linear viral DNA of Autographa califonica nuclear polyhedrosis virus (Pharmingen) and transfer vector pVL-(His)6-p38 using Lipofectin (Invitrogen). The individual recombinant baculovirus clones were purified by plaque assay using 1% low melting agarose.
EXAMPLE 16
Expression and Purification of Recombinant p38 Kinase
Trichoplusia ni (Tn-368) High-Five™ cells (Invitrogen) were grown in suspension in Excel-405 protein free medium (JRH Bioscience) in a shaker flask at 27° C. Cells at a density of 1.5×10 6 cells/ml were infected with the recombinant baculovirus described above at a multiplicity of infection of 5. The expression level of recombinant p38 was monitored by immunoblotting using a rabbit anti-p38 antibody (Santa Cruz Biotechnology). The cell mass was harvested 72 hours after infection when the expression level of p38 reached its maximum.
Frozen cell paste from cells expressing the (His) 6 -tagged p38 was thawed in 5 volumes of Buffer A (50 mM NaH2PO4 pH 8.0, 200 mM NaCl, 2 mM β-Mercaptoethanol, 10% Glycerol and 0.2 mM PMSF). After mechanical disruption of the cells in a microfluidizer, the lysate was centrifuged at 30,000×g for 30 minutes. The supernatant was incubated batchwise for 3–5 hours at 4° C. with Talon™ (Clontech) metal affinity resin at a ratio of 1 ml of resin per 2–4 mgs of expected p38. The resin was settled by centrifugation at 500×g for 5 minutes and gently washed batchwise with Buffer A. The resin was slurried and poured into a column (approx. 2.6×5.0 cm) and washed with Buffer A+5 mM imidazole.
The (His) 6 -p38 was eluted with Buffer A+100 mM imidazole and subsequently dialyzed overnight at 4° C. against 2 liters of Buffer B, (50 mM HEPES, pH 7.5, 25 mM β-glycerophosphate, 5% glycerol, 2 mM DTT). The His 6 tag was removed by addition of at 1.5 units thrombin (Calbiochem) per mg of p38 and incubation at 20° C. for 2–3 hours. The thrombin was quenched by addition of 0.2 mM PMSF and then the entire sample was loaded onto a 2 ml benzamidine agarose (American International Chemical) column.
The flow through fraction was directly loaded onto a 2.6×5.0 cm Q-Sepharose (Pharmacia) column previously equilibrated in Buffer B+0.2 mM PMSF. The p38 was eluted with a 20 column volume linear gradient to 0.6M NaCl in Buffer B. The eluted protein peak was pooled and dialyzed overnight at 4° C. vs. Buffer C (50 mM HEPES pH 7.5, 5% glycerol, 50 mM NaCl, 2 mM DTT, 0.2 mM PMSF).
The dialyzed protein was concentrated in a Centriprep (Amicon) to 3–4 ml and applied to a 2.6×100 cm Sephacryl S-100HR (Pharmacia) column. The protein was eluted at a flow rate of 35 ml/hr. The main peak was pooled, adjusted to 20 mM DTT, concentrated to 10–80 mgs/ml and frozen in aliquots at −70° C. or used immediately.
EXAMPLE 17
Activation of p38
P38 was activated by combining 0.5 mg/ml p38 with 0.005 mg/ml DD-double mutant MKK6 in Buffer B+10 mM MgCl2, 2 mM ATP, 0.2 mM Na2VO4 for 30 minutes at 20° C. The activation mixture was then loaded onto a 1.0×10 cm MonoQ column (Pharmacia) and eluted with a linear 20 column volume gradient to 1.0 M NaCl in Buffer B. The activated p38 eluted after the ADP and ATP. The activated p38 peak was pooled and dialyzed against buffer B+0.2 mM Na2VO4 to remove the NaCl. The dialyzed protein was adjusted to 1.1M potassium phosphate by addition of a 4.0M stock solution and loaded onto a 1.0×10 cm HIC (Rainin Hydropore) column previously equilibrated in Buffer D (10% glycerol, 20 mM β-glycerophosphate, 2.0 mM DTT)+1.1M K2HPO4. The protein was eluted with a 20 column volume linear gradient to Buffer D+50 mM K2HPO4. The double phosphorylated p38 eluted as the main peak and was pooled for dialysis against Buffer B+0.2 mM Na2VO4. The activated p38 was stored at −70° C.
EXAMPLE 18
P38 Inhibition Assays
A. Inhibition of Phosphorylation of EGF Receptor Peptide
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical IC50 determination, a stock solution was prepared containing all of the above components and activated p38 (5 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. EGF receptor peptide, KRELVEPLTPSGEAPNQALLR, a phosphoryl acceptor in p38-catalyzed kinase reaction (1), was added to each vial to a final concentration of 200 μM. The kinase reaction was initiated with ATP (100 μM) and the vials were incubated at 30° C. After 30 minutes, the reactions were quenched with equal volume of 10% trifluoroacetic acid (TFA).
The phosphorylated peptide was quantified by HPLC analysis. Separation of phosphorylated peptide from the unphosphorylated peptide was achieved on a reverse phase column (Deltapak, 5 μm, C18 100D, part no. 011795) with a binary gradient of water and acteonitrile, each containing 0.1% TFA. IC50 (concentration of inhibitor yielding 50% inhibition) was determined by plotting the % activity remaining against inhibitor concentration.
B. Inhibition of ATPase Activity
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical Ki determination, the Km for ATP in the ATPase activity of activated p38 reaction was determined in the absence of inhibitor and in the presence of two concentrations of inhibitor. A stock solution was prepared containing all of the above components and activated p38 (60 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 2.5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. The reaction was initiated by adding various concentrations of ATP and then incubated at 30° C. After 30 minutes, the reactions were quenched with 50 μl of EDTA (0.1 M, final concentration), pH 8.0. The product of p38 ATPase activity, ADP, was quantified by HPLC analysis.
Separation of ADP from ATP was achieved on a reversed phase column (Supelcosil, LC-18, 3 μm, part no. 5–8985) using a binary solvent gradient of following composition: Solvent A—0.1 M phosphate buffer containing 8 mM tetrabutylammonium hydrogen sulfate (Sigma Chemical Co., catalogue no. T-7158), Solvent B—Solvent A with 30% methanol.
Ki was determined from the rate data as a function of inhibitor and ATP concentrations. The results for several of the inhibitors of this invention are depicted in Table 6 below:
TABLE 6
Compound
K i (μM)
1
>20
2
15
3
5.0
5
2.9
6
0.4
Other p38 inhibitors of this invention will also inhibit the ATPase activity of p38.
C. Inhibition of IL-1, TNF, IL-6 and IL-8 Production in LPS-Stimulated PBMCs
Inhibitors were serially diluted in DMSO from a 20 mM stock. At least 6 serial dilutions were prepared. Then 4× inhibitor stocks were prepared by adding 4 μl of an inhibitor dilution to 1 ml of RPMI1640 medium/10% fetal bovine serum. The 4× inhibitor stocks contained inhibitor at concentrations of 80 μM, 32 μM, 12.8 μM, 5.12 μM, 2.048 μM, 0.819 μM, 0.328 μM, 0.131 μM, 0.052 μM, 0.021 μM etc. The 4× inhibitor stocks were pre-warmed at 37° C. until use.
Fresh human blood buffy cells were separated from other cells in a Vacutainer CPT from Becton & Dickinson (containing 4 ml blood and enough DPBS without Mg 2+ /Ca 2+ to fill the tube) by centrifugation at 1500×g for 15 min. Peripheral blood mononuclear cells (PBMCs), located on top of the gradient in the Vacutainer, were removed and washed twice with RPMI1640 medium/10% fetal bovine serum. PBMCs were collected by centrifugation at 500×g for 10 min. The total cell number was determined using a Neubauer Cell Chamber and the cells were adjusted to a concentration of 4.8×10 6 cells/ml in cell culture medium (RPMI1640 supplemented with 10% fetal bovine serum).
Alternatively, whole blood containing an anti-coagulant was used directly in the assay.
We placed 100 μl of cell suspension or whole blood in each well of a 96-well cell culture plate. Then we added 50 μl of the 4× inhibitor stock to the cells. Finally, we added 50 μl of a lipopolysaccharide (LPS) working stock solution (16 ng/ml in cell culture medium) to give a final concentration of 4 ng/ml LPS in the assay. The total assay volume of the vehicle control was also adjusted to 200 μl by adding 50 μl cell culture medium. The PBMC cells or whole blood were then incubated overnight (for 12–15 hours) at 37° C./5% CO 2 in a humidified atmosphere.
The next day the cells were mixed on a shaker for 3–5 minutes before centrifugation at 500×g for 5 minutes. Cell culture supernatants were harvested and analyzed by ELISA for levels of IL-1b (R & D Systems, Quantikine kits, #DBL50), TNF-α (BioSource, #KHC3012), IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves from which IC50 values were derived.
Results for the kinase assay (“kinase”; subsection A, above), IL-1 and TNF in LPS-stimulated PBMCs (“cell”) and IL-1, TNF and IL-6 in whole blood (“WB”) for various p38 inhibitors of this invention are shown in Table 7 below:
cell
kinase
IL-1
cell TNF
WB IL-1
WB TNF
WB IL-6
cmpd #
IC50
IC50
IC50
IC50
IC50
IC50
2
+
N.D.
N.D.
N.D.
N.D.
N.D.
3
+
N.D.
N.D.
N.D.
N.D.
N.D.
5
+
N.D.
N.D.
N.D.
N.D.
N.D.
6
++
++
+
N.D.
N.D.
N.D.
7
+
+
+
N.D.
N.D.
N.D.
8
+
+
+
N.D.
N.D.
N.D.
9
+
+
+
N.D.
N.D.
N.D.
10
+
N.D.
N.D.
N.D.
N.D.
N.D.
11
+
+
+
N.D.
N.D.
N.D.
12
++
++
++
+
+
+
13
+
+
+
N.D.
N.D.
N.D.
14
+
++
+
N.D.
N.D.
N.D.
15
+
++
++
N.D.
N.D.
N.D.
16
++
+
++
N.D.
N.D.
N.D.
17
+
+
+
N.D.
N.D.
N.D.
18
+
+
+
N.D.
N.D.
N.D.
19
+
+
+
N.D.
N.D.
N.D.
20
++
+
+
N.D.
N.D.
N.D.
21
++
++
+
N.D.
N.D.
N.D.
22
+
+
+
N.D.
N.D.
N.D.
23
++
++
+
+
+
+
24
++
++
++
+
+
N.D.
25
++
++
+
N.D.
N.D.
N.D.
26
+
+++
++
+
+
+
27
++
+
+
+
+
+
28
++
++
++
N.D.
N.D.
N.D.
29
++
++
++
N.D.
N.D.
N.D.
30
+
+
+
+
N.D.
N.D.
31
+
+
+
N.D.
N.D.
N.D.
32
++
+
++
+
+
+
33
++
++
++
+
+
+
34
+
+
+
N.D.
N.D.
N.D.
35
++
++
+
+
+
+
36
+
+
+
+
+
+
37
++
++
+
+
+
+
38
+++
+++
++
++
++
++
39
++
+
+
N.D.
N.D.
N.D.
40
++
++
+
N.D.
N.D.
N.D.
41
+++
+++
+++
N.D.
N.D.
N.D.
42
+
N.D.
N.D.
N.D.
N.D.
N.D.
43
++
+
+
N.D.
N.D.
N.D.
44
++
+
+
N.D.
N.D.
N.D.
45
++
N.D.
N.D.
N.D.
N.D.
N.D.
46
++
+
+
N.D.
N.D.
N.D.
47
++
++
+
N.D.
N.D.
N.D.
48
++
++
+
N.D.
N.D.
N.D.
49
++
+++
+
+
+
+
50
+
N.D.
N.D.
N.D.
N.D.
N.D.
51
++
N.D.
N.D.
N.D.
N.D.
N.D.
52
++
N.D.
N.D.
N.D.
N.D.
N.D.
53
+++
+++
+++
+++
+++
+++
101
++
+++
+++
+
+
++
102
+++
+++
+++
+
++
++
103
+++
+++
+++
+
++
++
104
++
++
++
+
+
+
105
++
+
+
N.D.
N.D.
N.D.
106
+++
+++
+++
+
++
++
107
++
+
+
N.D.
N.D.
N.D.
109
+++
+++
+++
+
+
++
108
+++
++
+++
++
+++
+++
110
++
+
+
N.D.
N.D.
N.D.
111
++
+
+
N.D.
N.D.
N.D.
112
++
++
+
+
+
+
113
+++
+++
++
+
+
+
114
+++
+++
+++
++
++
+++
115
+++
+++
+++
+
+
+
116
+++
+++
++
+
+
+
117
+++
+++
+++
++
++
+++
118
++
++
++
+
+
+
119
++
N.D.
N.D.
N.D.
N.D.
N.D.
120
N.D.
++
+
+
+
+
121
+++
+++
++
+
+
+
122
++
++
+
+
+
+
123
++
++
++
+
+
+
124
+
+
+
N.D.
N.D.
N.D.
125
+++
+++
+++
+
+
+
126
+
++
+
N.D.
N.D.
N.D.
127
+++
+++
+++
++
++
+++
128
+
+
+
N.D.
N.D.
N.D.
129
+++
+++
+++
++
+
++
130
+++
++
+
N.D.
N.D.
N.D.
131
+++
+++
+++
N.D.
N.D.
N.D.
132
+++
+++
++
N.D.
N.D.
N.D.
133
+++
+++
+++
N.D.
N.D.
N.D.
134
+++
++
+
N.D.
N.D.
N.D.
135
+++
++
+
+
+
+
136
+++
+++
+++
+
+
++
137
+++
+++
++
+
+
++
138
++
+++
++
+
+
+++
139
+++
+++
+
+
+
+
140
+++
+++
+++
++
+
++
141
+++
+++
+++
+
+
+
142
+++
+++
+++
+++
+++
+++
143
+++
+++
++
+
+
+
144
+++
+++
++
+
+
++
145
+++
+++
+++
+++
+++
+++
201
++
+
+
+
+++
+
203
+
N.D.
N.D.
N.D.
N.D.
N.D.
204
+
N.D.
N.D.
N.D.
N.D.
N.D.
205
+
N.D.
N.D.
N.D.
N.D.
N.D.
206
++
+
+
N.D.
N.D.
N.D.
207
+
N.D.
N.D.
N.D.
N.D.
N.D.
208
N.D.
++
N.D.
N.D.
N.D.
N.D.
209
N.D.
+
N.D.
N.D.
N.D.
N.D.
202/
+++
++
++
+
+
+
301
302
+++
+++
++
+
+
+
303
+
+
+
+
+
+
304
+
+
+
+
+
+
305
+++
+++
+
+
+
+
306
++
++
+
+
+
+
307
+++
++
+
+
+
+
308
+
N.D.
N.D.
N.D.
N.D.
N.D.
309
++
++
++
+
+
+
310
++
+
+
N.D.
N.D.
N.D.
311
++
+
+
N.D.
N.D.
N.D.
312
+++
++
+
+
+
+
313
++
+
+
N.D.
N.D.
N.D.
314
+
N.D.
N.D.
N.D.
N.D.
N.D.
315
+
N.D.
N.D.
N.D.
N.D.
N.D.
316
+
N.D.
N.D.
N.D.
N.D.
N.D.
317
+
+
+
N.D.
N.D.
N.D.
318
++
N.D.
N.D.
N.D.
N.D.
N.D.
319
+
N.D.
N.D.
N.D.
N.D.
N.D.
320
+++
++
++
N.D.
N.D.
N.D.
321
+
N.D.
N.D.
N.D.
N.D.
N.D.
322
++
+
+
N.D.
N.D.
N.D.
323
++
++
++
N.D.
N.D.
N.D.
324
++
++
+
N.D.
N.D.
N.D.
325
+++
+++
++
+
+
+
326
+
N.D.
N.D.
N.D.
N.D.
N.D.
327
++
N.D.
N.D.
N.D.
N.D.
N.D.
328
+
N.D.
N.D.
N.D.
N.D.
N.D.
329
++
++
+
+
+
+
330
+
N.D.
N.D.
N.D.
N.D.
N.D.
331
+
N.D.
N.D.
N.D.
N.D.
N.D.
332
++
++
+
+
+
+
333
++
+
+
N.D.
N.D.
N.D.
334
+
N.D.
N.D.
N.D.
N.D.
N.D.
335
++
+
+
+
+
+
336
+
N.D.
N.D.
N.D.
N.D.
N.D.
337
+
N.D.
N.D.
N.D.
N.D.
N.D.
338
+
N.D.
N.D.
N.D.
N.D.
N.D.
339
+
N.D.
N.D.
N.D.
N.D.
N.D.
340
+
N.D.
N.D.
N.D.
N.D.
N.D.
341
++
++
++
N.D.
N.D.
N.D.
342
+
N.D.
N.D.
N.D.
N.D.
N.D.
343
+
N.D.
N.D.
N.D.
N.D.
N.D.
344
+
N.D.
N.D.
N.D.
N.D.
N.D.
345
+
N.D.
N.D.
N.D.
N.D.
N.D.
346
++
+
+
+
+
+
347
+
N.D.
N.D.
N.D.
N.D.
N.D.
348
+
N.D.
N.D.
N.D.
N.D.
N.D.
349
+
++
+
+
+
+
350
+
++
+
N.D.
N.D.
N.D.
351
+
+
+
N.D.
N.D.
N.D.
352
+
+
N.D.
N.D.
N.D.
N.D.
353
++
+
+
N.D.
N.D.
N.D.
354
+
N.D.
N.D.
N.D.
N.D.
N.D.
355
+
N.D.
N.D.
N.D.
N.D.
N.D.
356
+
N.D.
N.D.
N.D.
N.D.
N.D.
357
+
N.D.
N.D.
N.D.
N.D.
N.D.
358
++
+
+
N.D.
N.D.
N.D.
359
+
N.D.
N.D.
N.D.
N.D.
N.D.
360
+
N.D.
N.D.
N.D.
N.D.
N.D.
361
++
++
+
N.D.
N.D.
N.D.
362
+++
++
++
+
+
+
363
+++
+++
++
+
+
+
364
+++
+++
++
+
+
+
365
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
366
+
N.D.
N.D.
N.D.
N.D.
N.D.
367
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
368
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
369
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
370
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
371
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
372
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
373
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
374
++
N.D.
N.D.
N.D.
N.D.
N.D.
375
+++
N.D.
N.D.
N.D.
N.D.
N.D.
376
+++
N.D.
N.D.
N.D.
N.D.
N.D.
377
+++
N.D.
N.D.
N.D.
N.D.
N.D.
378
+++
N.D.
N.D.
N.D.
N.D.
N.D.
379
+++
N.D.
N.D.
N.D.
N.D.
N.D.
380
++
N.D.
N.D.
N.D.
N.D.
N.D.
381
++
N.D.
N.D.
N.D.
N.D.
N.D.
382
+++
N.D.
N.D.
N.D.
N.D.
N.D.
383
+++
N.D.
N.D.
N.D.
N.D.
N.D.
384
++
N.D.
N.D.
N.D.
N.D.
N.D.
385
++
N.D.
N.D.
N.D.
N.D.
N.D.
386
+
N.D.
N.D.
N.D.
N.D.
N.D.
387
+
N.D.
N.D.
N.D.
N.D.
N.D.
388
+++
N.D.
N.D.
N.D.
N.D.
N.D.
389
++
N.D.
N.D.
N.D.
N.D.
N.D.
390
+
N.D.
N.D.
N.D.
N.D.
N.D.
391
++
N.D.
N.D.
N.D.
N.D.
N.D.
392
++
N.D.
N.D.
N.D.
N.D.
N.D.
393
++
N.D.
N.D.
N.D.
N.D.
N.D.
394
+++
N.D.
N.D.
N.D.
N.D.
N.D.
395
+++
N.D.
N.D.
N.D.
N.D.
N.D.
396
+++
N.D.
N.D.
N.D.
N.D.
N.D.
397
+
N.D.
N.D.
N.D.
N.D.
N.D.
398
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
399
+++
N.D.
N.D.
N.D.
N.D.
N.D.
1301
+++
N.D.
N.D.
N.D.
N.D.
N.D.
401
+++
++
++
+
+
+
402
+++
+++
+++
+
+
+
403
+++
+++
+++
+
+
++
404
+++
+++
+++
+
+
+
405
+++
+++
++
N.D.
N.D.
N.D.
406
++
++
+
N.D.
N.D.
N.D.
407
++
++
+
N.D.
N.D.
N.D.
408
+++
+++
++
N.D.
N.D.
N.D.
409
+++
+++
+++
+
+
++
410
+++
+++
+++
++
++
++
411
+++
+++
+++
+
+
+
412
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
For kinase IC50 values, “+++” represents ≦0.1 μM, “++” represents between 0.1 and 1.0 μM, and “+” represents ≧1.0 μM. For cellular IL-1 and TNF values, “+++” represents ≦0.1 μM, “++” represents between 0.1 and 0.5 μM, and “+” represents ≧0.5 μM. For all whole blood (“WB”) assay values, “+++” represents ≦0.25 μM, “++” represents between 0.25 and 0.5 μM, and “+” represents ≧0.5 μM. In all assays indicated in the table above, “N.D.” represents value not determined.
Other p38 inhibitors of this invention will also inhibit phosphorylation of EGF receptor peptide, and the production of IL-1, TNF and IL-6, as well as IL-8 in LPS-stimulated PBMCs or in whole blood.
D. Inhibition of IL-6 and IL-8 Production in IL-1-Stimulated PBMCs
This assay was carried out on PBMCs exactly the same as above except that 50 μl of an IL-1b working stock solution (2 ng/ml in cell culture medium) was added to the assay instead of the (LPS) working stock solution.
Cell culture supernatants were harvested as described above and analyzed by ELISA for levels of IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves from which IC50 values were derived.
Results for p38 inhibitor compound 6 are shown in Table 8 below:
TABLE 8 Cytokine assayed IC 50 (μM) IL-6 0.60 IL-8 0.85
E. Inhibition of LPS-Induced Prostaglandin Endoperoxide Synthase-2 (PGHS-2, or COX-2) Induction in PBMCs
Human peripheral mononuclear cells (PBMCs) were isolated from fresh human blood buffy coats by centrifugation in a Vacutainer CPT (Becton & Dickinson). We seeded 15×10 6 cells in a 6-well tissue culture dish containing RPMI 1640 supplemented with 10% fetal bovine serum, 50 U/ml penicillin, 50 μg/ml streptomycin, and 2 mM L-glutamine. Compound 6 (above) was added at 0.2, 2.0 and 20 μM final concentrations in DMSO. Then we added LPS at a final concentration of 4 ng/ml to induce enzyme expression. The final culture volume was 10 ml/well.
After overnight incubation at 37° C., 5% CO 2 , the cells were harvested by scraping and subsequent centrifugation, then the supernatant was removed, and the cells were washed twice in ice-cold DPBS (Dulbecco's phosphate buffered saline, BioWhittaker). The cells were lysed on ice for 10 min in 50 μl cold lysis buffer (20 mM Tris-HCl, pH 7.2, 150 mM NaCl, 1% Triton-X-100, 1% deoxycholic acid, 0.1% SDS, 1 mM EDTA, 2% aprotinin (Sigma), 10 μg/ml pepstatin, 10 μg/ml leupeptin, 2 mM PMSF, 1 mM benzamidine, 1 mM DTT) containing 1 μl Benzonase (DNAse from Merck). The protein concentration of each sample was determined using the BCA assay (Pierce) and bovine serum albumin as a standard. Then the protein concentration of each sample was adjusted to 1 mg/ml with cold lysis buffer. To 100 μl lysate an equal volume of 2×SDS PAGE loading buffer was added and the sample was boiled for 5 min. Proteins (30 μg/lane) were size-fractionated on 4–20% SDS PAGE gradient gels (Novex) and subsequently transferred onto nitrocellulose membrane by electrophoretic means for 2 hours at 100 mA in Towbin transfer buffer (25 mM Tris, 192 mM glycine) containing 20% methanol. The membrane was pretreated for 1 hour at room temperature with blocking buffer (5% non-fat dry milk in DPBS supplemented with 0.1% Tween-20) and washed 3 times in DPBS/0.1% Tween-20. The membrane was incubated overnight at 4° C. with a 1:250 dilution of monoclonal anti-COX-2 antibody (Transduction Laboratories) in blocking buffer. After 3 washes in DPBS/0.1% Tween-20, the membrane was incubated with a 1:1000 dilution of horseradish peroxidase-conjugated sheep antiserum to mouse Ig (Amersham) in blocking buffer for 1 h at room temperature. Then the membrane was washed again 3 times in DPBS/0.1% Tween-20 and an ECL detection system (SuperSignal™ CL-HRP Substrate System, Pierce) was used to determine the levels of expression of COX-2.
Results of the above mentioned assay indicate that compound 6 inhibits LPS induced PGHS-2 expression in PBMCs.
While we have hereinbefore presented a number of embodiments of this invention, it is apparent that our basic construction can be altered to provide other embodiments which utilize the methods of this invention.
|
The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders.
| 2
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CROSS REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 182,628 filed Aug. 29, 1980, now U.S. Pat. No. 4,354,610.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to closure caps for containers and, more particularly, to a reusable closure cap for containers having multiple sealing zones and a frangible locking means which can visually indicate whether the container has been opened.
2. Description of the Prior Art
Closure caps having a tamperproof feature have become an important item of commerce. Generally speaking, closure caps of this class include a locking member of some kind which interacts with a locking member included as part of a container. Upon breaking of the closure cap locking member, the cap can be removed from the container. Desirably, the closure cap locking member can be inspected visually to determine whether it has been tampered with. Accordingly, a consumer can readily detect whether the container has been opened previously.
Although container closures of this general class can function effectively, certain problems have not been addressed. One of these problems relates to reusability of the closure cap. With many closure caps made of a plastics material or metal foil, a so-called tear tab is pulled when it is desired to remove the closure cap from the container. Rupture zones often are provided in order to permit the tab to be torn easily. Sometimes the tab tears completely through the side wall of the cap and into the top wall of the cap. When this occurs, either by design or by accident, it is easy to remove the cap from the container, but the cap cannot be reused to seal the container again.
In an attempt to avoid the foregoing problem, container closure caps having tear tabs which do not enter the top wall of the cap have been provided. Certain of these caps are not reusable because, during the opening process, a skirt portion of the cap is sufficiently weakened that a good sealing function no longer can be carried out. Other caps are known in which a small locking member in the skirt portion of the cap is broken, either to permit removal of the cap or upon removal of the cap, but these caps also suffer certain drawbacks with respect to sealing capabilities.
Particularly when sealing a container containing a substance such as milk, it is quite important that the sanitary condition of the milk be maintained. In addition to at least one primary sealing area, it is desirable to provide a so-called bug shield in order to prevent dust, dirt, small insects, and so forth from having access even to the primary sealing area. Known container closures for milk containers either do not have a bug shield or are expensive to manufacture. Desirably, a closure cap for a milk container would be inexpensive to manufacture, easy to detect whether it had been opened previously, would adequately shield the primary sealing area from contamination, and would have desirable qualties of appearance.
Other types of containers are best sealed by a threaded closure cap. Prior threaded closure caps having tear tabs have not performed particularly well and tear tabs generally have been avoided with threaded caps. One known threaded closure cap not employing a tear tab is usable repeatedly, but it is made of relatively thick metal and it is difficult to initially untwist the cap from the container. In another known closure cap made of a plastics material, a so-called tear ring is disposed about the lower periphery of the cap. The tear ring includes serrations which engage mating serrations formed on the outer surface of the container. When it is desired to remove the cap, the tear ring is ripped from the cap and thrown away. Thereafter, the cap can be unthreaded because the mating serrations no longer prevent removal of the cap.
A problem with the foregoing construction is that it sometimes is difficult to grasp the tear ring in order to expeditiously remove it. Moreover, it is difficult to manufacture the cap such that the tear ring is connected to the remainder of the cap with material of the proper thickness. That is, a circumferential line of weakness between the tear ring and the remainder of the cap must be provided, and it is difficult to form such a line of weakness in a molding operation without ripping the tear ring from the closure cap upon removal of the cap from the mold.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing and other drawbacks in prior art proposals providing a novel and improved container closure suitable for use with containers such as milk bottles. The container closure includes multiple sealing zones as well as frangible locking means. The locking means, in untampered condition, locks the cap onto the container and, in tampered condition, permits the cap to be removed from the container. The locking means can be readily inspected by observation to determine if the container has been opened previously.
The closure cap includes a disc-like top wall from which an annular skirt depends. The top wall provides a primary sealing area for the container. The skirt includes, on its inner surface, a first wall portion conforming generally to the outer contour of a first wall portion of the container. The skirt also includes a locking member engageable with a locking member included as part of the container, as well as a second wall portion. In one embodiment of the invention, the second wall portion of the closure cap seals against a shoulder portion of the container to prevent dirt or other contaminants from having access to the primary sealing area. In this embodiment of the invention, the locking member also performs a sealing function.
In another embodiment of the invention, the first wall portion of the skirt includes threads which mate with complementary threads formed on the container. A locking member included as part of the closure cap engages a locking member on the container. In this embodiment of the invention, the locking member of the closure cap is part of the second wall portion of the cap. In yet another "threaded" embodiment of the invention, the locking member is serrated and is engageable with serrations formed on the outer surface of the container.
In each embodiment of the invention, spaced, vertically extending rupture zones extend from the lower rim of the skirt toward the top wall of the cap. The rupture zones do not extend into the top wall. A flexible tab extends laterally outwardly of the skirt from a location near the lower rim of the skirt. Upon flexure of the tab, the rupture zones will fail, thereby permitting the skirt to expand circumferentially near the lower rim of the skirt. In turn, the locking members will be disengaged, thus permitting the cap to be removed from the container.
In the first-mentioned embodiment of the invention, the cap can be reused repeatedly simply by snapping the cap onto the container. In this embodiment the second wall portion of the cap provides an effective "bug shield" prior to initial opening of the container. In the second and third-mentioned embodiments, the threaded portion of the cap permits the cap to tightly seal the container, and yet the flexible tab does not interfere with that function, even after the cap has been opened. All embodiments of the invention can be formed expeditiously in a molding operation, and the particular construction and arrangement of elements minimizes tolerances required during the molding operation.
The foregoing and other features and advantages, and a fuller understanding of the invention, may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of one embodiment of the invention and especially adapted for use with milk containers;
FIG. 2 is a plan view of the container closure of FIG. 1;
FIG. 3 is a view taken along a plane indicated by line 3--3 in FIG. 2, with portions of the container broken away and removed for clarity;
FIG. 4 is a side elevational view of an alternative embodiment of the invention, with a portion of a cap and container being shown in cross-section;
FIG. 5 is a plan view of the container closure of FIG. 4 with a portion of the cap being shown in cross-section;
FIG. 6 is a view taken along a plane indicated by line 6--6 in FIG. 5;
FIG. 7 is a side elevational view of an alternative embodiment of the invention, with a portion of a cap and container being shown in cross-section;
FIG. 8 is a plan view of the container closure of FIG. 7; and
FIG. 9 is a view taken along a plane indicated by line 9--9 in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein, such terms as "vertically," "downwardly," "upper" and the like are intended to indicate the relative position of certain elements of the invention with respect to each other and no particular spatial orientation of the invention is required or is to be presumed from the use of these terms. Referring to FIGS. 1-3, a container closure cap according to the invention is indicated generally by the numeral 10. The closure cap 10 is formed in a molding operation from a plastics material such as high density polyethylene. The cap 10 is shown in sealing position atop a container 20. The container 20 is in the form of a typical milk bottle having a large body portion 22 and a generally cylindrical neck portion 24 having a tapered shoulder portion 26. The container 20 typically is formed in a blow-molding operation from a suitable plastics material.
The neck portion 24 includes an annular rim 28 having a generally flat upper surface. The neck portion 24 includes a cylindrical inner surface 30 extending the length of the neck portion 24. The neck portion 24 also includes a first wall portion 32 immediately adjacent the rim 28. The first wall portion 32 is smooth-sided and cylindrical. A first locking member 34 is positioned vertically adjacent the first wall portion 32 on the outer surface of the neck portion 24. The first locking member 34 is in the form of a cylindrical groove having a diameter smaller than that of the first wall portion 32. A second wall portion 36 is located vertically adjacent the first locking member 34 and provides a transition between the neck portion 24 and the shoulder portion 26. The second wall portion 36, like the first wall portion 32, is cylindrical and smooth-sided. The second wall portion 36 is approximately the same diameter as the first wall portion 32.
The closure cap 10 includes a disc-like top wall 40 having a center section 42 slightly smaller in diameter than the inner diameter of the neck portion 24. A ledge 44 extends upwardly from the outer edge of the center section 42, and a rim 46, beveled on its outer surface, extends from the periphery of the center section 42 in a direction opposite to that of the ledge 44. A flange 48 extends laterally outwardly from the ledge 44 and overlies the rim 28.
An annular skirt 50 depends from the top wall 40. The skirt 50 extends downwardly from the outer periphery of the flange 48. The skirt 50 includes, on its inner surface, a third wall portion 52. The third wall portion 52 is smooth-sided and conforms generally to the contour of the first wall portion 32. A second locking member 54 is located vertically adjacent the third wall portion 52. The second locking member 54 is in the form of an inwardly projecting rim engageable with the first locking member 34. A fourth wall portion 56 is located vertically adjacent the second locking member 54 and extends to a lower rim 58 of the skirt 50. The fourth wall portion 56 is smooth-sided and conforms generally to the contour of the second wall portion 36. The lower rim 58 is flared outwardly on its inner surface as at 60. When the closure cap 10 is in sealing position atop the container 20, the inner surface 60 is in surface-to-surface contact with the shoulder portion 26.
The closure cap 10 also includes a flexible tab 70 extending laterally outwardly from the lower rim 58. A pair of spaced, vertically extending rupture zones, or lines 72 extend from the lower rim 58 to a point intermediate the lower rim 58 and the top wall 40. The rupture lines 72 are connected at their upper end by a hinge line 74. The lines 72, 74 essentially are areas of reduced material thickness (approximately 0.008 inch). As can be seen in FIGS. 2 and 3, a wall section 76 is bounded by the lines 72, 74 and is located slightly laterally outwardly of the outer diameter of the fourth wall portion 56. The tab 70 is an extension of the lower portion of the wall section 76. Upon upward flexure of the tab 70, the rupture zones 72 will fail and the wall section 76 will be pivoted about the hinge line 74.
During initial assembly of the closure cap 10 atop the container 20, the cap 10 is placed atop the neck portion 26 and a compressive force is applied uniformly to the flange 48. After enough force has been applied, the second locking member 54 will be slightly expanded, and the first wal portion 32 either will remain dimensionally stable or will be reduced in diameter slightly. Although an interference fit is created, the relative dimensions of the cap 10 and the neck portion 24 are such that the cap 10 will be able to be moved axially into that position shown in FIGS. 1-3. After the cap 10 is in that position illustrated in the FIGURES, the container 20 will be sealed. Several sealing areas are provided:
1. The interface between the upper, inner portion of the neck portion 24 and the rim 46.
2. The interface between the upper surface of the rim 28 and the underside of the flange 48.
3. The interface between the first wall portion 32 and the third wall portion 52.
4. The engagement between the first and second locking members 34, 54.
5. The interface between the shoulder portion 26 and the inner surface 60 of the lower rim 58.
The first three sealing areas may be referred to collectively as a primary seal. The fourth sealing area may be referred to as a secondary seal. The fifth sealing area has been referred to previously and may be identified as a tertiary seal. The surface-to-surface contact between the shoulder portion 26 and the inner surface 60 effectively functions as a "bug seal" to prevent dirt, dust, and other contaminants from reaching the other sealing areas.
In order to remove the closure cap 10 from the container 20, the tab 70 is lifted upwardly until the rupture zones 72 fail. At that point, the hoop strength in the lower portion of the skirt 50 is released. Under these circumstances, axial force can be applied to the cap 10 and, because the lower portion of the skirt 50 now can be expanded circumferentially, the first and second locking members 34, 54 can be disengaged relatively easily. In turn, the cap 10 can be removed from the container 20. After the rupture zones 72 have failed, the cap 10 can be removed and replaced as often as desired without adversely affecting the primary and secondary sealing areas. Because the tab 70 and the wall section 76 are readily observable by a consumer, it will be immediately apparent whether the cap 10 has been tampered with or removed from the container 20. Unlike certain prior art closure caps, the closure cap 10 according to the invention is relatively easy to open because the tab 70 can be grasped without difficulty, and there is no need to dispose of a severed portion of the cap 10.
An alternative closure cap according to the invention is indicated in FIGS. 4-6 by the numeral 100. The cap 100 is suitable for use with containers having threaded neck portions. The cap 100 also can be used for sealing containers having relatively high internal pressures.
The cap 100 is illustrated in sealing position atop a container 120. The container 120 includes a relatively large body portion 22, and a generally cylindrical, elongate neck portion 124 having a tapered shoulder portion 126. The neck portion 124 includes an annular rim 128 having a rounded upper surface. The neck portion 124 includes a cylindrical inner surface 130 extending the length of the neck portion 124. The neck portion 124 also includes a first wall portion 132 having a plurality of helical grooves 133 on its outer surface. The grooves 133 function as a locking member. Another locking member 134 is positioned vertically adjacent the first wall portion 132 on the outer surface of the neck portion 124. The locking member 134 is in the form of an annular groove having a diameter smaller than that of the first wall portion 132.
The closure cap 100 includes a disc-like top wall 140. An annular skirt 142 depends from the top wall 140. The skirt 142 extends downwardly from the outer periphery of the top wall 140 and terminates in a beveled lower rim 144. The skirt 142 includes, on its inner surface, a second wall portion 146. The second wall portion 146 includes a plurality of threads 148 which interlock with the grooves 133 on the first wall portion 132 and thereby function as another locking member.
An additional locking member 150 is located near the lower rim 144 of the skirt 142. In effect, the locking member 150 is part of the second wall portion 146. The locking member 150 is in the form of an inwardly extending projection, or tooth, engageable with the first locking member 134. The tooth 150 includes a flat upper surface 152 and a sharp inner edge 154.
An inwardly extending, flexible annular lip 156 is positioned at the interface between the top wall 140 and the skirt 142. In use, upon applying the cap 100 to the container 120, the lip 156 engages the rim 128 to effect a fluid-tight seal. The engagement between the lip 156 and the rim 128 may be referred to as a primary seal. The interlocking grooves and threads 133, 148 of the wall portions 132, 146 create a secondary seal. The rim 144 and the shoulder 126 engage each other in substantial surface-to-surface contact to create a tertiary seal.
The closure cap 100 also includes a flexible tab 160 extending laterally outwardly from the lower rim 144. A pair of spaced, vertically extending rupture zones, or lines 162 extend from the lower rim 144 to a point near the top wall 140. The rupture lines 162 are connected at their upper end by a hinge line 164. The lines 162, 164 essentially are areas of reduced material thickness (approximately 0.008 inch). As can be seen in FIGS. 5 and 6, a wall section 166 is bounded by the lines 162, 164 and constitutes a continuation of the outer diameter of the skirt 142. Upon upward flexure of the tab 160, the rupture lines 162 will fail and the wall section 166 will be pivoted about the hinge line 164.
During initial attachment of the closure cap 100 to the container 120, the cap 100 is placed atop the neck portion 124 and is threaded onto the neck portion 124. As the cap 100 is threaded, the tooth 150 will engage the grooves 133 of the wall portion 132. The skirt 142 will be expanded slightly out-of-round, and the first wall portion 132 either will be dimensionally stable or will be reduced in diameter slightly. Although an interference fit is created, the relative dimensions of the cap 100 and the neck portion 124 are such that the cap 100 be able to be moved axially to that position shown in FIGS. 4-6. After the cap 100 is in that position illustrated in the FIGURES, the container 120 will be sealed and the cap 100 cannot be removed because of the engagement of the flat upper surface 152 with the groove 134.
In order to remove the closure cap 100 from the container 120, the tab 160 is lifted upwardly until the rupture zones 162 fail. At that point, the hoop strength in the lower portion of the skirt 142 is released. Also, because the tooth 150 no longer engages the groove 134, a locking function no longer is carried out by the tooth 150 and the groove 134. Accordingly, the cap 100 can be unthreaded from the container 120. Because the wall section 166 constitutes only a small circumferential portion of the skirt 142, the skirt wll not be expanded excessively upon re-tightening the cap 100 so as to disengage the grooves 133 and the threads 148. Furthermore, the cap 100 can be removed and replaced as often as desired without adversely affecting the seal created by the lip 156 and the rim 128. Because the tab 160 and the wall section 166 can be readily observed by a consumer, it will be immediately apparent whether the cap 100 has been tampered with or removed from the container 120. Moreover, the closure cap 100 according to the invention is relatively easy to open because the tab 160 can be grasped without difficulty, and there is no need to dispose of a severed portion of the cap 100.
A third alternative closure cap according to the invention is indicated in FIGS. 7-9 by the numeral 200. The cap 200, like the cap 100, is suitable for use with containers having threaded neck portions. The cap 100 also can be used for sealing containers having relatively high internal pressures.
The cap 200 is illustrated in sealing position atop a container 220. The container 220 includes a relatively large body portion 222, and a generally cylindrical, elongate neck portion 224 having annular ledge portions 226, 227. The neck portion 224 includes an annular rim 228 having a flattened upper surface. The neck portion 224 includes a cylindrical inner surface 230 extending the length of the neck portion 224. The neck portion 224 also includes a first wall portion 232 having a plurality of helical threads 233 on its outer surface. The threads 233 function as a locking member. Another locking member 234 is positioned vertically adjacent the first wall portion 232 on the outer surface of the neck portion 224. The locking member 234 is in the form of serrations spaced circumferentially of the neck portion 224. The serrations 234 do not extend completely about the circumference of the neck portion 224, but are located at pre-determined circumferential locations where a locking function needs to be carried out. Those circumferential locations not including serrations 234 are occupied by vertically extending walls 236. As seen in FIG. 7, the walls 236 connect the ledges 226, 227.
The closure cap 200 includes a disc-like top wall 240 having a center section 242 slightly smaller in diameter than the inner diameter of the neck portion 224. A ledge 244 extends upwardly from the outer edge of the center section 42, and a rim 246, beveled on its outer surface, extends from the periphery of the center section 242 in a direction opposite to that of the ledge 244. A flange 248 extends laterally outwardly from the ledge 244 and overlies the rim 228.
An annular skirt 252 depends from the top wall 240. The skirt 252 extends downwardly from the outer periphery of the top wall 240 and includes a laterally extending ledge 254 from which a wall 256 extends downwardly. A rim 258, beveled on its outer surface, extends downwardly from the skirt 252 at the inner periphery of the skirt 252. The skirt 252 includes, on its inner surface, a second wall portion 260. The second wall portion 260 includes a plurality of grooves 262 which interlock with the threads 233 on the first wall portion 232 and thereby function as another locking member.
An additional locking member 264 is included as part of the skirt 252. The locking member 264 is in the form of inwardly extending flexible serrations engageable with the first locking member 234. The serrations 264 project from the back face of a wall portion 266 having a diameter slightly larger than the diameter of the wall 256. The wall portion 266, as shown in FIG. 7, has a greater height than does the wall 256. The wall portion 266 is connected to the skirt 252 by a ledge 268 and by vertically and horizontally extending rupture zones, or lines 270. The lines 270 essentially are areas of reduced material thickness (approximately 0.008 inch). The ledge 268 includes an opening 272 to enable the serrations 264 to be formed expeditiously in a molding operation. A tab 274 extends outwardly from the lower portion of the wall 266. Upon upward flexure of the tab 274, the rupture lines 270 will fail and the wall section 266 will be pivoted upwardly.
During initial attachment of the closure cap 200 to the container 220, the cap 200 is placed atop the neck portion 224 and is threaded onto the neck portion 224. As the cap 200 is threaded, the rim 246 eventually engages the rim 228 to effect a fluid-tight seal. The engagement between the rim 246 and the rim 228 may be referred to as a primary seal. The interlocking threads and grooves 233, 262 of the wall portions 232, 260 create a secondary seal. The rim 258 and the ledge 226 engage each other in substantial line-to-line contact to create a tertiary seal. The lowermost portion of the wall 256 also engages the ledge 227 in substantial surface-to-surface contact to create yet a fourth seal. After the cap 200 is in that position illustrated in the figures, the container 220 will be sealed and the cap 200 cannot be removed because of the engagement of the interlocking serrations 234, 264.
In order to remove the closure cap 200 from the container 220, the tab 274 is lifted upwardly until the rupture zones 270 fail. At that point, the hoop strength in the wall 256 is released. Also, because the serrations 264 no longer engage the serrations 234, a locking function no longer is carried out by the serrations 264, 234. Accordingly, the cap 200 can be unthreaded from the container 220. Because the wall portion 266 essentially is only a circumferential portion of the wall 256 and not the remainder of the skirt 252, the skirt 252 will not be expanded upon retightening the cap 200 so as to disengage the threads 233 and the grooves 262. Furthermore, the cap 200 can be removed and replaced as often as desired without adversely affecting the seal created by the rims 246, 228, and the rim 258 and the ledge 226. Because the tab 274 and the wall portion 266 can be readily observed by a consumer, it will be immediately apparent whether the cap 200 has been tampered with or removed from the container 220. Moreover, the closure cap 200 according to the invention is relatively easy to open because the tap 274 can be grasped without difficulty, and there is no need to dispose of a severed portion of the cap 200.
In addition to the advantages of the invention described previously, it will be appreciated that each embodiment of the invention can be formed expeditiously in a molding operation. In particular, unlike certain prior caps, the vertically extending rupture lines can be molded easily to close tolerances and the cap according to the invention can be removed quickly from a mold even while still in a softened condition. In part, this is because forces required to remove the cap from the mold are exerted in the direction of the rupture lines, rather than laterally of the rupture lines.
Although the invention has been described with a certain degree of particularity, it will be understood that the present disclosure of the preferred embodiment has been made only by way of example, and that numerous changes in the details of construction and the combination and arrangement of elements can be resorted to without departing from the true spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed.
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A closure cap particularly suited for use with containers such as milk bottles includes multiple sealing areas as well as frangible locking means. The locking means is located near the lower rim of a skirt portion of the closure cap. If the locking means has not been tampered with, an interlocking engagement between the locking means and a complementary portion of the container retains the cap on the container. If the locking means has been tampered with, the cap can be removed from the container. A visual inspection of the closure cap readily indicates whether the locking means is in tampered or untampered condition. In one embodiment, the cap can be repeatedly snapped into place on the container, and in other alternative embodiments, the cap can be repeatedly threaded onto the container. The multiple sealing areas not only seal the contents of the container, but one of the areas also prevents dust, dirt, or other contaminants from having access to the other sealing areas.
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[0001] This invention relates to a method of fabricating a flexible graphite laminate with a metal core.
BACKGROUND OF THE INVENTION
[0002] A flexible graphite facing reinforced with steel to form a laminated flexible graphite-to-steel gasket is presently used in the automotive industry as a gasket replacement for the gasket sealing in the automotive engine block and head. The laminate is formed by impressing a flexible graphite facing over a metal sheet containing multiple tangs which perforate the flexible graphite facing. This is followed by a calendering operation which flattens the perforated tangs to mechanically interlock the laminate. This procedure limits the practical maximum thickness of the steel core to a limited range between 0.004 inches to about 0.010 inches thick. A flexible graphite laminate with a thicker or thinner reinforcing core bonded to the flexible graphite facing is often preferred.
[0003] A flexible graphite laminate having an interlayer can also be formed as taught in U.S. Pat. No. 4,961,991 by interposing a polymer resin coated cloth of e.g. polytetrafluroethylene between two sheets of flexible graphite to permit the sheets to be adhesively bonded at elevated temperature. This is an expensive alternative to the above described mechanical assembly. The use of a thermosetting adhesive for bonding the graphite sheets to a metal core would be preferable provided it does not cause blistering to occur at the elevated temperatures required to cure the thermosetting composition and forms a chemically and thermally stable bond impervious to organic solvents.
SUMMARY OF THE INVENTION
[0004] The metal laminate of the present invention is formed with a core of metal bonded to a flexible graphite sheet through a polymerized phenolic resin bonding agent under controlled conditions which avoids surface blistering and produces a chemically and thermally stable bond impervious to organic solvents.
[0005] The method of the present invention for fabricating an adhesively bonded laminate composed of at least one sheet of metal and a sheet of flexible graphite comprises the steps of:
[0006] preparing a fluid adhesive composition comprising a phenolic resin, a diluent and a compound of natural or synthetic rubber;
[0007] feeding said sheet of metal simultaneously with said sheet of flexible graphite through a calender roll assembly in a superimposed relationship;
[0008] interposing said fluid adhesive composition between said sheet of flexible graphite and said sheet of metal before said sheets are calendered to form said laminate;
[0009] discharging said laminate of flexible graphite and metal from said calender roll assembly; and
[0010] heating said discharged laminate gradually and at a slow rate of no more than 25° C. per hour until a temperature is reached sufficient to polymerize said phenolic resin and vaporize said rubber compound from said adhesive composition without blistering said flexible graphite.
BRIEF DESCRIPTION OF THE DRAWING
[0011] The preferred embodiment for carrying out the invention is schematically illustrated in the single FIGURE.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The term “flexible graphite” as used herein is the product obtained by compressing the exfoliated reaction product of rapidly heated graphite particles which have been treated with an agent capable of intercalating into the crystal structure of the graphite to expand the particles at least 80 or more times in the direction perpendicular to the carbon layers in the crystal structure as taught in U.S. Pat. No. 3,404,061, the disclosure of which is incorporated herein by reference. Flexible graphite may be compressed into a thin sheet of between 5-25 mils in thickness with a density approaching theoretical density, although a density of about 70 lbs/ft 3 is acceptable for most applications.
[0013] A laminate of flexible graphite and a core of metal of e.g. steel or aluminum is formed in accordance with the method of the present invention using a calender roll assembly 10 as shown in the drawing. The calender roll assembly includes two rolls 12 and 14 aligned relative to one another to calender two sheets of flexible graphite 15 and 16 into engagement, preferably under a pressure of between 100-200 psi, with an interposed sheet 18 of metal. The sheet of metal 18 is fed from an unwind supply roll 20 between the two sheets of flexible graphite 15 and 16 for forming a laminate 22 with the flexible graphite sheets 15 and 16 superimposed on the metal sheet 18 . An applicator 23 is located in-line to apply a suitable thermosetting adhesive composition between the engaging surfaces of the metal sheet 18 and the sheets of flexible graphite 15 and 16 to form a chemical bond between such engaging surfaces. A dryer 19 is located downstream of the applicator 23 to dry the adhesive composition. The dryer 19 may be an air dryer or a radiant heater.
[0014] The flexible graphite sheets 15 and 16 are fed from supply rolls 24 and 25 around idler rolls 26 and 27 and then over calendering rolls 12 and 14 to a take-up roll 28 . In accordance with the method of the present invention the calendering rolls 12 and 14 should be preheated to bond the laminate 22 at an elevated temperature of between 100° F. to 300° F.
[0015] The laminate 22 formed between the rolls 12 and 14 consists of two flexible graphite sheets 15 and 16 on opposite sides of a center core of a metal sheet 18 . The calender roll assembly 10 can also be used to form a single coated laminate with only one flexible graphite sheet 15 or 16 . The assembly 10 may also be modified using additional rollers (not shown) to form a laminate having multiple sheets each of which are bonded together by the adhesive composition 23 under nominal pressure of between 100-200 psi at the above designated temperature.
[0016] The adhesive composition applied by the applicator 23 is a thermosetting phenolic resin modified with the addition of a synthetic or natural rubber compound and a diluent of preferably an alcohol such as isopropanol or isopropyl alcohol or methyl ethyl ketone. The concentration of the diluent should be sufficient to liquify the composition so that it may be applied by spraying, roll coating or brushing onto the opposite surfaces of the metal sheet 18 and/or over the opposed surfaces of the flexible graphite sheets 15 and 16 which engage the sheet 18 . Alternatively, the adhesive composition may be directly applied to the flexible graphite sheets 15 and 16 and dried before they are superimposed on the center core and passed through the calender rolls 12 and 14 . The calender rolls 12 and 14 are adjusted to apply a nominal pressure of between 100-200 psi to the laminated sheets and are preferably preheated to a temperature of between 100° F. to 300° F. The phenolic composition should include up to 10% by weight of a natural or synthetic rubber compound such as neoprene or butadiene. The rubber compound assures uniform contact between the metal sheet 18 and the sheets of flexible graphite 15 and 16 respectively. A suitable adhesive composition is available commercially and sold under the designation HRJ-2903 by Schenectady Chemicals Inc.
[0017] The laminate 22 is subjected to a post heat treatment operation to polymerize the phenolic resin and to release volatiles from the adhesive composition. The post heat treatment must be carried out in a gradual manner by incrementally increasing the temperature to avoid blistering of the flexible graphite sheets and possibly, delamination. The flexible graphite sheets 15 and 16 are essentially non-porous in the direction transverse to the plane of the sheet 18 . Accordingly, the temperature must be raised gradually at a slow enough rate to permit the volatiles to escape through the flexible graphite in a direction parallel to the longitudinal. The temperature should be increased at no more than 250° C. per hour and preferably between 10-15° C. per hour until a temperature is reached sufficient to cause polymerization of the phenolic. A temperature of at least 200° C. is necessary to cure the phenolic and preferably over 300° C. with 330° C. being preferred. Once cured the laminate 23 is impervious to delamination in the presence or an organic solvent such as methy ethyl ketone.
[0018] Blistering and delamination may be entirely avoided without the necessity for a post heat treatment operation or limited solely to an on-line heat treatment of the laminant following calendering with the heat treatment limited to a time interval of only minutes and up to a maximum heat treatment of ½ hour as opposed to the very slow and gradual post curing time interval measured in hours as indicated heretofore. This may be accomplished by practicing the invention subject to the following steps prior to calendering:
[0019] 1. (1) The phenolic resin adhesive should be of a composition as hereinbefore described and limited in thickness to a maximum of between 0.00005 and 0.0005 inch, and
[0020] 2. (2) The applied phenolic composition should be heated before calendering until it has gelled.
[0021] The above requirements may be carried out on line prior to calendering with the flexible sheet advanced at a rate of over 10 ft/min and up to 30 ft/min. On line operation requires the resin to be dried and heated in unit 19 representing an air circulating oven or an IR heater. The temperature of the air circulating oven should be between 105° C. to 110° C. with the length of the oven selected to heat the resin for five minutes. Alternatively the oven may be raised to a temperature of between 210-220° C. with the resin treated for only for 30 seconds. Using an IR heater a peak temperature of about 165° C. is required for an application of only five seconds. These conditions apply only for the very thin coatings as specified in the above paragraph (1).
[0022] The resin may be applied full strength with a Mayer bar to the desired thickness or diluted with 100-200 parts solvent to 100 parts resin and painted on with a brush or roller. It is necessary to apply the resin to the metal surface to form a bond between metal and flexible graphite whereas in the case of two flexible graphite sheets both graphite sheets should be coated with resin adhesive.
[0023] Provided the above process constraints are followed the thin film of resin adhesive will be properly gelled before calendering and may be cured thereafter at a temperature of up to 242° C. in minutes and on-line depending upon thickness to produce a blister-free laminate.
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A method of fabricating a bonded flexible graphite laminate having an intermediate core of metal bonded on opposite sides to a flexible graphite sheet through a polymerized phenolic resin bonding agent under controlled conditions which avoids surface blistering and produces a chemical bond impervious to an organic solvent.
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FIELD OF THE INVENTION
This invention is directed to a method for fracturing and propping radial fractures created during controlled pulse fracturing of hydrocarbonaceous formations or reservoirs.
BACKGROUND OF THE INVENTION
It has been known for some time that the yield of hydrocarbons, such as gas and petroleum, from wells can be increased by fracturing the formation so as to stimulate the flow of hydrocarbons in the well. Various formation fracturing procedures have been proposed and many now are in use. Among these procedures are treatments with various chemicals (usually acids in aqueous solutions), hydraulic fracturing in which liquids are injected under high pressure (usually with propping agents), explosive methods in which explosives are detonated within the formations to effect mechanical fracture, and combinations of the above procedures.
Chemical treatments usually involve the use of large volumes of chemicals which can be expensive and difficult to handle, and which pose problems of contamination and disposal. Hydraulic fracturing ordinarily requires that large volumes of liquids be made available at the well site and that equipment be made available for handling these large volumes of liquid. Again, there can be disposal problems, as well as contamination of the well. Explosive methods can be exceptionally hazardous from the standpoint of transporting and using the necessary explosives. These methods also present difficulties in controlling the effects of such a procedure.
Other suggestions for increasing the yield of existing wells entail heating the formation to induce the flow of hydrocarbons from the formation. Methods and apparatus have been developed by which various combustion devices have been lowered into the borehole of a well to attain heating of the formation adjacent the device. The effectiveness of such devices is limited by the necessity for fitting the devices into a borehole and then obtaining only more-or-less localized effects.
A combustion method designed to stimulate the well through mechanical fracture is known as controlled pulse fracturing or high energy gas fracturing. A good description of this method appears in an article by Cuderman, J. F., entitled "High Energy Gas Fracturing Development," Sandia National Laboratories, SAND 83-2137, October 1983. Using this method enables the multiple fracturing of a formation or reservoir in a radial manner which increases the possibility of contacting a natural fracture. Unfortunately, these radial fractures often do not penetrate deeply enough into the formation.
Slusser in U.S. Pat. No. 4,109,721 issued on Aug. 29, 1978 discusses a method of proppant placement during a hydraulic fracturing treatment. Via this method, a first proppant pack was deposited in the lower portion of a fracture. Afterwards, a slug of fracturing fluid liquid containing fluid loss additives was injected into the formation to deposit the fluid loss additives along the upper leading edge of the proppant pack. This provided a seal along the upper edge of the proppant pack. Thereafter, a high filter loss fracturing fluid, containing proppants, with no fluid loss additives was injected into the formation at a pressure to extend the fracture further.
During hydraulic fracturing when a proppant is utilized the fracturing fluid must be selected to allow the proppant to remain suspended until said fracturing treatment is completed which may require several hours. Because there is a time interval between the hydraulic fracturing treatment and the injection of the fluid containing the proppants, often sufficient proppant does not enter the desired fracture.
Therefore, what is needed is a method which will provide for proppant placement within fractures upon the initiation of said fractures thereby allowing for increased amounts of proppant placement within said fractures.
SUMMARY
This invention is directed to a method for treating fractures resultant from controlled pulse fracturing. In the practice of this invention, a high energy impulse device is placed into a well bore contained in a subterranean formation near said formation's productive interval. Afterwards, a proppant, of a size sufficient to prop said fractures, is injected into the wellbore. Said proppant is suspended in a liquid which covers said productive interval.
Thereafter, said high energy impulse device is ignited. Upon ignition said device generates fracturing pressure and maintains a peak pressure load sufficiently above the in-situ stress pressure but below the rock yield stress for a time sufficient to simultaneously create multiple radial fractures. Said pressure is also sufficient to cause proppant entry into said fractures thereby propping and extending said fractures.
Creating fractures by this method leads to the production of increased volumes of desired resources from said formation. This method is particularly applicable to formations containing hydrocarbonaceous fluids.
It is therefore an object of this invention to create and simultaneously prop multiple radial fractures, near the wellbore and extend those fractures into the formation.
It is yet another object of this invention to avoid damaging rock near the wellbore when creating multiple fractures and extending said fractures into the formation.
It is still another object of this invention to create simultaneous multiple fractures large enough to contain sufficient amounts of a proppant and generate pressure sufficient to extend more than two multiple fractures into a formation.
It is a further object of this invention to extend at least three simultaneous multiple fractures into the formation for a distance sufficient to contact at least one natural hydrocarbonaceous fluid producing fracture.
It is a still further object of this invention to obtain increased quantities of natural resources from underground formations, particularly formations containing hydrocarbonaceous fluids.
It is a yet further object of the present invention to increase the productivity of damaged wells by creating simultaneous multiple fractures in combination with a proppant suspended in a liquid.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred embodiment of this invention, it is desired to create simultaneous multiple radial fractures into a wellbore or borehole and extend said fractures without crushing the wellbore or borehole. It is desired to create multiple extended radial fractures to enhance the possibility for recovering natural resources, oil, or hydrocarbonaceous fluids. To accomplish this a high energy impulse device containing a propellant is suspended into a wellbore. This device is placed downhole next to the productive interval of a formation containing said resources, e.g. oil, or hydrocarbonaceous fluids.
The propellant in said device can belong to the modified nitrocellulose or the modified and unmodified nitroamine propellant class. Suitable solid propellants capable of being utilized include a double-based propellant known as N-5. It contains nitroglycerine and nitrocellulose. Another suitable propellant is a composite propellant which contains ammonium perchlorate in a rubberized binder. The composite propellant is known as HXP-100 and is purchasable from the Holex Corporation of Hollister, Calif. N-5 and HXP-100 propellants are disclosed in U.S. Pat. No. 4,039,030 issued to Godfrey et al. which patent is hereby incorporated by reference.
A N-5 solid propellant was utilized by C. F. Cuderman in an article entitled "High Energy Gas Fracturing Development," Sandia National Laboratories, SAND 83-2137, October 1983. This article is also incorporated by reference. High energy gas fracturing or controlled pulse fracturing is a method used for inducing radial fractures around a wellbore or borehole. Via this method a solid propellant-based means for fracturing is employed along with a propellant composed to permit the control of pressure loading sufficient to produce multiple fractures in a borehole at the oil or hydrocarbonaceous fluid productive interval. A peak pressure is generated which is substantially above the in-situ stress pressure but below the rock yield stress pressure.
After placing said device into said wellbore or borehole, a proppant of a size sufficient to prop resultant fractures is injected into the wellbore or borehole. Said proppant is suspended in a liquid carrier fluid prior to being injected into said wellbore or borehole. Proppants and methods for packing said proppants are discussed in U.S. Pat. No. 4,109,721 issued to Slusser on Aug. 29, 1978. This patent is hereby incorporated by reference.
Liquid carrier fluids which can be utilized herein are discussed in U.S. Pat. No. 3,642,068 issued to Fitch et al. on Feb. 15, 1972. This patent is hereby incorporated by reference. Some of these liquids include water, lease cruide oil, diesel oil, natural gums, gels, and thixotropic fluids for example. An aqueous solution which can be used as a carrier liquid is discussed in U.S. Pat. No. 4,067,389 issued to Savins on Jan. 10, 1978. This patent is hereby incorporated by reference.
Once the injection of the carrier fluid with proppant therein is in place at the desired productive interval, said device is ignited. Ignition of the propellant causes the generation of heat and gas preesure and provides the means for creating multiple fractures. As is known to those skilled in the art, the amount of heat and pressure produced is dependent upon the kind of propellant used, its grain size and geometry. Heat and pressure generation also depends upon the burning rate, weight of charge and the volume of gases generated. Subsequently, the heat and pressure are maintained for a time sufficient to allow fluid penetration and extension of fractures. As is known, heat generation and pressure maintenance are dependent upon the nature of the formation and the depth it is desired to extend the fractures into the formation. Simultaneous with the generation of pressure, proppant contained in the carrier fluid is caused to enter at least three vertical radial fractures thereby propping said fractures, and causing said fractures to be extended. When the pressure has dissipated said proppant props said fractures and prevents them from closing. Upon intersecting a fracture containing desired resources, particularly hydrocarbonaceous fluids, the propped fractures allow increased volumes of said resources to be produced from said formation.
One application of this method is for facilitating the removal of ores from a formation containing same. Sareen et al. in U.S. Pat. No. 3,896,879, disclose a method for increasing the permeability of a subterranean formation penetrated by at least one well which extends from the surface of the earth into the formation. This method comprises the injection of an aqueous hydrogen peroxide solution containing therein a stabilizing agent through said well into the subterranean formation. After injection, the solution diffuses into the fractures of the formation surrounding the well. The stabilizing agent reacts with metal values in the formation which allows the hydrogen peroxide to decompose. The composition of hydrogen peroxide generates a gaseous medium causing additional fracturing of the formation. Sareen et al. were utilizing a method for increasing the fracture size to obtain increased removal of copper ores from a formation. This patent is hereby incorporated by reference. Utilization of the present invention will increase a formation's permeability by creating additional fractures.
In addition to removing ores, particularly copper ores and iron ores from a formation, the present invention can be used to recover geothermal energy more efficiently by the creation of more fractures. A method for recovering geothermal energy is disclosed in U.S. Pat. No. 3,863,709 which issued to Fitch on Feb. 4, 1975. This patent is hereby incorporated by reference. Disclosed in this patent is a method and system for recovering geothermal energy from a subterranean geothermal formation having a preferred vertical fracture orientation. At least two deviated wells are provided which extend into the geothermal formation in a direction transversely of the preferred vertical fracture orientation. A plurality of vertical fractures are hydraulically formed to intersect the deviated wells. A fluid is thereafter injected via one well into the fractures to absorb heat from the geothermal formation and the heated fluid is recovered from the formation via another well.
The present invention can also be used to remove thermal energy produced during the situ combustion of coal by the creation of additional fractures. A method wherein thermal energy is produced by in situ combustion of coal is disclosed in U.S. Pat. No. 4,019,577 which issued to Fitch et al. on Apr. 26, 1977. This patent is hereby incorporated by reference. Disclosed therein is a method for recovering thermal energy from a coal formation which has a preferred vertical fracture orientation. An injection well and a production well are provided to extend into the coal formation and a vertical fracture is formed by hydraulic fracturing techniques. These fractures are propagated into the coal formation to communicate with both the wells. The vertical fracture is propped in the lower portion only. Thereafter, a combustion-supporting gas is injected into the propped portion of the fracture and the coal is ignited. Injection of the combustion-supporting gas is continued to propagate a combustion zone along the propped portion of the fracture and hot production gases generated at the combustion zone are produced to recover the heat or thermal energy of the coal. Water may also be injected into the fracture to transport the heat resulting from the combustion of the coal to the production well for recovery therefrom.
Recovery of thermal energy from subterranean formations can also be used to generate steam. A method for such recovery is disclosed in U.S. Pat. No. 4,015,663 which issued to Strubhar on Apr. 5, 1977. This patent is hereby incorporated by reference.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims.
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A controlled pulse fracturing (CPF) process conducted with the addition of a proppant. Said proppant can comprise sand or similar material which is injected into the fluid adjacent to the perforations. Upon ignition of the CPF device, said proppant is injected into the created fractures, thereby propping said fractures open. This causes a production increase from the well. Said fluid can comprise water, a gel, a thixotropic fluid, or similar type fluids.
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